| Industrial Corrosion Protection in Power plants
Steuler delivers complete corrosion protection systems for:
• Flue gas desulphurisation plants
• Hard and soft coal as well as heavy-oil power plants
• Hydroelectric power plants
• Nuclear power plants
The most important feature of industrial corrosion protection in power generation facilities is to ensure plant availability and operational safety at all times. Steuler is one of the leading providers of corrosion protection systems in the power generation industry as a result of innovative materials and lining technologies, many years of experience and an outstanding performance record in project execution. The close interface between the business units of Surface Protective Systems, Refractory Systems and Plastics Technology has created a unique range of services for lining technologies and know-how.
From research and development to consulting, construction and production, installation and servicing, Steuler offers custom-designed solutions for every area of a facility, including for various production processes.
Numerous references substantiate Steuler's expertise in new construction, retrofits and maintenance. With more than 260 experienced, specially trained fitters and applicators as well as national and international subsidiaries and branch offices, Steuler is a specialised global contractor who can guarantee reliable project execution within scheduled deadlines.
Hard and soft coal as well as heavy-oil power plants
Steuler delivers and installs such corrosion protection linings as rubber linings, topping systems and brick and tile masonry for steel and concrete substrates, thermoplastic linings on concrete and equipment, piping and plant components made of thermoplastics and duroplastics.
Boiler rooms, power houses, water treatment plants
Industrial flooring and ceramic tiling systems, coatings and rubber linings for tanks and trenches are used in the boiler rooms, power houses and water treatment facilities of power plants. Thermoplastic linings from Steuler also have a proven track record of over 30 years and have been shown to have important advantages when used in concrete structures in direct contact with the ground. The mechanical bond between the thermoplastic lining Bekaplast and the concrete substrate creates an ideal combination of stability, durability and reliability.
In addition to lining systems, Steuler also offers an extensive programme of processing tanks, storage tanks, piping systems and special assemblies made of thermoplastic and duroplastic materials.
Steuler can apply large-surface ceramic tile linings in power houses using the vibration method, and line tanks with sprayable materials on a polyurethane, vinyl ester or epoxy resin base.
Field-proven solutions for expansion joints and trench connections, but also for sealing features on foundation skirting and workshop hall constructions round out the selection of Steuler flooring systems.
Steuler's team of specialised fitters and supervisors is trained in the use of innovative application technologies that assure a prompt and cost-effective execution of projects. The suitable system is selected from a broad range of lining systems so that the requirements specific to each power plant are met safely and reliably.
Surfaces and chemical storage in conformity with the German Water Management Act (WHG)
The requirement for lining systems with general Building Permits in many areas of power generation facilities is more the rule than the exception.
Steuler presently has nine approved lining systems so that the right solution is available for each requirement and specification. Steuler lining systems with generally approved building permits are subjected to constant third-party inspections and assure the highest and the most uniform quality.
Steuler is your competent partner for everything from planning to material selection right down to final approval to ensure that the project meets all official regulations. Many of Steuler's lining systems with general building permits can also meet such other requirements as those for walking safety and vehicle traffic.
Flue gas desulphurisation plants
Steuler offers complete corrosion protection solutions for all plant sections in flue gas desulphurisation systems. The demand for 100% plant availability places the greatest demands on individual components. It is only natural for Steuler that this results in the absolute reliability of the corrosion protection materials as well. Innovative materials and lining technologies, many years of experience and an outstanding performance record in project execution have made Steuler one of the leading providers of corrosion protection in this industry as well. The close interface between the business units of Surface Protective Systems, Refractory Systems and Plastics Technology has created a unique range of services for lining technologies and know-how.
Flue gas scrubbers
Flue gas scrubbers to clean sulphurous combustion gases are also built in various construction modules and material constellations depending on the scrubbing technology used. Steuler has suitable and reliable materials for every scrubbing process.
Mechanically anchored thermoplastic lining (Bekaplast) for concrete scrubbers
The Bekaplast system Steuler has been using in flue gas scrubbers since 1999 is setting new standards. Steuler also makes use of the advantages offered by polypropylene as mechanically anchored linings in concrete scrubber constructions. Thanks to its outstanding chemical, thermal and mechanical resistance properties as well as its particularly good resistance to abrasion and excellent anti-adhesive properties, polypropylene can also be employed as an ideal mechanically anchored corrosion-protection lining in concrete scrubber constructions.
Steuler uses its special Bekaplast lining system that has been field-proven for more than 30 years, e.g. in the chemical industry. It consists of large-format thermoplastic sheets in thicknesses of 5 to 8 mm. Conical knobs are welded onto the reverse side. These large knobs create a permanent, inseparable mechanical bond between the plastic lining and the concrete structure. The service life of this Bekaplast lining is much superior to such well-known lining materials as rubber and resin coatings. Damage caused by media absorption, the formation of deposits or chemical changes on the surface can be virtually ruled out. Because spray nozzle levels, piping systems, drip separators and sieve boxes are also made of polypropylene, there is only one material in use throughout the entire flue gas scrubber.
Polymer coatings for scrubbers made of carbon steel
Steuler also has a number of excellently suitable resin coatings to protect steel scrubbers. Use is made here of either sprayed-on coatings or trowel-applied coatings on a vinyl ester resin base to match the requirement profile. These vinyl ester resin coatings on a bisphenole A and novolac base have a special feature: excellent diffusion resistance achieved by the use of special glass or mica platelets. Coatings with a high level of abrasion resistance as well as coatings with glass-matting reinforcement are also available for use in critical areas in flue gas scrubbers.
Spray nozzle levels, Drop separators, Sieve boxes, Piping systems, Supply tanks
Experience gained over the course of the 25 years during which Steuler has been using a wide variety of corrosion protection materials in flue gas scrubbers has led to the development of a technically advanced and economically viable manufacturing concept. Instead of following the standard and costly practice of protecting spray levels against severe chemical, thermal and mechanical stresses, Steuler today manufactures these large-dimensioned components entirely from polypropylene.
The main advantage of using polypropylene is that this material does not require any further protection. The surface is smooth and pore-free which prevents caked on deposits and incrustations from forming. Damage caused by media absorption, the formation of deposits or chemical changes on the surface can be virtually ruled out. As a result, the structural design of such piping systems, an anticipated service life in excess of 25 years is fully justifiable.
The ease of replacement, the definable assembly times and the standardised construction process meet all the requirements for optimal economic efficiency, freedom from maintenance and a long service life, particularly for retrofit application and scrubber refurbishments.
The excellent properties of the material polypropylene are also used for the manufacturing of circulation piping systems, drip separators, sieve boxes and supply tanks.
In addition to the manufacture, delivery and final assembly of the spray level, the scope of delivery also includes the complete engineering as well as the preparation of all structural and manufacturing drawings. Welding is done in accordance with the guidelines established by the German Association of Welding Engineering (DVS).
Raw gas ducts, raw gas channels and heat exchangers
Steuler can also deal with the extreme requirements found in raw gas ducts and heat exchangers with suitable and reliable materials. Whereas raw gas ducts display conditions similar to those found in scrubber heads – here it is a matter of the diffusion resistance of the lining that plays the decisive role – linings in raw gas ducts and heat exchangers have to deal with high temperatures and be particularly acid resistant. Steuler has linings available that display temperature resistance values up to 220°C combined with good resistance to acids. In extreme areas, such as those found in some heat exchanger systems, Steuler makes use of special film linings on a PFA and MFA base with the highest level of temperature and acid resistance.
Tanks and trenches
For steel tanks and concrete trenches, Steuler can offer suitable rubber linings and coatings that are used as specified by the chemical, thermal or mechanical loads encountered. In concrete trenches, the preference for use is more on thermoplastic, rubber or laminate linings due to their good crack-bridging properties.
Chimneys
Refractory linings
Dry-pressed Steuler chimney bricks with tongue and groove in special grades in accordance with DIN 1057 protect chimneys/stacks from thermal and chemical attack by flue gases flowing through them. Steuler chimney bricks display excellent dimensional stability, durability and resistance to acids. Steuler's product range includes hand-rammed and pressed shaped bricks for special applications (e.g. burner bricks, bricks for in- and outlet cones, etc.). The ramming process also allows us to manufacture smaller quantities as well as extremely complex configuration in alumina and SiC-based grades. From design to manufacture of the bricks, Steuler is your one-stop source. Shaped bricks from our product range are available in all refractory grades.
Polymer coatings and linings
For retrofitting or renovating power generating facilities, or after installation of a flue gas desulphurisation facility, the corrosion protection in the chimney has to be adjusted to cope with the new conditions. Due to the low flue gas temperatures, corrosive condensates can attack unprotected or masonry chimney walls.
Steel pipes are often inserted into existing chimneys and then have to be protected from corrosion. For this application, Steuler uses, as it also does in raw gas ducts, field-tested spray-on coatings on a special vinyl ester base which can be effectively applied to these areas. These coatings offer a great deal of resistance to high temperatures and acids. Proper planning of the entire process of corrosion protection and the steps involved in it can shorten assembly times and thus get the plant up and running again quickly.
Hydroelectric power plants
In addition to floor toppings suitable in conformity with DIN 28052-3 and brick and tile in accordance with DIN 28052-5 for floors and corridors, Steuler also has solvent-free linings for basins and pipes with excellent application properties, also under unfavourable climatic conditions.
Nuclear power plants
Material components for nuclear power plants require special approval and are offered on a project-by-project basis by our specialist business units. Our range of linings includes several with the rating "excellent" in terms of their decontamination ability. Of course, the entire range of our product portfolio is available for areas not exposed to radiation.
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