Belzona Protects a Pulverised Coal Burner Pipe Against Abrasive Wear
The Challenge
A leading cement plant in India was experiencing severe abrasive wear on a section of its pulverised coal burner pipe.
The pipe transports fine coal particles towards the combustion zone. Continuous exposure to fast-moving pulverised coal had gradually worn the pipe surface, particularly near the furnace-end section where the equipment was subjected to intense abrasive conditions.
During inspection, the maintenance team identified:
- Extensive wear over a substantial length of the pipe
- Progressive deterioration of the exposed surface
- A high risk of further material loss
- The possibility of eventual perforation and premature replacement
- An uneven surface profile requiring abrasion-resistant protection
Metal studs were already present on the pipe surface as part of the existing wear-protection arrangement. However, the exposed areas between and around the studs still required a durable protective system.
The Conventional Solution
The conventional repair approach would have involved extensive hardfacing, welding or replacement of the affected pipe section.
These methods could have resulted in:
- Longer maintenance downtime
- Extensive hot work
- Possible heat distortion
- Additional handling and alignment requirements
- Higher fabrication and replacement costs
- Recurring maintenance as the hardfaced surface continued to wear
The plant therefore required a cold-applied system that could utilise the existing studded surface and provide protection against fine-particle abrasion.
Why Belzona Was Recommended
Belzona was recommended because the application required an abrasion-resistant system capable of being applied around the existing metal studs without extensive welding or replacement.
Belzona 1812 and Belzona 1813 were selected according to the temperature conditions across the application area.
The system offered several advantages:
- Resistance to fine-particle abrasion
- Cold application without heat distortion
- Application over irregular and studded surfaces
- Reduced requirement for extensive hot work
- Protection of the existing pipe structure
- Selection of suitable materials according to operating temperature
The Belzona Solution
The existing metal studs were retained and used as part of the repair configuration.
Belzona 1812 and Belzona 1813 were applied over and around the studs to create a continuous abrasion-resistant protective layer. Product selection was based on the temperature criteria of the respective sections of the pipe.
The materials were carefully worked into the spaces between the studs to ensure full contact with the prepared steel surface and to minimise the possibility of voids.
Application Process
1. Inspection and assessment
The pipe section was inspected to determine the extent of abrasive wear and identify the areas requiring protection.
The condition and distribution of the existing metal studs were also reviewed before proceeding with the application.
2. Cleaning and degreasing
The repair area was thoroughly cleaned using an appropriate cleaner and degreaser.
This removed:
- Oil and grease
- Dust and loose contamination
- Process deposits
- Other substances that could affect adhesion
The surface was allowed to dry before further preparation.
3. Hand-tool surface preparation
As abrasive blasting was not used, the exposed metal surfaces were prepared using suitable hand tools.
The surface was mechanically roughened to:
- Remove loose material and surface contamination
- Create a coarse profile
- Improve mechanical adhesion
- Prepare the spaces around and between the existing studs
Particular care was taken to reach the restricted areas surrounding the metal studs.
4. Application of Belzona 1812 and Belzona 1813
The Belzona materials were mixed and applied in accordance with the temperature criteria of the respective pipe sections.
The materials were firmly pressed:
- Around the existing metal studs
- Between the studs
- Into the prepared surface profile
- Across the complete wear-prone area
Careful application ensured that the studded surface was encapsulated and that a continuous abrasion-resistant layer was formed.
5. Inspection and curing
The completed application was visually checked for:
- Continuous coverage
- Adequate encapsulation around the studs
- Absence of visible gaps or voids
- Suitable transition between repaired and unrepaired areas
The applied materials were then allowed to cure before the pipe was returned to service.
The Outcome
The completed Belzona system created a continuous abrasion-resistant barrier over the wear-prone section of the pulverised coal burner pipe.
The repair:
- Utilised the existing metal studs
- Protected the exposed steel between the studs
- Reduced the rate of further abrasive wear
- Avoided extensive hardfacing and replacement
- Eliminated the need for additional heat during application
- Allowed different Belzona materials to be selected according to temperature conditions
- Extended the service life of the existing pipe section
The combined use of Belzona 1812 and Belzona 1813 provided the cement plant with a practical cold-applied solution for protecting a critical component against recurring fine-particle abrasion.
