150 MW NBEIL CFBC BOILER

REFRACTORY

Refractory in CFBC Boiler

Outlet Duct

Inlet duct
Screen coils

Ash return pipe

J-seal

3)Cyclone system
a) Inlet Duct
b) cyclone
4)

Lower part

a) Burner
b) Wind box

Combustion
chamber
2)
a) Lower part
b) Upper part
c) screen coils

Cyclone

Combustion
chamber

1)

Fluidizd bed

5)
Burner

Bed /Ash
return system
a)
j-seal
Outlet
system
a) cod
b) 2nd

Furnace
Operating conditions:
Temperature T = 850 950C
Partially reducing atmosphere
Strong abrasion due to turbulent bed
(sand, ash)
Demands on the refractory
Combustion chamber

system:
Abrasion resistance ( ABR < 7

Lower part

ccm)
CO resistance
Low permanent linear
change

Furnace

Refractory system :
Refractory material: Heavy high
alluminia
Thickness: 80 mm
Anchoring through studs on tube
wall
Bituminous paint 2 mm thk

Wind box
Operating conditions:
Temperature T = 850 950C
Partially reducing atmosphere
Strong abrasion due to turbulent bed

Wind box
Refractory system :
Refractory material: Middle weight
shaped material
Thickness: 100 mm
SS 310 AnchorS welding on fin plate
of tube wall
Bituminous paint 2 mm thk on
Anchors

Screen
Coils

Operating conditions:
Temperature T = 850 950C

Screen coils

Partially reducing atmosphere

Strong abrasion due to turbulent
bed (sand, ash)
Demands on the refractory
system:
Abrasion resistance ( ABR < 8 ccm)
CO resistance
Low permanent linear change

Screen
Coils
Refractory system :
Refractory material: Heavy high
alluminia
Thickness: 80 mm
Anchoring through studs on coils
Bituminous paint 2 mm thk on
anchors

Cyclone Inlet duct

Operating conditions:

Strong abrasion through ash/bed erosion

Inlet
duct

Temperature T = 800 950C

Flue gas flow touching the duct wall

Demands on the refractory system:

Abrasion resistance (ABR < 9 ccm)
CO resistance
Low permanent linear change

Bull nose

Refractory system Inlet Duct

Multilayer system on steel wall
SS310 anchors welded to steel casing and
painted with bituminous black of 2mm thk
Back up with lightweight heat insulated
pouring material 240 mm thk
High strength castable refractory with120
mm thk

Cyclone Target Zone

STEEL (COLD WALL )
CASING
INSULATING CASTABLE
INSULATING LAYER

HIGH STRENGTH WEAR RESTING CASTABLE

Refractory system target zone

Multilayer system on steel wall
Refractory: High strength castable refractory
with 120 mm thk
Back up : Liight weight heat insulated pouring
material of 240 mm thk

Cyclone Target Zone

Cyclone cylinder and cone

Operating conditions:

Strong abrasion through ash /

bed erosion (ABR < 9 ccm)
Cyclone
Rckfhrzykl
on

Temperature T = 800 950C

Flue gas flow touching the inle

wall

Cyclone cylinder and cone

Demands on the refractory s

ystem:
Abrasion resistance (ABR <
10cm3)
CO resistance

Cyclone

Refractory system
Multilayer system on steel wall
Refractory: High strength castable
refractory with 120 mm thk
Back up with Light weight heat insulated
pouring material with 240 mm thk

Wear resistant brick

Light weight brick

Ceramic blanket

J-seal
Demands on the refractory system:
Abrasion resistance (ABR < 7 cm3)
CO resistance
Low permanent linear change

Ash return pipe

J-seal

J-seal
Operating conditions:
Strong abrasion through
ash/bed erosion
Temperature T = 800 950C
Refractory system :
Refractory material: Heavy high
alluminia with thk 120 mm
Back up with light weight heat
insulated pouring material 170 mm
thk
ss310 Anchoring through casing
material

CO
D
Cross over
Duct

Demands on the refractory

system:
Abrasion resistance (ABR < 10 cm3)
CO resistance
Low permanent linear change

COD
Refractory system :
Refractory material: High strenght
wear resisting pouring material with
110mm thk
Back up with light weight heat
insulated pouring material 240 mm
thk
ss310 Anchoring welded through
casing
Bituminous paint 2 mm THK

Burner
Operating conditions:
Temperature T = 850
950C
Partially reducing
atmosphere
Strong abrasion due to
turbulent bed (sand, ash)
Demands on the refractory
system:
Abrasion resistance ( ABR <
10 ccm)
CO resistance
Low permanent linear

Burner

change

Burner
Refractory system :

Refractory material: High strenght

wear resisting pouring material with

100mm thk
Back up with light weight heat

insulated pouring material 160 mm

thk
ss310 Anchoring welded through
casing
Bituminous paint 2 mm THK

REFRACTORY
MATERIAL
150 MW PP - BOILER REFRACTORY (CHINA PRODUCTS)

S.N
O

AREA

CYCLONE,COD &
PARTICAL RETURN
DEVICE(FIRST LAYER)

Light Weight Heat Insulating

Pouring Material (50kg/Bag)

CYCLONE & COD

High Strength Wear Resisting

Material (YG-JZ-13(50kg/Bag)

CYCLONE & ECONOMISER

Light Weight Brick(Insulation

Brick)

CYCLONE

Wear Resistant Brick

FURNACE & PARTICAL

RETURN DEVICE

Heavy High Alumina Pouring

material
(YG-GJ-15)

PLENUM

Middle Weight Shaped Material

10
11

FURNACE OUTLET
,SCREEN COILS , OVER
HEAD,CAGEWALL AND
ECONOMISER
SUPPORTING BEAM
FURNACE BED(FIRST
LAYER)

ECONOMISER SUPPORT
BEAM
BURNERS,J-SEAL AND
FURNACE

DESCRIPTION

ADDITIVE

WATER QTY

REMARKS
CA-50-G6
(17.5
20 -22 Liters
kg/Bag)

CA-70
shutter to be removed
( 3.5kgs/Bag
3.5 Liters
after 12 hours of
)
application
Slurry
Soak 12 Hrs Before
Equal amount of water
(50kg/Bag)
Use
Wear
Resistant Equal amount of Binder(Wear
Mortor
Resistant Binder)
(50kg/Bag)
CA-70
shutter to be removed
( 3.5kgs/Bag
3.5 liters
after 12 hours of
)
application
CA-50-G6
5-7 Liters
( 8.75 kgs )
Wear Resistant Binder(2.5
CA-70(1kg) kgs premix time and 2.5 kgs
at the time of mixing)

Wear Resisting castable

Reractory
(YG-GS-14)

Middle Weight Heat Insulated

CA-50-G6
5-7 Liters
pouring material
( 8.75 kgs )
INDIAN REFRACTORY PRODUCTS
5.375 kgs
Binder(10.75
Phoscast-60
1.75- 2 liters(3.5-4%)
%) OR
3350ml
Hypercast-80(LC-80)
Insulcast-900

2.87 Litres(5.75%)
29 Litres(58%)

Soak 12 Hrs Before

Use by mixing 2.5
liters of binder
-

Refractory
properties

Befor
e

After

Cyclone Target area High strength castable refractory

repaired with wear resistant Ccastable refractory

BEFOR
E

AFTER

Cyclone inlet joint repaired with Phoscast90 xr

BEFOR
E

AFTER

Cyclone bull nose area High strength castable refractory area repaire
with Phoscast 90 xr

Before

After

Refractory failure in furnace at coal

chute area

Before

After

Furnace area eroded patched with PHOSCAST9O XR

Refractory failure in
wind box

INFERIOR DESIGN PARAMETERS

Inferior abrasion resistant property, low Volume Stability, low Strength

refractory material used
Velocity and particle profile more than design parameters it is said
that an increase in 10 % of velocity can lead to an increase of erosion
of 21 % in refractory lining
Improper expansion joints
Not providing retainer plates at profile change areas
Size and shape of pressed refractory / Bricks
Wrong material selection, Faulty design, profile and pitch of anchors
Inappropriate refractory lining thickness
Negligence of a possible alkali attack from the fuels especially from
bio mass and coal based fuels

QUALITY OF
REFRACTORY MATERIAL

Usage of expired or worn out refractory material

Haphazard storage of refractory
Usage of partially set or bags having lump formation
Using refractory from damaged bags

POOR INSTALLATION PRACTICES

Usage of sub standard quality of water
More mortar between bricks
Usage of more water percentage Adding 1 % of excess water can lead
to 10 % reduction in CCS of castable
Improper mixing sequence and mixing time
Improper welding of anchors
Long lead time for pouring refractory in to forms
Improper compaction of castable refractory
Over sized panels and wrong orientation of same
Improper of curing and form work removal
Improper or insufficient dry out

PRECAUTIONS
The following things has to be taken care during the application:
Proper handling & storing of refractory materials
Proper execution plan.
Good quality of water.
Suitable welding electrode for the anchors.
Proper welding of anchors and cleaning of slag.
Proper applying Bituminous paint in the anchors/ provide PVC caps.
Proper shuttering panels
Proper mixing and placing of refractory castable as per manufacturer
recommendation.
Proper vibration of the castable in the shuttering.
Providing expansion joint as per design.
Proper de-shuttering and inspection of cast panels.
Proper dry out of refractory.

Materials for refractory

application

Muller M/c

VIbrator

Digital weighing
M/c

Test
tube