MANUFACTURING PROCESS-II UNIT-1 THEORY OF METAL CUTTING
Boiler GRH.ppt
1. Stronger with…
Castolin Eutectic
1
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
Castolin Eutectic‘s History in Boiler Coating
█ First trials in Boiler protection in USA in 1973
█ Arc, Combustion, Plasma, PTA, HVOF, spray and fuse technologies
█ Global Boiler Coating team formed in 1990.
█ Boiler OEM partners (ABB,Babcock, etc) and operators (RWE, CEGB,
TIRU, etc)
2. Stronger with…
Castolin Eutectic
2
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
Powders, wires and densification Know-How
█ Alloy
• Powder or cored wire
█ Process
• Thermal Spray: Arc, Combustion, HVOF, Plasma
• Welding
• Fusing, densification
█ Choice of Coating System
• Cost
• Speed, access for on site work
• Corrosion/wear performance, bonding, smoothness, thickness
3. Stronger with…
Castolin Eutectic
3
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
CastoLab® Services - Coating on site
4. Stronger with…
Castolin Eutectic
4
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
CastoLab® Services – Coating in workshops
5. Stronger with…
Castolin Eutectic
5
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
Quality, reliability and technology
█ Consumable-ISO 9001, TUV, Lloyds of London
█ Equipment-CE
█ In house ASTM G65 Wear Testing. Erosion, impact, high temperature
█ Independent corrosion testing HCl (33%), HNO3 (55%), H2SO4 (96%) and
acetic acid (80%)
█ CastoLab investments
DIN 50021
Neutral salt spray test with a 5%
sodium chloride solution to 240hrs.
6. Stronger with…
Castolin Eutectic
6
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
Boiler Issues
Tube thins due to:
█ Erosion
█ Corrosion
7. Stronger with…
Castolin Eutectic
7
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
Boiler Coating - Difference between types
█ Erosion
█ Corrosion
Arc Wire
Arc/powder
plus Densification
S&F
Power- Coal
Power- Coal-Low NOx
Waste incineration
Waste with Power
8. Stronger with…
Castolin Eutectic
8
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
Boiler issues - Corrosion
█ Chlorine content in Municipal Waste estimate
Drivers for corrosion problems
█ Lower grade coal- more sulphur
█ Higher combustion temperatures
due to emission limits (NOx)
█ Longer outages needed 3-5 years
█ Higher Steam temperatures
█ More waste/biomass combustion
9. Stronger with…
Castolin Eutectic
9
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
Waste Incineration and Energy
Power
Incineration
█ ~70 MVA Waste Power Plants in Germany with further 30 plants planned
█ 1.5 % of the total gross energy production with Waste Power Plants
█ Fuel supplement is tyres, textiles, plastics, pellets
10. Stronger with…
Castolin Eutectic
10
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
Waste Treatment EU 27 (2007)
0%
10%
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30%
40%
50%
60%
70%
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100%
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Country
Waste
treatment
Deponierung Verbrennung Recycling Kompostierung
█ Internship at Castolin Eutectic
05.08.2010 – 01.10.2010
Philipp Staudt
Incineration Distribution
11. Stronger with…
Castolin Eutectic
11
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
Biomass
█ The market of biomass
power plants is very big
and growing.
█ In Germany alone more
than 200 plants existed in
2008. A study conducted
by “ecoprog / Fraunhofer
UMSICHT”in 2009
mentions 130 planned
biomass power plants in
Europe for the next few
years.
█ Internship at Castolin Eutectic
05.08.2010 – 01.10.2010
Philipp Staudt
12. Stronger with…
Castolin Eutectic
12
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
Results Waste-to-Energy
█ The waste-to-energy market is the most interesting for our S+F technology.
█ There are about 430 installations in Europe. The biggest market by numbers
is France while the highest amount of waste is burned in Germany.
█ The total amount of treated waste is about 70 000 000t and there are more
than 800 boilers. More than 23 000 GWh of electricity and more than 40 000
GWh of heat are produced every year.
█ The biggest operators come from France. Those are Veolia, GDF Suez
Novergie and Tiru in that order. The biggest Operator outside of France is
E.ON.
█ Internship at Castolin Eutectic
05.08.2010 – 01.10.2010
Philipp Staudt
13. Stronger with…
Castolin Eutectic
13
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
Reference
Belt
NOVERGIE VALORLY à Lyon
SET MONT BLANC 74 PASSY / NOVERGIE
COMPAGNIE DE CHAUFFAGE URBAIN DE
GRENOBLE
By-pass tubes
NOVERGIE VALORLY à Lyon
NOVERGIE VEDENE
VEOLIA ORLEANS
SETMI VEOLIA TOULOUSE
OSTENDE IVOO (dernier mètre des panneaux)
NOVERGIE CARHAIX
LAVERA ENERGIE
VEOLIA VALENE
Tubes Open pass
• TIRU St OUEN NOVERGIE
• Tubes porteurs
• VEOLIA CGECP
Evaporator tubes
• VEOLIA CHALON EN CHAMPAGNE
• VEOLIA LASSE
• VEOLIA CGECP
15. Stronger with…
Castolin Eutectic
15
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
Coated Tubes produced in CastoLab
16. Stronger with…
Castolin Eutectic
16
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
Publications and patents
█ Patents
• BTC 561
• BTC 251
█Publications
• Energy magazine
• ASM Materials Week
• Power Engineer
17. Stronger with…
Castolin Eutectic
17
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
Boiler Team France : already 5 years of R&D to improve performances of boilers in
waste incinerators
BoilerTeam :
18. Stronger with…
Castolin Eutectic
18
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
BoilerTeam : some results
BTC 8995CH Weld INCONEL 625
After6 months: Strong pitting
12 months. No change in coating
New Coating
CASTOLIN 8995CH
in working conditions
850°C/390°C !
After 6 month of competition
with inconel 625 (right)
CASTOLIN 8995CH still in
place after 12 months
19. Stronger with…
Castolin Eutectic
19
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
Development of Spray and Fuse for Panels
█ GROUP R&D Project to develop automated Spray and Fuse for Panels
█ More difficult as can not rotate and it is not symetric
█ Need multiple Spray guns and fusing facility
█ Looking at flame, oven, induction fusing.
20. Stronger with…
Castolin Eutectic
20
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
Arc wire spraying of coal boilers
█ 3 cored wires specifically developed and proven in boilers
█ Advantages:
█ No gases, combustion. Simple deposition
█ High spray rate
█ Highest coating density and bonding of cold processes
21. Stronger with…
Castolin Eutectic
21
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
CastoLab inPoland – Arc Wire Spray Boiler
coating capabilities
█ Two spray booths, and two grit blasting chambers allowing on direct
part transfer between them.
█ All equipment installed in heated halls allowing an operation through
whole year.
█ Probably the heaviest duty ventilation/filtration system in Europe
meeting all ecological regulations.
█ 40 certified spray operators ready to complete jobs in extremely short
time
22. Stronger with…
Castolin Eutectic
22
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
Potential markets for anti erosion arc
spray coatings.
0.0
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80.0
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160.0
TWh/year
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Power generation from lignite