900–1,600 °C
Electric power industry refractory solutions
Boiler, CFB and biomass linings engineered against fly-ash erosion and sulphur corrosion.
- Operating temperature
- 900–1,600 °C
- Main driver
- Erosion rate, outage interval
- Typical units
- CFB, PC boiler, biomass, cyclone
- Install method
- Gunning, casting, anchored panels
Applications
Coal-fired boilers, biomass boilers, circulating fluidised bed (CFB) boilers, pulverised coal furnaces and cyclone separators, typically operating between 900 and 1,600 °C. In CFB units the dominant wear mechanism is not temperature but high-velocity particle erosion; in biomass units it is alkali and chlorine from the fuel. Linings are judged by whether they survive to the next scheduled outage.
Main challenges
Fly-ash and bed-material erosion
Circulating bed particles at high velocity abrade cyclone and return-leg linings faster than any chemical attack.
Sulphur and chlorine corrosion
Acid gases condense in cooler tail sections and attack both the lining and the steelwork behind it.
Alkali attack in biomass firing
Potassium-rich straw and wood ash form low-melting eutectics that glaze and dissolve conventional castables.
Thermal cycling on load swings
Two-shifting and renewables balancing subject linings to far more start-stop cycles than base-load design assumed.
Anchor failure
Most premature lining loss traces back to anchor design, spacing or alloy selection rather than the castable itself.
Our engineering approach
- 01
Erosion-graded castables
Low-cement corundum and SiC-bearing castables are placed only where velocity justifies them, with cheaper grades elsewhere.
- 02
Alkali-resistant tail-end materials
Acid- and alkali-resistant castables in the tail flue stop condensation attack on the cold end.
- 03
Correct anchoring and expansion joints
Anchor alloy, spacing and joint layout are specified with the lining so it can move without cracking.
- 04
Dryout and cure control
Documented dryout schedules prevent steam spalling of dense low-cement castables on first firing.
Recommended products by zone
| Zone | Recommended material | Why it works |
|---|---|---|
| Combustion chamber & bed area | Wear-resistant castables, corundum and SiC castables | Maximum abrasion resistance at the highest particle velocities. |
| Cyclone & return leg | Low-cement high-strength castables, SiC-based plastics | Handles continuous impingement erosion at 850–950 °C. |
| Tail flue & ducting | Alkali- and acid-resistant castables, lightweight insulating castables | Resists acid condensation while cutting casing heat loss. |
| Boiler insulation | Aluminium-silicate fibre modules, insulating boards | Low heat storage for fast start-up and reduced shell temperature. |
Other industries
1,500–1,600 °C
Glass industry
Melting-end linings engineered for 8–15 year campaigns without glass contamination.
≈1,450 °C
Cement industry
Rotary-kiln linings for burning, transition and cooling zones under alkali, sulphur and clinker abrasion.
up to 1,700 °C+
Metallurgical industry
Blast furnace, converter, EAF, ladle and tundish linings for steel and ferroalloy plants.
1,100–1,300 °C
Lime (calcium) industry
Rotary and shaft lime kiln linings for calcination, transition and preheating zones.
850–1,200 °C
Waste incineration industry
Municipal and hazardous waste incinerator linings for the most aggressive chemistry in the industry.