Power is one of the major industries for the economic growth & welfare of the nations. The existence & development of adequate infrastructure is essential for the sustained growth of the nation’s economy. India’s power sector is one of the most diversified in the world, Sources of power generation range from conventional sources such as coal, natural gas, oil, hydro and nuclear power to viable non-conventional sources such as wind, solar & agricultural/domestic waste. India ranks 3rd among 40 countries in EY”s Renewable Energy Country Attractiveness index on the back of strong focus by the government. The Government of India’s focus on attaining “Power for All” has accelerated capacity addition in the country.

The power Industry has many industrial components which periodic repair & maintenance for delivering effective output during its life cycle. EWAC Alloys plays a major role in the repair & maintenance of the components through our value-added products & services.

Coal Burner Nozzle & Tip

The Coal Burner Nozzle and Tip Assembly inject pulverised coal through the splitter plates tangentially from the four corners of a boiler. The three main factors determining the efficiency of the coal burner nozzle and tip are the flue-gas exit temperature, excess air, and burnout.
  • The flue-gas exit temperature is linked with the boiler design rather than the combustor.
  • Accurate control of the amount of air is essential to boiler efficiency:
    • Too much air will cool the furnace and carry away proper heat.
    • Too little air and combustion will be incomplete, unburned fuel will be carried over, and smoke may be produced.

The splitter plate assembly of the coal burner nozzle tip is subjected to severe pulverized coal erosion. The point at which the pulverized coal and primary air meets the steel components of the burner nozzle is the point of change of direction of flow and the point where the maximum erosion takes place.

  • Inside surface of the Victaulic area of the coal nozzle body.
  • The area of the coal nozzle body along the edge of the divider plate at the entry of the divider plate.
  • The location of the divider plate at the entry of the Pulverized coal.

  • Velocity Adopted for Fuel-Air Mixture: It has been learnt that the velocity adopted influences the wear rate on the coal burner. The higher the velocity, the higher the rate of wear, but this cannot be varied much as it depends on the burner requirement.
  • The Pulverized Coal Fineness: Coal fineness has an influence on the rate of wear depending upon the segregation of ash from the organic portion of the coal.
  • The geometry of the Burner/Coal Nozzle Tips: Burner /coal nozzle tip wear is a complex phenomenon. Amongst several factors affecting wear, burner/nozzle tip geometry plays a paramount role.
  • Material (Alloys) for the Burner/Coal Nozzle Tips/ Splitter Plates: As burners are subjected to heat radiation from burning fuel, they are made of very high alloy steels. The more often preferred material is stainless steel 310 Grade.
  • The Flame Profile and Distance from the Burner/Coal Nozzle Tip: The flame intensity and flame distance from the burner tip have two influences on the wear of the burner. One, it leads to warping of the burner tip and second, it creates eddies that accelerate wear.

    • We boast a 100% success rate.
    • For coal burner Nozzle and Tip, our Proven Product is an advanced electrode for hard facing a wide range of base materials for abrasion/erosion at elevated temperatures. The deposit consists of a complex Carbide system that retains Abrasion/Erosion resistance up to 850°C with a Hardness of 62-68 HRc.
    • The hard facing layer on the Coal burner Nozzle and Tip maintains the hardness of 62-68 HRc at an elevated temperature of 850°C due to its abrasion/erosion and heat resistance properties. This controls the air-fuel consumption, which promotes Boiler Efficiency.