Application Review

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Power Generation
End User
Duke Allen
Allen Plant

Application Details

In 2002 the Allen Plant was in the process of completely relining their ABB Steam Boilers. At that time the boilers were lined with 4 inches of rock wool board only. Prior to using the rock wool board, asbestos insulation had been used. Ceramic was not to be considered.

Application Challenges

Rockwool boards are manufactured by taking loose fiber, mixing it with phenolic resin, which serves as a binder, and pressing it. In application at high temperatures the phenolic resin was burning away, leaving the fiber un-bonded. These loose fibers would then fall down within the wall cavity of the boiler, resulting in many un-insulated hot spots. These hot spots allowed tremendous amounts of heat to escape, causing boilers to run inefficiently.

Application Solution

Engineers designed a system utilizing 2 inches of TreoTM, which would serve as the material against the boiler wall, and 2" of Rockwool board as back up to the Treo™. This new two-part design proved extremely effective. The Economizer, Penthouse and the Water Walls were all relined in this manner.

Results and Impact

Shortly after start up and at regular periods later, thermal imaging equipment clearly showed the two-part system on the newly lined boilers showed more efficient insulation system. The thermal performance was much improved. Boiler efficiency increased and no time-induced hot spots ever developed with Treo™ as the primary thermal barrier.

The contractor installing the TreoTM also increased efficiencies because of the available widths: 24", 36", 48" and 60". This resulted in significant labor savings on the installation. The 2002 project was completed ahead of time, in part due to this delivery of special sizes direct from the Tritex.