Henkel offers high temperature abrasion resistance coating

Loctite PC 7000 HTARC designed to protect industrial processing equipment like coal tip burners in boilers and furnaces, against harsh temperature and abrasion environment

 Traditional coal tip burners are prone to wear due to exposure to high heat from furnace flame and erosion caused by coal particles in high velocity air stream. High levels of erosion lead to deformation of the coal burner tips that instantly and negatively impact the boiler efficiency.

A typical boiler has four vertically tilting burners, each with four coal nozzles and two fuel ignition guns. The maximum temperature of the fire ball in the boiler is 1,200 C. The coal fired into the boiler is more than 5 microns in size with the coal firing velocity around 28-30 m/s which translates to a feed rate of approximately 110-120 TPH (tonnes per hour).

At this rate of coal firing, the coal burner tips get damaged due to abrasion by the impinging coal particles. The resulting damage to the tip causes poor fuel distribution, which in turn leads to reduced combustion efficiency, coal wastage and higher heat input costs. Frequent repair and replacement of the coal burner tips extend downtime and leads to higher production losses.

The conventional practice is to prepare these nozzle tips using hard facing materials, which offer higher resistance to abrasion and oxidation but these tips are still prone to erosion and impact wear. Although these tips have a somewhat extended life, the furnace still needs frequent shutdowns to replace tips. This conventional method of hard facing requires a heat source for fusing the materials and a skilled welder. Moreover the heat fusing can cause thermal stress in the tip metal. Hard facing makes the tip surface rough affecting laminar flow of coal and air.

To overcome these shortcomings and provide a reliable, cost efficient solution to burner tip wear, Henkel recently introduced Loctite PC 7000 High Temperature Abrasion Resistant Coating (HTARC). This is a unique three-component rapid setting silica-based composite coating system. It is designed to protect industrial processing equipment like coal tip burners in boilers and furnaces, against harsh temperature and abrasion environment. Loctite PC 7000 HTARC is an innovative environmentally friendly water based system that offers high abrasion resistance even at 1,000 C and above. Loctite PC 7000 HTARC offers twice the protection compared to conventional methods, leading to almost double life for the burner tip. This results in sustained boiler efficiency and lesser downtime as well as associated production losses, making it a cost effective solution. It is easy to apply on most substrates and does not require skilled labour.

This product has already been tried and tested in operating conditions by a leading natural resources mining & extraction company in India. They have verified that Loctite PC 7000 HTARC was intact on the burner tip even after more than 12 months of continuous operation.

In addition to coal burner tips, Loctite PC 7000 HTARC can be used on baffle plates of coal burner tips, aluminium and steel smelters, flue gas ducts, coal burner pipes and refractory brick structure of chimneys and kilns.