Power Plants and Boilers
Erosion/corrosion protection with boiler tube and panel coatings in thermal power plants, circulating fluidised bed (CFB) boilers, biomass and recovery boilers.
In brief: Power plant and boiler equipment is damaged by the combined effect of ash and bed material erosion, high-temperature corrosion and thermal cycling. UMEK evaluates arc spray, HVOF and PTA options for boiler tubes and panels according to the operating conditions.
Application Areas
Our Solutions for Power & Boilers
- Arc spray coating of boiler tubes
- Inconel, stainless and high-alloy thermal spray coatings
- Protective coatings against erosion and corrosion
- Ceramic sealant / densifier applications
- On-site grit blasting and coating
- Ultrasonic wall thickness inspection
- Local tube and panel repairs
- Inconel 625 weld overlay
- Service life extension of combustion chambers and critical boiler zones
Typical Causes of Wear in Power Plants and Boilers
Ash and bed material erosion
In circulating fluidised bed (CFB) and coal-fired boilers, fly ash and bed material progressively thin the tube surface.
High-temperature corrosion
Fuel-related chlorine and sulphur compounds, combined with high temperature, can accelerate corrosion of the metal surface.
Thermal cycling
Frequent heating and cooling creates stress between the coating and the base material; the coating system is selected with this effect in mind.
Which Part, Which Problem, Which Process?
| Part / equipment | Typical damage | Process considered |
|---|---|---|
| Boiler tubes and panels | Erosion, high-temperature corrosion | Arc spray, HVOF Cr₃C₂-NiCr or Inconel 625 weld overlay |
| CFB boiler, refractory transition zones | Bed material erosion | Arc spray or hardfacing, depending on the zone |
| Fan blades and housings | Particle erosion | PTA or hardfacing, wear plate cladding |
| Coal mill components | Abrasive wear | Tungsten carbide or chromium carbide hardfacing |
The process for each part is finalised through an engineering assessment of operating conditions, base material and damage condition. At our facility in Ankara, coating and final grinding are carried out in a single workflow.
Read Before You Decide
About Power Plants and Boilers
Which coating is used against erosion on boiler tubes?
Depending on temperature, ash characteristics and erosion rate, arc spray, HVOF (e.g. Cr₃C₂-NiCr) or weld overlay is considered. Arc spray is fast and economical on large surfaces; HVOF can be the better choice at high temperatures and under severe erosion.
How do arc spray and HVOF differ in boiler applications?
Arc spray coats large surfaces quickly and economically; HVOF produces a denser, harder coating. The choice depends on budget, operating temperature and expected service life. For more detail, see our guide on the difference between HVOF and PTA.
Can boiler equipment be coated on site?
Our field team can carry out on-site overhauls on large equipment; scope and feasibility are assessed based on the condition of the equipment and access conditions.
Have a Project in Power & Boilers?
Send us the technical details of your part and we will prepare a quotation with an engineering assessment within 24-48 hours.