Advanced Coatings on Furnace Wall Tubes

Nickel-based self-fluxing alloy coating extends the service life of furnace wall tubes at waste incineration plants due to its excellent corrosion resistance and heat resistance. Fusing of such coatings by induction heating offers improved efficiency and reliability of products. Compared with conventional plasma, flame, and high-velocity oxy-fuel spraying thermal-sprayed coatings, induction-fused coatings provide a far stronger metallurgical bond at the interface, while minimizing the inclusion of pores. In addition, the tubes are less costly than those with welded coatings, and the process reduces the distortion of the products, facilitating easier final assembly. A successful experimental application of 11 units in a waste incinerator revealed virtually no corrosion on the exposed surfaces, and showed an improved water heating efficiency over that of the original tubes. Such units are now being employed in four incinerators in Taiwan, and continuing tests are showing great promise.