Low NOx Burners & Coal Spreaders

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Wisconsin Electric Power Valley Generating Station

Plant Specifications

• Largest US cogeneration facility producing electricity and steam
• Generates steam heat to approx 460 customers in downtown Milwaukee
• Supplies 280 MW from two coal fired units
• Utilizes Riley CCV Burner with axial swirl spreaders
• Burner capacity 50-250 MM Btu/hr
• 70% reduction in NOx emissions – equivalent to 0.068kg/MM Btu

Conforma Clad Solution

• Burner operating conditions 426° C
• Coal velocity 30.48mps
• Ash content 9% – comprised of 80% silicon dioxide and aluminum oxide
• Stellite weld overlay 38mm erosion after 22 months operation
• Silicon carbide ceramic 1.77mm erosion and significant cracking and spalling
• Conforma Clad^® WC cladding – 0.177 inches erosion
• Conforma Clad increased service life to 48 months with low NOx emissions
• Generation revenue gains - $3.63m / year

Silicon carbide spreader

Protected with Conforma Clad® cladding

Dynegy Power Corporation Wood River Generating Station

Plant Specifications

• 650 MW boiler
• T-fired boiler with balanced draft
• Powder River Basin coal (low Btu high ash content)
• Burner velocities – 24.3mps

Conforma Clad Solution

• Chrome carbide weld overlay useful service life 8-9 months
• Conforma Clad^® WC cladding useful service life 48 months
• Other materials tested using ASTM G73 test*, 73 mps particle velocity
  • Stellite 6/31 weld overlay
  • Chromium carbide coating
  • A 532 casting
  • Silicon carbide ceramic tile
• Above materials showed material loss of 1.15g -2.36 g
• Conforma Clad^® WC showed material loss of only 0.21g

* Conducted by EPRI — Electric Power Research Institute

Protected with standard weld overlay

Protected with Conforma Clad ® cladding

Conforma Clad ® WC showed material loss of only 0.21g. Generation revenue gains – $3.63m/year.