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Custom-Engineered Power Generation Solutions

Kennametal Conforma Clad™ offers custom-engineered power generation solutions for coal-fired or biomass power plants. Our cladding formulas are designed to protect equipment from multiple modes of wear including abrasion, corrosion, erosion or all three combined.

This proprietary cladding technology can be applied to a broad range of applications including:

  • Fan blades
  • Fan blade liners
  • Boiler tubes and tube shields
  • Burner components
  • Screens

Equivalent Erosion Resistance

Transformational Performance

With Conforma Clad tungsten carbide cladding, you can stop the wear. As part of a research project conducted by a large coal fired power generation utility and the Electric Power Research Institute (EPRI), blades from six different suppliers were examined so metal loss could be measured.

The EPRI field trials showed that 1/16” of Conforma Clad cladding provides equivalent resistance to 1” of chrome carbide weld overlay at 1/10th the weight and 3” of carbon steel at 1/30th the weight.

 

 

Fan Components

Significantly extend fan life and reduce unplanned downtime

Fan failures triggered by high velocity ash impingement often result in reduced gas flow and fan efficiency, sudden fan imbalance, and catastrophic detachment of blades. Conforma Clad infiltration-brazed tungsten carbide wear protection has helped operators increase fan runtimes by more than 4x.

EPRI testing results  (EPRI CS-6068, Project 1649-4) show that Kennametal’s WC-210 provides superior erosion protection for power boiler fan blades exposed to high-velocity bituminous coal fly ash.

Significantly thinner and lighter in comparison to chrome carbide overlay, cladding can also be applied to leading and trailing fan edges, centerplate weldment areas, and fan inlet hubs, protecting the entire fan and improving overall efficiency. With superior erosion resistance-to-weight ratio, cladded fans resist chipping and spalling.

Fly Ash Erosion Test

40° Impingement Angle, 550 ft/sec - 30 Minute Test

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Boiler Tubes/Fluidized Bed Boiler Tubes

Certified by the National Board of Boiler & Pressure Vessel Inspectors, Conforma Clad protects replacement boiler tube segments from severe wear, reducing the risk of boiler tube leaks.

  • Hot erosion protection up to 10x better than INCONEL® materials
  • Selectively protect high-wear sections of your boiler tubes
  • Consistent cladding thickness and minimal dilution
  • True metallurgical bond preventing flaking or spalling
  • Meets requirements of the ASME Boiler & Pressure Vessel Code (PRT Stamp)

Conforma Clad tube shields are available as an alternative to direct cladded boiler tubes.

Burner Components

Conforma Clad protected burner components last longer and sustain maximum performance levels by maintaining critical component geometries for extended run times.

“Riley Power conducted laboratory testing, following ASTM G73 standards, on low swirl coal spreaders to determine the best erosion protection from fine-grit black beauty coal slag. Testing was conducted at 90-degree impingement angle with a particle velocity of 240ft/sec for 30 minutes.

Kennametal WC 219 cladding provided top wear projection while retaining critical component geometries. Kennametal increased Riley Power’s low-swirl coal spreader’s life from 1-2 years to 3-4 years.”
                                                                                 
                                                                                 
-Babcock Power, CCV-DAZ Development Project.

 

Power Generation Solutions

Read more about our capabilities and this success story.

View Brochure

Screens

The Conforma Clad process provides complete protection of entire screens - up to 4 x 12’ with screen openings ¼” and larger - with metallurgically bonded tungsten carbide cladding. Common screen types include perf plates, woven mesh, wedge wire and grates.

 

Customized Power Generation Cladding Solutions

For Power Gen customers, a number of Conforma Clad solutions can be employed to resolve multiple issues in their specific application as is outlined in our Conforma Clad™ Solutions for Economizer to SCR application bulletin.

View Application Bulletin
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