ISOMEMBRANE introduction

Our special HASLE ISOMEMBRANE technology presents a unique solution to the problem of boiler dead space sealing at both coal- and gas fired power plants. What is the problem? Across the world, the design and operation of power plants face the challenge of sealing the roof on Pulverized Fuel (PF) fired boilers, against ingress of fly ash into the so called dead space on top of the boiler. In all steps of the operation of the boiler, the pipe work in the boiler - carrying water and steam under high pressure - will move slightly due the thermal expansion of the metal. This movement causes the concrete wall of the boiler to crack, in the areas around the pipe lead-in. Locating a durable metallic sealing to prevent fly ash from entering the leaks created has been difficult. As the pressure outside the boiler is lower than that of the boiler house environment, flue gas, carrying the fly ash from the incineration of the pulverised coal, will pass through the leaks in the boiler wall. Once outside the incineration chamber, the fly ash will precipitate in the dead space or be carried further towards the top of the boiler (convection pass, penthouse etc.)

Emission of fly ash is not the sole problem of leaks in the boiler. Leaks around the front cross, nose arch, ash hopper and the expansion joints, result in ingress of cold air from the atmosphere. This greatly reduces the efficiency of the incineration process.

Why use the ISOMEMBRANE? The following consequences of the leakage have been experienced: The build up of fly ash may grow to several meters in height, with a combined stress of several hundred tons on the boiler roof. Over time, this strain on the building structure may result in metallurgical fatigue, and in rare cases, entire boilers have collapsed under the weight of the fly ash. Ingress of steam or water in the fly ash layer will further increase the risk of damage, as the weight will increase accordingly.

The hot fly ash constitutes good insulation conditions, and un-cooled construction parts such as rods and hangers may reduce in strength and lifetime, due to overheating. Until the thick layer of fly ash has cooled down and removed, a process that normally takes one week, repairs to pipe works is impossible. With the ISOMEMBRANE in place, the cool down process is shorter, and repairs possible immediately, as there is no ash layer to remove first. The bypass of flue gas and fly ash into the upper dead spaces of the boiler environment will reduce the combustion efficiency. Tight pipe lead-ins with an ISOMEMBRANE seal will ensure the best incineration environment, as flue gases and fly ash is kept in the incineration chamber and routed through filters to the chimney. Loss of energy because of heating up ingress air and extra load on the induced draught fan

What is HASLE ISOMEMBRANE? The ISOMEMBRANE is a flexible, elastic, ash- and gas tight sealing, based on a special combination of mainly refractory materials. The HASLE ISOMEMBRANE is a sandwich-type construction. It consists of an ISOMASK made by layers of specially designed high density ceramic fibre, a special metal lattice, or mesh. Between the layers HASLE's ISOFIX High Temperature Adhesive is applied. The combination of the ISOMASK, ISOFIX and expandable metal is finally coated with a high temperature HASLE CS1500 castable, to ensure a durable surface. (Please see separate section on the safe use of ceramic fibres).

The HASLE ISOMEMBRANE can be installed in many shapes according to the actual need of the different sealing areas. It can be fixed to any clean surface by welding, casting or gluing.

The HASLE ISOMEMBRANE has proven its excellence for two decades. The technology has been applied to both gas- and coal fired power plants in Sweden, Denmark, UK, Australia, USA and China. The HASLE ISOMEMBRANE was applied in the 1980's on most of the Danish utility boilers and in the 1990's in the UK. In the USA the ISOMEMBRANE has been applied to several hundred power plants during the past 20 years. In China the technology has been used in the past 15 years. The HASLE ISOMEMBRANE is today considered the most advanced and efficient way of boiler top dead space sealing. It can be applied for retrofitting older PF-fired boilers or as a construction demand in new boilers, and with an expected lifetime expectancy of more than 10 years, the installation will ensure a positive return on invest. Regardless whether applied in new or existing boilers.

HASLE has its own certified installation team, which is able to undertake any installation task worldwide. A Supervisor ensures that the material and installation quality is always at the same high standard.

The HASLE ISOMEMBRANE technology is a Danish invention, which is developed by- and is the property of HASLE Refractories A/S . No-one else in the world has demonstrated a similar economical and flexible solution to the difficult problem of boiler top dead space sealing.

References HASLE ISOMEMBRANE has been applied to several hundred power plants all over the world. Please find selected references in the list below . Power plant Job description I/S Fynsvaerket Complete turbine insulation boiler no.5 & 6 DK-5000 Odense Denmark Stigsnaesvaerket SEAS DK-4230 Skaelskr Denmark I/S Vestkraft DK-6700 Esbjerg Denmark Nordkraft DK-9000 Aalborg Denmark Oeresundsverket Malmoe Sweden National Power Tilbury Power Station UK Sealing against flue gas fired leakage in a coal fired Steinmller boiler (200 MW) Sealing against fly ash in boiler top, boiler no. 2

Complete sealing against fly ash in boiler roof block 1 & 2 and complete dry turbine insulation 200 MW

B&W boiler no. 5 sealing against fly ash

Top dead-space sealing on power plant boiler. Unit no. 10, 350 MW Top dead-space sealing on power plant boiler. Unit no. 9, 350 MW Top dead-space sealing on power plant boiler. Unit no. 2, 500 MW

National Power Eggborough Power Station UK National Power Thorpe Marsh Power Station UK National Power Tilbury Power Station UK National Power Aberthaw Power Station UK

Top dead-space sealing on power plant boiler. Unit no. 2, 500 MW

Top dead-space sealing on power plant boiler. Unit no. 8, 350 MW

Top dead-space sealing on power plant boiler. Unit no. 7, 500 MW

Due Power Marshall North Carolina USA CP&L Mayo Plant North Carolina USA Tennessee Eastman no.24 Tennessee USA Duke Power Plant Marshall North Carolina USA Duke Power Dan River North Carolina USA DP&L JM Stuart Ohio USA Duke Power Plant Allen North Carolina USA Tennessee Eastman no.18 Tennessee USA CP&L Lee Plant North Carolina USA Duke Power Cliffside North Carolina USA Panxian no.2 Guizhou China Yaxi no.4 Guizhou China

Penthouse

Precipitator

Penthouse

Expansion Joints

Expansion Joints

Penthouse

Precipitator

Rear Wall

Economizer

Expansion Joints

Penthouse

Penthouse

Shidongkou no.4 Shanghai China Zhangze no.6 Shanxi China Yuanbaosan no.1 Liaoning China Yuanfu no. 2 Guangdong China International Power Hazelwood Power Station Australia

Penthouse

Penthouse

Penthouse

Penthouse

Penthouse and tubes

Please feel free to contact the undersigned for any query or clarifications
RUPAM ADHIKARI Manager-Sales & Supports HASLE Refractories India Pvt. Ltd 4th Floor, K S R Tower, High Tech City Main Road, Madhapur HYDERABAD-500081 _____________________________________ Tel/Fax: + 91 40 4220 5001 Mobile No: + 91 9949013794 E-mail: ra@hasle-refractories.com Web: www.hasle-refractories.com