As core components in the operation of coal-fired power plant boiler units, the pulverizing system and flue gas and air duct systems are chronically subjected to harsh conditions including high-velocity pulverized coal scouring, high-temperature flue gas corrosion, and airflow impact. Wear issues are particularly prominent at elbows, reducers, guide vanes, and coal drop pipes. Continuous wall thinning readily leads to coal dust and air leakage faults, which not only reduce boiler combustion efficiency and cause energy waste but also require frequent replacement and build-up welding of worn areas during maintenance periods, consuming substantial manpower, materials, and time costs. This severely constrains the continuous and stable operation of the units and has become a significant pain point in power plant production and maintenance. To fundamentally address the wear failure issues in the flue gas and air systems, improve equipment wear resistance, extend service life, and reduce leakage points, Beijing Titan-Shield Technology Development Co., Ltd. has introduced the "Hexagonal Mesh + Wear-Resistant Ceramic Coating" composite anti-wear process. This solution has been widely applied in maintenance and anti-wear treatment of flue gas and air systems in coal-fired power plants under Datang, Huadian, Huaneng, and other major power groups, achieving significant application results and economic value.
I. Core Protective Material – Wear-Resistant Ceramic Coating
The wear-resistant ceramic coating used in this process is an inorganic non-metallic cementitious material. Developed through special raw material treatment and composite reinforcement technology, it consists of two phases: wear-resistant aggregates and ultra-fine powders. The particles form a dense packing structure with no significant macroscopic defects and high bulk density. Relying on the strong bonding characteristics of ionic and covalent bonds, combined with composite reinforcement measures, it forms a high-strength chemical bond, delivering excellent wear resistance, high-temperature resistance, and impact resistance far surpassing ordinary concrete and refractory castables. It perfectly adapts to the demanding operating conditions of coal-fired power plant flue gas and air systems.
II. "Hexagonal Mesh + Wear-Resistant Ceramic Coating" Composite Anti-Wear Construction Process
This process deeply combines the mechanical anchoring advantages of hexagonal mesh with the high-performance protective features of wear-resistant ceramic coating. Through the composite construction method of hexagonal mesh welding anchoring + ceramic coating tamping/troweling, the protective layer forms a dual connection with the equipment substrate—mechanical interlocking plus chemical bonding—solving the problems of traditional build-up welding and single coating protection, such as easy detachment, short service life, and multiple leakage points. The process is convenient to operate and aligns with power plant maintenance schedule requirements. After forming, the protective layer is firm and durable. The specific construction procedures are as follows:
1. Surface Pretreatment: Thoroughly clean the worn areas of flue gas and air ducts and pulverized coal pipes, removing dust, rust, oil stains, and loose substrate material. Pre-treat severely thinned areas to ensure the substrate surface is smooth, dry, and free of impurities, enhancing the bonding strength between the substrate and the hexagonal mesh and coating.
2. Hexagonal Mesh Cutting and Welding: Precisely cut the hexagonal mesh according to the actual dimensions and shapes of the equipment. Closely fit the mesh to the pipe wall surface and secure it evenly using spot welding, ensuring the mesh is free from looseness, arching, or edge lifting, forming a firm mechanical anchoring skeleton that provides reliable support for the coating.
3. Ceramic Coating Mixing and Application: Mix the wear-resistant ceramic coating according to the specified ratio until a uniform plastic consistency is achieved. Using tamping or troweling methods, firmly pack the coating into the mesh openings and onto the equipment surface, layer by layer, without voids or air bubbles, ensuring uniform coating thickness and complete interlocking with the hexagonal mesh. After integral forming, the surface is smooth and even.
4. Natural Curing and Acceptance: After initial setting, the coating requires no additional baking. It cures naturally under on-site conditions within 24 hours. Upon completion of curing, a comprehensive inspection is conducted to check for cracking, detachment, or hollow spots. Once standards are met, the equipment can be put into service without occupying additional production time at the power plant.
III. Core Value of the Composite Process in Flue Gas and Air System Applications
The application of the "Hexagonal Mesh + Wear-Resistant Ceramic Coating" composite anti-wear process in the flue gas and air systems of coal-fired power plants has fundamentally transformed the traditional passive maintenance model of "frequent weld repair and periodic replacement." It plays a significant role in equipment protection, production efficiency, and cost control, delivering multiple core values to power plants:
1. Significantly Extended Equipment Service Life: The composite protective layer integrates the mechanical strength of the hexagonal mesh with the wear resistance, high-temperature resistance, and corrosion resistance of the ceramic coating. It effectively disperses the scouring stress from coal powder and flue gas, substantially reducing the wear rate of flue gas and air ducts and pulverized coal pipes. The wear-resistant service life of equipment is greatly enhanced, reducing the frequency of component replacement during maintenance periods.
2. Fundamental Reduction of Leakage Faults: The integrated seamless protective layer completely resolves coal dust and air leakage issues caused by wear, ensuring the sealing integrity of the boiler pulverizing system and flue gas and air systems. It improves pulverized coal combustion efficiency and flue gas conveying efficiency, avoiding energy waste, environmental problems, and boiler combustion imbalance caused by media leakage.
3. Significant Reduction in Production and Maintenance Costs: A single application provides long-term wear protection, substantially reducing subsequent labor, material, and welding costs for maintenance. It prevents unplanned outages caused by wear failure, increases continuous and stable unit operation time, and lowers comprehensive operation and maintenance costs.
4. Perfect Adaptation to Power Plant Maintenance Schedules: The construction process is simple and efficient, allowing all worn areas to be treated during routine power plant maintenance periods without additional equipment modifications or production time occupation. After curing, the equipment can be quickly put into service. The construction offers excellent cost-effectiveness and aligns with the power plant's production and maintenance rhythm.
IV. Application Scope and Service Guarantee
(I) Application Scope
This composite process is widely applicable to anti-wear treatment of all severely worn areas in coal-fired power plant boiler pulverizing systems (coal mill air ducts, coal drop pipes, coal conveying pipes, coal mill outlet elbows, etc.) and flue gas and air duct systems (duct elbows, guide vanes, horizontal flue ducts, economizer-adjacent pipes, reducers, etc.). Construction plans can be flexibly adjusted according to the wear characteristics of different units and operating conditions.
(II) Professional Service Guarantee
Beijing Titan-Shield Technology Development Co., Ltd. has deep expertise in the industrial wear protection field. Leveraging a professional technical R&D team and extensive on-site construction experience at power plants, the company provides full-process one-stop customized services for coal-fired power plants – from on-site wear inspection, anti-wear solution design, and precise material supply, to on-site construction guidance and construction quality acceptance. Dedicated personnel oversee the entire process, ensuring perfect compatibility between the composite process and the power plant's flue gas and air system equipment, maximizing the protective effect.
The wear failure issues in the flue gas and air systems of coal-fired power plants directly affect the safe, stable, and efficient operation of the units. The "Hexagonal Mesh + Wear-Resistant Ceramic Coating" composite anti-wear process, with its excellent material properties, reliable anchoring construction method, and significant anti-wear results, effectively addresses the pain points of traditional protection methods and provides a high-quality solution for anti-wear treatment during power plant flue gas and air system maintenance. In practical applications, this process not only significantly improves equipment wear protection levels, reduces leakage faults and maintenance costs, but also ensures continuous and stable unit operation, building a solid protective barrier for cost reduction, efficiency improvement, and safe production in coal-fired power plants.