Indian thermal power plant reduces 80% castable consumption by using HASLE D59A-ht

2022-02-17

Feb. 17, 2022 - A fantastic 80% reduction in annual castable consumption has been achieved at a thermal power plant in India. The plant, which has a production capacity of 3x30 MW boilers and runs mainly on coal, was facing serious refractory failure problems in all three CFBC Boilers. The critical areas were the Target Zones such as Bull Nose, Target and Cyclone Walls, the Combustor Outlet Duct and in the Burner and Nozzle openings in combustor area. The damage was mostly caused by the hot particle mix (i.e. unburnt coal and bed material with a temperature between 800-950 °C), which is carried through the system with dense flue gases at a velocity of app. 30 m/sec.

Having supplied castable and precast solutions to the cement production lines in same premises since 1995, HASLE suggested lining these critical areas with HASLE D59A-ht castable – our strong, dense castable, which is known to extend the lining lifetime significantly i.e. due to its high mechanical strength and excellent thermal shock- and abrasion resistance.

As a result of the installation of HASLE D59A-ht castable, the power plant has significantly improved its run factor. It has seen reduced maintenance costs, labor costs and material costs – in fact, the annual refractory consumption has gone down from a past consumption of 10-15 MT per boiler per year to just to 2-3 MT per boiler per year. For a performance comparison between HASLE D59A-ht and the previously used castable, see the image on this post.