Boiler plants
Refractory lining and insulation of industrial boiler plants for steam and energy generation.
Furnace profile at a glance.
Combustion chamber
Central combustion space of the boiler with refractory lining in the lower area (hopper, grate transition). The upper areas are protected by water-cooled membrane walls, which receive a refractory gunned or rammed coating.
Boiler membrane wall
Water-cooled tube walls that enclose the combustion chamber. They are provided with a refractory protective coating (SiC-bearing gunning mix) that protects against erosion, corrosion and slagging.
Flue gas passes
Ducts routing the flue gas from the combustion chamber to the stack. In deflection areas and at constrictions the erosive loading from fly ash is particularly high.
Cyclones
Centrifugal separators in fluidised bed boilers for returning bed material and unburned fuel. The lining of abrasion-resistant refractory castable is exposed to extreme erosion.
Economiser
Heat exchanger for preheating the feed water using the residual heat of the flue gases. The refractory lining of the casing and the transition areas protects against dew point corrosion.
Refractory construction for maximum boiler efficiency.
Industrial boiler plants form the backbone of energy supply in power stations, district heating companies and industrial operations. The refractory lining and insulation of these plants largely determine the operational reliability, energy efficiency and service life of the entire boiler system. SBS Refractory Service offers comprehensive refractory solutions for all boiler types — from large water-tube boilers to industrial steam generators.
The demands placed on refractory construction in boiler plants are complex: membrane walls have to be protected against erosion and corrosion, combustion chambers need heat-resistant linings, and flue gas passes require abrasion-resistant materials to withstand fly ash. Added to this is thermal insulation, which minimises heat losses and increases the overall efficiency of the plant. Our material concepts take all of these factors into account and are tailored to the particular fuel and operating conditions.
With years of experience in boiler construction we know the challenges of every plant. Our teams are practised in working in confined spaces, on scaffolding and at great heights. From the annual overhaul and partial repairs through to complete relining, we offer the full range of services — on schedule and quality-assured.
Typical problems with the Boiler plants.
These loads determine the choice of material and the design of the refractory lining.
Erosion of the membrane wall coating
Fly ash and particles in the flue gas stream erode the protective coating on the water-cooled boiler tubes. Without protection there is a risk of corrosion and tube damage.
Slagging in the combustion chamber
Low-melting ash constituents form slag deposits on combustion chamber walls and superheaters that impair heat transfer and can cause mechanical damage.
Thermal heat losses
Inadequate or aged insulation leads to considerable energy losses. Even a temperature rise of 10 °C on the boiler outer wall means significant efficiency losses.
Work in confined spaces and at height
Boiler combustion chambers and flue gas passes require work on scaffolding at great height and in confined spaces. Special safety concepts and qualified personnel are indispensable.
Materials & lining
Every zone of your furnace places its own demands on temperature resistance, chemical resistance and mechanical load capacity. We select the optimum material combination.
Click on a material for details
Refractory castable
Refractory castableCombustion chamber lining and cyclones
SiC tiles
Wear protectionWear protection on membrane walls
Insulating castable
InsulationFlue gas passes and transitions
Typical work on the Boiler plants.
Our services for this furnace type — from complete relining to ongoing maintenance.
From site inspection to acceptance.
Our structured process guarantees quality, on-time delivery and safety in every project.
Assessment & site inspection
Inspection of the combustion chamber lining and the membrane wall coating
Planning
Repair concept coordinated with the overhaul date
Execution
Repair or renewal of the refractory lining
Safety
Scaffolding work, fall protection, confined spaces
Assessment & site inspection
The inspection begins with a systematic walk-through of the cooled boiler. All refractory areas are examined for cracks, spalling, erosion and slagging. The membrane wall coating is checked for detachment and loss of thickness. In cyclones we measure the residual thickness of the refractory lining by ultrasound. The results are summarised in a digital condition report with photographs and a dimensional record.
Planning
Based on the inspection findings we prepare a prioritised repair concept. Critical areas such as cyclone linings and membrane wall damage are dealt with first. The material concept takes account of the fuel used and the specific wear mechanisms. Scaffolding planning, logistics and manpower planning are matched to the overhaul time frame in order to optimise the shutdown time.
Execution
Execution comprises breaking out damaged areas, surface preparation and rebuilding of the refractory lining. Membrane wall coatings are freshly applied after thorough cleaning and blasting. Cyclone linings are renewed with abrasion-resistant refractory castable using casting or gunning techniques. Insulation work completes the measure. All work is carried out in parallel in order to make the fullest possible use of the overhaul period.
Safety
Boiler work requires extensive safety measures: scaffolding erected to structural specifications, fall protection for all employees, ventilation in confined spaces and dust protection during break-out. Before entry, the complete cooling and emptying of the boiler is confirmed. All employees receive project-specific instruction and wear the prescribed PPE.
From our project portfolio.
Over 500 successfully completed refractory construction projects in the DACH region and the Benelux countries.
Boiler plants
Frequently asked questions
Everything you need to know about the Boiler plants
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