kalpraxis economic wear protection in coal fired power plants

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A typical application in powerplants is pulverized fuel piping,here protected by ABRESIST

Reduce Costs andAvoid Downtime

Large quantities of bulk materialare handled in the conveying andstoring systems of coal firedpower plants. Unless they aresuitably protected these systemswill experience frequent failurerequiring repair or replacement.Kalenborn offer the completearray of wear protection materialsincluding not only ceramic andmetallic materials but alsoplastics and rubber.

In addition, Kalenborn haveextensive experience in the fieldof slide promotion. Interruptionsof material flow inside of bunkersand silos must be avoided andKalenborn cover the entire mate-rial range with plastics as well asmetallic and ceramic materials.

In any case we can supply atailor-made solution for yourparticular problem. Our expertsare prepared to be of assistance.

Service by Kalenborn:rebuilding a grinding table withKALMETALL-W 100

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1 Bunkers ABRESIST, KALEN*, KALCERAM*, KALINOX*

2 Coal transport Transfer chutes ABRESIST, KALOCER, KALMETALL-W, KALEN*

Pyrite pipes ABRESIST, KALCOR

3 Coal pulverizers Ball mills- feeding KALMETALL-C, KALMETALL-W, KALCOR- housing KALMETALL-C, KALMETALL-W

Roller mills- side walls/housing KALMETALL-W, KALMETALL-C- rolls, tables KALMETALL-W, KALMETALL-C

4 - separators ABRESIST, KALOCER, KALSICA, KALMETALL-W,KALCRET

5 - Pneumatic discharge KALCRET, ABRESIST, KALMETALL-W

Hammer mills- housing KALMETALL-C, KALMETALL-W- hammers KALMETALL-C

6 Coal feeding Pneumatic ABRESIST, KALCRET, KALCOR, KALOCER,KALMETALL-C, KALMETALL-W

Mechanical ABRESIST, KALCOR, KALOCER, KALMETALL-C,KALMETALL-W

7 Coal distributor KALSICA, KALMETALL-W

8 Pulverized coal burners Lances KALSICA, KALMETALL-W

Reflectors KALSICA, KALMETALL-W

9 Fly ash Protection of boiler tubes KALSICA

10 Housing KALCRET, KALSICA, KALMETALL-W

11 Cyclones – dust collection KALCOR, KALCRET, KALMETALL-W

12 Pneumatic transport ABRESIST, KALCOR, KALOCER

13 Silos ABRESIST, KALEN*

14 Wet ash (Bottom ash) Wet ash removal systems ABRESIST, KALOCER, KALMETALL-W

Chain conveyors ABRESIST, KALOCER

Granulators ABRESIST, KALMETALL-W

15 Silos ABRESIST

Mixers (w. fly ash) ABRESIST, KALMETALL-W

16 Hydraulic transport ABRESIST

17 Limestone Bunkers ABRESIST, KALEN*

18 Limestone grinding mill- feeding ABRESIST, KALCRET, KALMETALL-W

19 Pneumatic transport ABRESIST

21 Mixers ABRESIST, KALMETALL-W

22 Gypsum Stores (silos, bunkers) ABRESIST, KALEN*

Material Handled / Plant Lining MaterialSystem Component as Wear Protection / Slide Promotion*

DESULPHURIZATION

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Fly ash pipes are among theplant components that areparticularly endangered bywear. Kalenborn offer a varietyof materials to ensure optimalservice lifetimes: ABRESISTfused cast basalt, KALCORzirconium corundum andKALOCER high aluminaceramics.

ABRESIST fused cast basaltis the accepted standard for

piping in wet ash pipe systemsall over the world. The picture

shows a plant in India.

Coal bunkers require a reliablematerial flow. This is ensured bythe use of KALEN slide promotionplastics. Slide promotion steel -perhaps combined with KALEN -will be best in case of moreintense wear.

Reliable wear protection is ofparticular importance for

trouble-free continuousoperation of the coal injection.

These PF-bends are madeof plates with hard

overlay welding.

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15 Silos ABRESIST

DESULPHURIZATION

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overlay welding.

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15 Silos ABRESIST

DESULPHURIZATION

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overlay welding.

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Wear Protected Components

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Impact coal pulverizers operate in lignite firedpower plants; the impact plates have been lined

with KALMETALL-W 100

Coal transfer equipment is protected with ABRESISTfused cast basalt or KALOCER high aluminaceramics (example: Philippines)

Coal bunkers lined withKALEN slide promotion

plastics ensure a reliablematerial flow

Kalenborn also supply grinding rolls and grindingtables for coal pulverizing; the picture on the leftshows regeneration of a worn grinding roll withKALMETALL-W 100; the cast grinding roll made ofKALMETALL-C 155 on the right is a new piece(both have a diameter of 1,500 mm)

Housing of a pulverized coal fan protected withKALMETALL-W 100; the diameter is 2,600 mm

Separators are frequently protected byKALMETALL-W hard overlay welding or byKALCRET hard compound (pictures) installedwithout joints

Weight saving design ofa separator cage withKALSICA-A siliconcarbide ceramics;alternative linings areKALMETALL-W andKALOCER mosaics

Time-tested wear protectionmaterial for separators set upin coal pulverizing systems isABRESIST fused cast basalt withreferences all over the world

Pulverized coal burnermade with plates ofKALMETALL-W 100 hardoverlay welding readyfor installation

Wear protection for hydraulicand pneumatic pipes

Extended service life ofplant components

Kalenborn Service solveswear problems on site

Optimal Solution forEvery Plant Component

Plant components are at risk in all power plantsystems, especially in coal storage and coaltransport. This includes coal pulverizing andinjection into the boiler, dust collection andash removal including fly ash and wet ash.The situation is similar for limestone andgypsum in desulphurization systems.

Service lifetimes of many years are oftenachieved with the following materials:

� ABRESIST fused cast basalt� KALCOR zirconium corundum� KALCOR-S sintered zirconium corundum� KALOCER high alumina ceramics� KALCRET hard compound� KALSICA silicon carbide ceramics� KALMETALL-C hard casting� KALMETALL-W hard overlay welding� KALINOX slide promotion steel� KALEN slide promotion plastics

In addition, material combinations have beenvery successful in practice. They enable bothtechnically and economically optimal solutions.

Components Lining Material

Cyclones ABRESIST, KALCOR, KALOCER,KALSICA, KALMETALL-W

Fan housings KALOCER, KALCRET,KALMETALL-W, KALMETALL- C

Fan rotors KALOCER, KALMETALL-W

Gates KALOCER, KALCOR, KALSICA,KALMETALL-W, KALCRET

Hydraulic ABRESIST, KALCOR, KALOCER,conveyors KALCRET

Mechanical ABRESIST, KALOCER, KALCRET,conveyors KALMETALL-W, KALMETALL-C

Nozzles KALOCER, KALSICA

Pneumatic ABRESIST, KALCOR, KALOCER,conveyors KALCRET, KALMETALL-C, KALMETALL-W

Pumps KALSICA

Separators ABRESIST, KALCOR, KALOCER,KALSICA, KALMETALL-W

Transfer ABRESIST, KALOCER,stations KALMETALL-W

Valves KALOCERand fittings

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Pumps KALSICA

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Pumps KALSICA

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Jointless lining with KALCREThard compound - also possiblewith asymmetric cross section

Kalenborn have extensive experi-ence and offer a complete range ofsolutions for PF-pipe. With diame-ters between 400 and 800 mmmany possible combination liningshave been used in practice.

Depending on the specific opera-ting conditions (such as particlesize, ash portion, volume to beconveyed and transport velocity)successful designs have achievedservice lifetimes of more than10 years.

KALCOR-S allows the use of largelining segments, thin walls andhomogeneous structure

Material combinations of KALCORand ABRESIST provide economicwear solutions

KALCOR zirconium corundum lining and unlined transition elements;488 mm diameter

Long lifetimes at favorable costs are achieved with KALMETALL-C hardcasting; this example shows 518 mm diameter bends up to 700 kg weight

Lining of a PF-pipe withKALMETALL-C

KALMETALL-W hard overlay welding enables the production of self-supporting structures for PF-bends without an additional lining

PF-distribution boxes protected with KALCOR for large area lining andKALOCER to ensure maximum wear resistance

Typical solution for PF-bends:pipe-bricks made of KALOCERhigh alumina ceramics

Reflectors of PF-burners protectedby KALSICA-N (photo) orKALMETALL-W

PF-distributor made of KALSICA-Nsilicon carbide ceramics

PF-burner lined withKALMETALL-W

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When particularlyhigh dust loads

occur, the wastegas ducts areprotected by

KALCRET hardcompound or

KALMETALL-Whard overlay

welding

Time-tested materials for fly ashpipes: ABRESIST, KALCOR orKALOCER

Chain conveyors for wet ash removal are efficientlylined with ABRESIST fused cast basalt; KALCOR,KALOCER or KALMETALL-W can be used as well

Limestone may have a veryabrasive effect on FGD systems; atypical lining material is ABRESIST

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Sticky FGD gypsum is stored inbunkers; KALEN slide promotionplastics ensure trouble-free discharge

Solution adoptedfor economizertubes to handle

large dustquantities: tube

protectingshapes made ofKALSICA siliconcarbide ceramics

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In the last 50 years Kalenbornhave supplied many thousands ofmeters of wet ash pipes to plantsall over the world, normally linedwith ABRESIST fused cast basalt.This material has proven to be anexcellent choice for this particularapplication.

ABRESIST combines the proper-ties of high wear resistance andhigh corrosion resistance. Theservice lifetimes of these pipingsystems frequently cover morethan 20 years. There is no othermaterial that has reached similarservice lives in practice.

Kalenborn offer wet ash pipes ofmany different configurations withinside diameters between 200and 500 mm. The steel casingcan also be efficiently protectedagainst corrosion.

The pipes are usually joined byflanges. However, any type ofcoupling is feasible. In addition,welded and screwed joints haveproven successful in practice. Pipes in Australia;

the pipes areconnected by"Victaulic"couplings

Wet ash pipe in NorthAmerica; the pipes areflanged together

Erection of wet ash pipes inMalaysia (350 mm diameter)

Long pipes require the use ofexpansion joints for compen-sation of length

Pipe for several units running tothe central disposal site in Brasil

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°C °F

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��Lining Material Hardness Process Parameters Remarks

KALSICA-S silicon 9.3 (2,300) 35 >3.0 1,000 1,832 ++++ ++ For extremecarbide ceramics applications

KALOCER high 9.1 (2,100) >30 >3.0 350 662 0 + Standard tiles, thinalumina ceramics wall cylinders and tiles

KALCOR zirconium 9 (2,000) >30 >3.0 800 1,472 ++ ++ Large tiles, shapedcorundum elements, great wall

thickness

KALSICA-N silicon 8.8 (1,800) >25 >3.0 1,000 1,832 +++ + Good temperaturecarbide ceramics resistance/thermal

shock resistance

KALCOR-S sintered 8.5 (1,600) >25 800 1,472 +++ ++ Economic KALCORzirconium corundum

KALCRET-B 8.1 (1,250) 22 3.0 800 1,472 +++ + Supplied in bags,hard compound no joints, high

temperatures

ABRESIST 8 (1,140) 22 3.0 350 662 0 + Flow volumesfused cast basalt up to 3.0 g/cm³,

up to 22 m/sec,limited temperatures

KALMETALL-W 100 (7.5) 700 20 - 350 662 ++ ++ Impact resistant,hard overlay welding low weight

KALMETALL-C (7.2) 580 20 - 350 662 ++ +++ Impact resistant,hard casting economic in case

of large quantities

KALCERAM 6 (500) - - 350 662 0 + Bunker lining,hard ceramics slide promotion

Mohs(1) Vickers Max. con- Material Max. Thermal ImpactHV (2) veying volocity density temperature (3) shock wear

m/sec g/cm² °C °F resistance resistance

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KALEN slide +++++ 80 176 + No corrosion, very smoothpromotion plastics surface, low weight

KALINOX slide +++ 550 1,022 ++ Slide promotion in case both slidingpromotion steel wear and sticking problems exist

KALCERAM +++ 350 662 +++ Slide promotion and morehard ceramics efficient wear protection

ABRESIST +++ 350 662 ++++ Good material flow in case offused cast basalt hard, abrasive conveyed material

(1) The Mohs scale is applicable only to ceramic materials - no more than comparison values for other materials (values given in brackets)(2) The Vickers HV values are only valid for metallic materials - no more than comparison values for other materials (values given in brackets)(3) The specified temperatures refer to standard applications; other temperatures must be agreed upon with the technical departments of Kalenborn

Lining Slide Promotion Max. Temp. Wear Resistance Remarks

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ABRESISTfused cast basaltMineral protection made ofcast basalt to protectagainst abrasive wear.

Advantages: high wearresistance, permanent smoothsurface, no corrosion.

KALCORzirconium corundumCast or sintered material madeof alumina and zirconia oxide.

Advantages: high wearresistance, resistant againsthigh temperatures, corrosionresistant.

KALOCERhigh alumina ceramicsSpecial oxide ceramics for plantcomponents subject to extremewear.

Advantages: high wear resistance,permanent smooth surface,no corrosion.

KALSICA siliconcarbide ceramicsSuitable for plant componentsthat are exposed to extreme wearand/or high temperatures.

Advantages: highly wear resistant,resistant against thermal shocksand producible with narrowdimensional tolerances.

KALEN slidepromotion plasticsRange of different polyethylene(PE) and polyurethane (PU)materials.

Advantages: good durability,free of corrosion, smooth surface.

KALMETALL-W hardoverlay weldingTough basic body and hardoverlay welding with primarychromium carbides.

Advantages: highly wear resistant,good resistance against impactwear, self-supporting structures.

KALMETALL-Chard castingDifferent materials characterizedby corresponding resistanceagainst abrasion and impactwear.

Advantages: alloy matched to thespecific application, of advantagein case of larger quantities.

KALCREThard compoundCement bonded compound forjointless protection to be trowelled,cast or sprayed-on.

Advantages: high wear resistanceand compressive strength,jointless, temperature resistant.

Ceramic wear protection

� very good abrasion resistance� tile, cylindrical or jointless lining� temperatures up to 1,000 °C / 1,832 °F

Metallic wear protection

� good resistance against sliding and impact wear� thin walls, self-supporting structures� good thermal shock resistance

Plastic lining

� excellent slide promotion� good resistance against impact wear� low weight

Material combinations

� optimal wear protection for every application� optimized lining cost� optimized weight

Advantages of Lining Materials

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Reliable protection of pipe.ABRESIST fused cast basalt as

time-tested solution for thetransport of wet ash in the USA

(250 mm diameter).

Material combinations allowsafe and economic operationof PF-pipes. Here a combinationof KALCOR zirconium corundumand KALOCER high aluminaceramics.

Kalenborn supply wear protected plant components.In addition we provide for regeneration of worncomponents - here a grinding table of a coal pulverizer.

KALENBORN, ABRESIST, KALCOR, KALOCER, KALSICA, KALCRET, KALMETALL, KALINOX and KALEN are trademarks of Kalenborn.This brochure and other technical information are general only. They do not cover any guarantee with legal effect. Technical changes and errors are reserved.

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Abresist Corporation5541 North State Road 13P.O. Box 38Urbana, IN 46990, USA Phone (800) 348-0717

(260) 774-3327Fax Business (260) 774-8188

Sales (260) 774-3832eMail [email protected] www.abresist.com

Kalenborn KalprotectDr. Mauritz GmbH & Co. KGVettelschoss, GermanyInternet www.kalenborn.de

kalpraxis economic wear protection in coal fired power plants

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