Power Industry
Circulating Fluidized Bed Combustion (CFBC) and Atmospheric Fluidized Bed Combustion (AFBC) boilers are widely used in power plants and industrial applications due to their fuel flexibility, low emissions, and high efficiency. Refractory materials play a critical role in boilers, as they protect the boiler components from high temperatures, abrasion, and corrosive environments.
MMP Refratech offers a wide selection of power generation refractories that can add value to your plant operations. We also provide a host of support services to keep your heat-treatment equipment in peak operating condition.
Key areas of a Power boilers where refractory applications are essential:
1. Combustion Chamber (Furnace)
Refractories used in the combustion chamber (furnace) play a critical role in maintaining thermal efficiency, durability, and safety in high-temperature environments. These specialized materials are designed to withstand extreme heat, thermal shock, and chemical reactions that occur during the combustion process. Refractories used in combustion chambers are Fire bricks, High alumina bricks, Refractory Castables, Ceramic Fiber Products. We provide all kind of refractory materials with customized.
2. Cyclone Separator
Cyclone separators are used in these industrial applications to extract particulates from air flows, hydro flows, and gas streams. For cyclone separators to withstand the high temperatures and abrasive conditions encountered during the separation process, refractory linings are essential. Common refractory materials utilized in cyclone separators include high alumina bricks, silicon carbide bricks, and abrasion resistant refractory castables. Proper selection and installation of refractories are essential to ensuring the durability and efficiency of cyclone separators in industrial processes.
3. Furnace Walls
Refractories for furnace walls are essential components in industrial furnaces, providing thermal insulation, structural integrity, and protection against high temperatures and chemical reactions. These are similar to combustion chambers (furnace), only difference is that in a furnace, only heat is produced with a single fuel, whereas in a combustion chamber, there is decomposition and various fuels are used. These materials are designed to withstand the harsh conditions within the furnace environment and ensure efficient heat containment and transfer. Refractory Fire bricks , High alumina bricks, refractory castables, and ceramic fiber products are used as refractory materials to protect the walls.
4. Windbox
A windbox is a part that is frequently seen in industrial furnaces and boilers. It functions as an air distribution chamber that supplies the burners with the combustion air. By ensuring that the right quantity of air is combined with the fuel for an effective and regulated combustion, it plays a critical part in the process of combustion. In industrial heating applications, the windbox aids in controlling the distribution and circulation of combustion air to provide the best possible temperature control, fuel combustion, and overall system efficiency. Common refractory materials used in windboxes include high alumina bricks, insulating firebricks, and castables with abrasion-resistant properties.
Components of a Windbox that also require the above refractories:
Dampers: Control the flow of air into the windbox and subsequently to the burners, allowing for fine adjustments in the air supply.
Baffles: Guide the air within the windbox to ensure even distribution to each burner.
Pressure Sensors: Monitor the pressure within the windbox to ensure it is within the desired range, triggering adjustments if necessary.
5. Seal Pots
Seal pots are utilized in industrial settings, such as steam turbines and pumps, etc to manage and uphold the pressure of sealing systems. These vessels, often compact in size, function as containers for sealing fluids like oil or water, establishing a seal between moving and stationary parts in machinery. Fireclay, and Aluminia are common refractory materials used to seal pots.
6. Fluidized Bed Combustion Boiler (FBC Boiler) & Circulating fluidized Bed Combustion Boiler
A Fluidized Bed Combustion (FBC) Boiler is a type of boiler that utilizes a bed of solid particles (typically sand or limestone) suspended in an upward-flowing stream of air to facilitate combustion. In an FBC boiler, the solid particles are fluidized by the air, creating a "fluidized bed" that promotes efficient mixing of fuel and air for combustion. This process allows for better heat transfer, lower emissions, and improved fuel flexibility compared to traditional combustion methods.
A Circulating Fluidized Bed Combustion Boiler is a variation of the FBC boiler where the solid particles in the fluidized bed are circulated back into the combustion chamber multiple times to enhance combustion efficiency. This circulating action helps achieve higher combustion temperatures, better fuel burnout, and reduced emissions of pollutants like sulfur dioxide and nitrogen oxides
Common refractory materials used in FBC and circulating fluidized bed boilers include high alumina bricks, silicon carbide bricks, castables, and ceramic fiber products.
Cyclone separators in Fluidized Bed Combustion (FBC) boilers use centrifugal force to separate solid particles like ash and unburned fuel from the flue gas. The clean gas exits the top, while heavier particles are collected at the bottom, either to be re-injected into the furnace or disposed of.
Refractory linings protect the cyclone from abrasion, high temperatures, and chemical corrosion. Common materials include high-alumina refractories for abrasion resistance, silicon carbide for high durability, and castable or gunned refractories for flexibility and ease of repair. Regular maintenance is crucial to prevent wear and extend the cyclone's service life.
7. Ash Hoppers and Discharge Systems
Ash hoppers and discharge systems in the power industry are components of boilers and furnaces that handle the collection and removal of ash generated during the combustion of coal or other solid fuels. These require basic refractories like Ceramic Fiber Products
8. Refractory lined expansion joint
Expansion joints are structural components designed to absorb thermal expansion or contraction of building materials, pipelines, bridges, and other structures due to temperature variations, seismic activity, or settlement. These joints allow for controlled movement, preventing stress buildup and potential damage that could occur if materials were rigidly connected. The refractory which has high properties for thermal resistance can be used here as fire bricks, insulation bricks.
9. Refractory Anchors and Support Structures
A refractory anchor is a specialized component used to secure refractory linings to the shell or structure of high-temperature equipment such as furnaces, boilers, and kilns. These anchors are essential for holding the refractory material in place and preventing it from shifting or falling off due to thermal expansion, contraction, or mechanical stress during operation. We provide complete in-house manufacturing and design services for customized anchor designs.
10. Air Preheaters
A device that heats air before to a process with the main goal of boosting the process's thermal efficiency is an air preheater. So this area need to high refractories like alumina bricks, silicon carbide bricks, firebricks.
11. Overbed and Underbed Feeding Systems
Refactories used in overbed and underbed feeding systems play a critical role in high temperature industrial processes, particularly in boilers and furnaces. These feeding systems are designed to introduce solid fuel into the combustion chamber for efficient and controlled burning. Refractories in these systems are subjected to extreme temperatures, abrasion, and chemical exposure, requiring materials with specific properties to withstand these conditions effectively. Refractory materials used in overbed and underbed feeding systems include high alumina bricks, silicon carbide bricks, castables, and ceramic fiber products.
12. Flue Gas Duct
Flue gas duct refractory lining is a specialized protective layer used in the flue gas ducts of industrial furnaces, boilers, and incinerators. This lining is designed to withstand high temperatures, corrosive gases, and abrasive particles present in the flue gas stream. By providing thermal insulation and erosion resistance, the refractory lining helps maintain structural integrity, optimize heat transfer efficiency, and extend the service life of flue gas duct systems in industrial processes. All kinds of Flue gas ducting refractory lining we provide for longevity and durability of the duct.
13. Plenum Chamber
A plenum chamber is a compartment or enclosure in a heating, ventilation, and air conditioning (HVAC) system where air is collected or distributed. In industrial applications, a plenum chamber is often used in combustion systems, such as furnaces or boilers, to distribute air or gases evenly to various parts of the system. The plenum chamber is mostly implanted in power plant as there are furnace, boiler are in used. So these plenum chamber required refractories to protect against thermal shocks, high temperatures.
14. Fuel Feed Chutes
Fuel feed chutes are components used in industrial boilers, furnaces, and combustion systems to deliver solid fuel, such as coal, biomass, or waste materials, into the combustion chamber for burning. These chutes provide a controlled pathway for the fuel to enter the combustion zone, ensuring efficient and consistent fuel delivery for optimal combustion performance. Refractory castables are mostly used in Fuel Feed Chutes. Proper selection and installation of refractories in fuel feed chutes are essential for optimizing combustion efficiency, reducing maintenance costs, and extending the service life of industrial heating systems
15. Secondary Air Nozzles
Secondary air nozzles are components in combustion systems that introduce additional air into the combustion chamber to ensure the complete combustion of fuel. They help improve fuel efficiency and reduce emissions by providing a secondary source of oxygen for the combustion process. Refractory materials used for secondary air nozzles in power industries are high alumina refractory castables , and many more.
Refractory materials are integral to the efficient and safe operation of power plants. Selecting the right type of refractory for each area ensures the longevity and performance of the equipment, reduces downtime, and enhances overall productivity. By understanding the specific requirements of each area within a power plant, manufacturers can optimize their refractory usage, leading to more sustainable and cost-effective operations. MMP Refratech provide various kind of refractory materials and installation in power industry with customize specifications to all above applications.
For more information on refractory materials and their applications in the power industry, Contact us at MMP Refratech today