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THERMAL SPRAY COATING

APPLICATIONS
FOR
REFINERY & BOILER
JGC Corporation
Start Up & Operation Service Department
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Copyright 2012J GC Corporation All rights reserved
Thermal Spray is a technology
to form coating by depositing
molten materials on metal
surfaces at high speed.
Metal
Alloy
Cermet
Ceramic
Coating Materials
Combustion Flame
Plasma
Spray Gun
Coating Deposition
Particle
Impact
Molten Particle
Acceleration
Base
Metal
Heat Sources
Un-molted
Meta
Gas Hole
Base Metal
Molten
Particle
What is Thermal Spray?
Copyright 2012J GC Corporation All rights reserved
Examples of Field Applications
CDU Tower Corrosion Protection
FCC Cat Section Applications
Boiler Tube Applications
Other Applications
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1. CDU Tower Corrosion Protection
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Stainless steel cladding is typically installed
in top head of the distillation tower to protect
against acid corrosion.
Due to the long service life, corrosion of the
metal cladding has been increasing.
Ni/Cr alloy or Ni-base alloy coating is one of
the options for top head repair.
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8500
Clad Portion
Top and Weld Seam
Area : 65
4
2
0
0
2
5
8
0
CS Shell Portion
TL #1 Accumulator Tray
Area : 70
Example of Actual Application
Coating Material
Ni-base alloy + SiO2 Sealing
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Step 1 - Check the site condition
and working environment
Step 12 - Remove the materials,
equipment, cleaning
Step 4 - Check the appearance of
the surfaces to be coated
Step 2 - Carry in the equipment
and materials
Step 3 - Setting up, wiring and
trial run of TSC equipment
Step 5 - Cure the un-coated area
and confined space ventilation
Step 6 - Blasting for removing the
scale
Step 7 - Intermediate inspection
(visual observation of chips,
cracks, etc.)
Step 8 - Grid blasting for surface
treatment
Step 9 - Intermediate inspection
(visual observation, roughness
checking)
Step 10 - Thermal spraying
(manual) and sealing
Step 11 - Final inspection
(thickness checking, visual
observation, etc)
Process of On-site TSC Work
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Work Duration12 Days
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This process consisting of TSC sprayed with
Arc Wire Process and Sealer
Coating materials are as follows
For TSC = NiCr base alloy or Ni base alloy
For Sealer = SiO2 System material
This coating is applicable from ambient temp
to high temperature up to 450
Expected lifetime of the coating would be at
least 5 years or more depends on the
operating condition)
Hybrid Thermal Spray Coating
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Sealer
Corrosion resistance material which
need the interspaces to fix itself
EP-J B coating
Corrosion resistance layer
without interspaces
Hybrid
Composition of Hybrid Coating
TSC layer
Corrosion resistance layer with interspaces
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Cross-Section of Hybrid Layer
Depth of the sealers penetration (Ni-Cr system TSC layer)
Above photos show that SiO2 sealer penetrate deeply enough to the pores
in the TSC layer ( almost all of the pores are filled with the sealer).
Pores
Si penetrate into the pores
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TSC
Area
TSC
Area
Non TSC
Area
After 4 years,
performance of TSC was
confirmed
TSC area :
Sprayed film was still in
good condition and no
increase of corrosion was
observed
Non TSC area :
Surface was rusty and
increase of corrosion was
observed
Actual Performance of TSC
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Advantage of TSC
Wide range of material selection
High deposition rate of coating
Low cost and simple work
No heat to affect base metal
The best material can be selected for the service.
One third of the cost compared to strip lining.
TSC can be applied repeatedly because there are
no metallurgical effect on shell material.
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135can be sprayed within 2 weeks during TA.
Copyright 2012J GC Corporation All rights reserved
2. FCC Cat Section Applications
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2. FCC Cat Section Applications
The severest operating conditions.
Erosion caused by catalyst flow
High temperature corrosion
Damage to mechanical components in FCC
Cat Section is a problem for reliable, long-
term continuous operation.
Damage can be effectively prevented or
mitigated with various metal coatings using
TSC technology.
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Feed Injector
Air
Distributer
Rx Stripper
Rx Cyclone
Internal
Rx Plenum
Chamber
Slide Valve
Stem
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RgPlenum
Chamber
RgCyclone
Internal
FCC Cat Section Applications
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Rx / Rg Plenum Chamber
HVOF/Cr3C2-Cermet
Anti-Erosion Coating
Arc Flame/Fe-Cr-B
Anti- Erosion Coating
Rx / Rg Cyclone Y
Sleeve
Self-Fluxing Alloy/Fe-Cr-B
Anti-Erosion Coating
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Examples of Actual
Applications
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Rg Air Grid Nozzle
HVOF/Cr3C2-Cermet
Anti-Erosion Coating
VPS/Cr3C2-Cermet
Anti-Erosion Coating
Plug Valve Stem
HVOF/Cr3C2-Cermet
Anti-Erosion Coating
Examples of Actual
Applications
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Main Fractionator
Bottom Pump
HVOF/Cr3C2-Cermet
Anti-Erosion Coating
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Examples of Actual
Applications
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3.Boiler Tube Applications
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Confidential
Water leak damage of
reheat combustion
chamber tube
Corrosive compound contained in fossil fuel ashes and its MP
Petroleum FuelHeavy oil,
Asphalt,Petroleum coke)
Coal
Chemical compound MP Chemical compound MP
V2O5 690 K3Fe(SO4)3 618
NaVO3 560 K3Al(SO4)3 654
Na2SO4 884 Na3Fe(SO4)3 624
2Na2O3V2O5 565 Na3Al(SO4)3 646
10Na2OV2O5 573 KFe(SO4)2 694
Na2OV2O45V2O5 625 NaFe(SO4)2 690
5Na2OV2O411V2O5 535 Na2SO4/K2SO4 884/1,069
Damage of Steam Generating Boiler Tube
Cross section of reheat
combustion chamber tube
damaged by high-temperature
corrosion
Cross section of air heater tube
damaged by high-temperature
corrosion
Cross section macro structure
of reheat combustion chamber
tube of coal fired boiler
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Example 1 : Thermal Spray for Generating Tube
Industry Iron and Steel
Capacity : 260t/h (Evaporation)
Spray area Generating Tube inside furnace
Material 50Ni-50Cr
Applying
Thermal Spray
Finished
Repair damage by
weld overlay
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Example 2 : Thermal Spray for Generating Tube
Industry Paper maker
Capability : 120t/h
Sprayed area Generating Tube inside furnace
Material 50Ni-50Cr
Spraying Finished
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Corrosion resistance of thermal spray
layer applied to superheater tube of
Heavy oil fired boiler
Test result of Corrosion resistance/50Cr-50Ni
Corrosion test result of Ni-Cr-
(Fe) alloy with 80%V2O5-
20%Na2SO4 ashes
Mass Loss
(mg/cm3 16hr)
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.Other Applications
Copyright 2012J GC Corporation All rights reserved
Other Applications
Rotating Machinery Applications
Developed and used for wear protection and thermal
barrier of machine parts.
Permanent repair of critical components of rotating
machines.
pump shafts, mechanical seal sleeves, etc.
piston rods, piston rings
gas turbine blades, combustion chambers
Aluminum Thermal Spray Coating for CUI protection
Al coating is the ultimate option for CUI protection.
Plant owners no longer need to be concerned about
CUI.
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Thank you
for
your attention!
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