Advanced wear protection solutions safeguard biomass efficiency

Mike Parr, Key Account Manager for Biomass at Castolin Eutectic, explores how advanced coating technologies can enhance the efficiency and longevity of biomass and energy-from-waste applications.
 Biomass is transforming the energy landscape. In Belgium, 64% of renewable energy is produced from biomass, with a target to reach 17.4% by 2030. Sweden relies on wood pellets, while Brazil leads in sustainable transportation with sugarcane ethanol. By 2035, the UK plans to expand biomass use to reduce reliance on unstable fuels like gas, with biomass currently accounting for 11% of UK energy.

Many biomass and energy-from-waste (EfW) plants operate year-round without planned outages, leaving engineering teams too occupied for maintenance until critical issues arise. Castolin Eutectic offers preventative solutions to safeguard operations, minimize downtime, and extend the lifespan of industrial parts.

Biomass and EfW plants face significant challenges due to problematic fuels, leading to increased corrosion and erosion. Mechanical grabs erode quickly due to constant movement and abrasive fuel handling. Castolin Eutectic’s solutions, including hard-faced plates and protective coatings for boilers, filters, and flue gas systems, address these issues holistically, ensuring smooth operations.

Collaborations with leading boiler manufacturers ensure a prolonged lifespan from the outset. For older plants facing obsolescence and requiring life extension, this approach is both effective and efficient, providing a seamless transition until new facilities are ready. 

Beyond product sales, technical consultation is key. Unlike some competitors who simply offer boiler coatings, Castolin Eutectic’s approach involves a thorough analysis of boiler specifics and potential fuel changes, accommodating future industry shifts. The goal is to find the most economical outcomes for customers, drawing from a comprehensive product range that includes wear plates and an array of coatings for every stage of the process. Advanced solutions include using a 3D scanner with an accuracy of around 0.1mm to create engineering drawings, eliminating the hassle of lost documentation. This technological edge ensures precision and efficiency in solving problems.  

Castolin Eutectic’s boiler coatings enhance efficiency by increasing emissivity and reducing clagging, optimizing fuel use. Longer operational intervals reduce outages, improving safety and minimizing risks. Detailed quality control ensures customers can monitor exactly what has been applied to their equipment. For instance, ChromeClad XC is used in EfW boilers to combat prevalent corrosion. TubeArmor, a densifying agent, can also be applied as a ceramic coating. Its bright green color allows for easy inspection, indicating ongoing protection. A black variant is also available to enhance boiler emissivity and heat transfer. 

 Castolin Eutectic’s protective coatings and wear plates significantly extend plant lifespans, allowing operations to run continuously for 12 to 18 months without shutdowns due to tube leaks in the protected area. Castolin Eutectic is also ready to support bio-energy carbon capture and storage (BECCS) systems, offering specialized coatings to enhance performance and reliability. Direct communication with operators ensures tailored solutions that enhance efficiency and longevity while addressing each plant’s unique needs.