CYCLONE BOILER STUDS

Although similar, the conditions to which Recovery Boiler studs and cyclone boilers studs are exposed are rather different.

In a cyclone, abrasion is the most important factor by far although high temperature, corrosion and erosion also play important roles.

From the moment a coal particle is admitted into a cyclone to the point where its completely decomposed into gas/slag phases, different factors become predominant in the attack to the studs and refractory. Initially a coal particle with its maximum mass and high velocity translates into an abrasion problem, as its mass reduced it liberates Sulphur which starts becoming a factor and finally slag may become a problem specially if deviations from design conditions take place. Under normal circumstances the portion of a cyclone covered by slag should be insulated and protected from all adverse factors but as the industry is well aware, this is not the case. Inadequate repair procedures, premature restudding, attempts to use same materials for areas with different requirements are among the main causes for cyclone tube failure and forced outages.

Our company addresses the needs of each individual cyclone through a meticulous analysis of the causes of wear for each specific area. Apropriate solutions are customized to the specific cyclone needs which normally include the application a combination of corrosion resistant, abrasion resistant of high heat transfer studs. Frequently stud density and/or distribution pattern must be improved as well.

Our very first stride into this market showed the results below. Applied on same boiler (different cyclones), upper pictures show our results after one cycle. Pictures below show what our competitor achieved.

Continuous R&D has so far brought the additional improvements:

Our cyclone studs are specifically designed and manufactured to withstand the conditions to which they will be exposed. That is the key to the results we are showing.

And now the results show as for example below, where studs in operation for 19 months still show traces of our logo on their top.