I. Project Background
As the core equipment for pulverized coal preparation in thermal power plants, the coal mill is subject to continuous scouring by high-velocity dust-laden airflow in the inlet hot primary air duct, which causes severe wall erosion and perforation, leading to leakage of hot air and pulverized coal media. Such failures directly constrain stable unit output and increase the probability of unplanned outages, while simultaneously causing thermal energy waste, dust pollution, shortening the service life of the duct and auxiliary equipment, and continuously increasing power plant maintenance and operational costs. To address the severe wear issues in the pulverizing air duct system, Beijing Titan-Shield Technology, leveraging years of technical expertise in power plant wear protection and on-site construction experience, has adopted a custom hexagonal wire mesh wear-resistant composite process for duct anti-wear repair and rehabilitation. Long-term operational verification has demonstrated excellent protective performance.
II. Customized Anti-Wear Solution Design
The scouring intensity and operating temperature vary significantly across different zones of the coal mill inlet air duct. Generic wear protection processes are highly prone to localized detachment and premature failure. Our technical personnel conducted on-site surveys and inspections, developing exclusive protection solutions based on actual operating conditions. The wear-resistant composite protective layer can withstand temperatures up to 800°C. Depending on the varying degrees of wear at different positions along the duct, the hexagonal wire mesh specifications and wear-resistant lining material thickness are adjusted accordingly, precisely matching on-site conditions to fundamentally prevent protective layer damage and failure caused by inadequate solution adaptability.
III. Standardized and Regulated Construction Management
Throughout the entire project, we strictly adhere to the construction principles of "Quality First, Safety Foremost," with operations carried out step by step in full accordance with the specialized technical plan:
Thoroughly clean the inner wall of the air duct, removing accumulated dust, impurities, and oil stains to ensure a clean and solid substrate for construction.
Precisely cut the hexagonal wire mesh to size, and secure it uniformly to the duct wall by spot welding, establishing a stable wear-resistant framework.
Apply the wear-resistant lining material in layers, with thorough compaction and surface finishing, forming an integrated composite protective layer.
During construction, technical personnel provide full-time on-site supervision. Upon completion, a comprehensive self-inspection is conducted, with any identified defects immediately corrected and reworked to ensure comprehensive quality control throughout the construction process.
IV. Comprehensive Benefits of Project Implementation
The repair project has maintained stable long-term operation since commissioning, receiving high praise from the owner and delivering triple value in safety, economy, and environmental protection:
Safety Benefits: Thoroughly eliminates air duct leakage of pulverized coal and hot air, removing equipment and on-site safety hazards caused by media leakage, and significantly reducing the risk of sudden unit outages.
Economic Benefits: The wear-resistant composite protective layer offers a service life of up to 6 years, reducing frequent pipe replacement and repeated maintenance expenditures, minimizing shutdown losses, and significantly improving unit equipment utilization efficiency.
Environmental Benefits: Effectively prevents the escape of pulverized coal and high-temperature hot air, reduces dust pollutant emissions, and supports thermal power plants in achieving green and low-carbon upgrade and transformation.