Coal-fired power plants, particularly aging circulating fluidized bed (CFB) and pulverized coal (PC) units, remain essential contributors to grid reliability. Many of these assets are operating well beyond their original design parameters. Operators are now managing increasing risks of metal wastage, reduced availability, and unplanned outages. Replacing or converting these units represents a major capital outlay, often requiring years of planning and regulatory approval. In contrast, targeted engineering interventions such as High Velocity Thermal Spray (HVTS®) cladding allow plants to reclaim performance, reduce forced outages, and extend boiler life with minimal disruption.

HVTS as a Proven Engineering Solution

HVTS is a field-deployed, high-density thermal spray technology engineered to protect boiler pressure parts against fireside corrosion and erosion. The process creates a uniform micro-mechanical interlocking microfusion bond with the tube surface, producing a dense and durable cladding layer. Unlike weld overlays, HVTS does not introduce significant heat input to the tube metal, reducing the risk of distortion or residual stress.

Independent testing has validated the long-term performance of HVTS. In an Electric Power Research Institute (EPRI) program, HVTS was exposed to over 39,000 hours of severe service conditions, and was the only material in the study that remained uncompromised throughout the exposure period. Applications can be targeted to known high-wear areas such as waterwalls, nose arches, lower combustor corners, cyclones, and ductwork. This flexibility enables plants to address site-specific degradation without requiring extensive boiler modifications.

Demonstrated Value at ADM

The long-standing partnership between Integrated Global Services (IGS) and Archer Daniels Midland (ADM) illustrates the operational impact of HVTS. Beginning in 1992 with a single application in Cedar Rapids, the program has grown to encompass 18 CFB boilers across four ADM facilities. Over three decades, more than 200,000 square feet of boiler surface has been protected with HVTS and ceramic coatings.

The performance results include:

Extended reliability

Maintenance-free operating cycles have doubled or tripled.

Avoidance of forced outages

Since IGS assumed responsibility for boiler surface protection, ADM has not experienced unplanned outages on its CFB units.

Long-term partnership

ADM recognized IGS with its 2023 Supplier Safety Excellence Award and renewed a three-year blanket agreement in 2024.

These results highlight not only the durability of the technology but also the importance of consistent inspection, application, and quality control in maintaining asset reliability.

Integration with Plant Maintenance

The HVTS approach is designed to integrate seamlessly into planned outages. Inspections are conducted to identify degradation patterns, and applications are executed during scheduled downtime without extending the outage window. Quality oversight ensures compatibility with other contractor work, and protection is focused on erosion-prone areas to deliver the greatest impact.

By mitigating metal wastage, HVTS reduces the risk of derating and helps maintain efficiency across load ranges. Plants also benefit from lower capital and operating costs compared to major equipment replacement or fuel system conversion.

Sustaining Asset Reliability

As utilities balance long-term decarbonization strategies with near-term reliability requirements, extending the life of existing CFB and PC boilers is an essential option. HVTS provides a technically proven method to restore pressure part integrity, reduce unplanned downtime, and improve availability. For operators of aging assets, the priority is no longer simply running longer, but running reliably and efficiently. Targeted engineering upgrades such as HVTS offer a clear pathway to achieve that goal.

Integrated Global Services, IGS - Your Efficiency & Reliability Partner