How to cut the energy consumption of compressed air systems

FPS Air Compressors can provide a number of tips and initiatives to reduce the energy consumed by compressed air systems. In particular, the company offers the new NOBEL PM series of oil-injected rotary screw compressors, which feature IE4 permanent magnet motors, variable speed drives and an extended airflow range for the highest level of energy efficiency and quiet operation. This industry-leading performance helps to counter the current trend of spiralling energy costs, which look likely to remain high for the foreseeable future. Compared with the operating costs of a standard compressor. As an example, a user operating a 37 kW Nobel DVPM air compressor can enjoy savings of up to £25,000 a year or more.

Compressed air usage represents a significant proportion of electricity costs at manufacturing plants, food production facilities, machine shops, packaging plants, garages, body shops and woodyards – essentially any facility using compressed air. A big part of the solution is to get savvy about specifying the optimal technology, notably the compressor. The energy costs linked to an air compressor’s operation during its service life represent more than 80% of total lifecycle costs.

There are three principal compressor metrics to consider: specific energy; greater FAD (free air delivery) performance; and a wider operating range to suit varying demand.

The specific energy value reveals how much power (kW) is used to generate a specific volume of compressed air (1m³). Users unfortunately often overlook this highly accurate measure of an air compressor’s energy efficiency. However, NOBEL PM series models from Power System deliver a 3-8% better specific energy performance in comparison with competitor alternatives.

​​​​​​​​​​​​​​Continued ……

Regarding the second metric, the maximum available capacity is important because a compressor with better FAD performance is able to cope with peaks in demand that would otherwise require an additional or even larger, higher energy consuming compressor. NOBEL PM models provide extremely high maximum capacity figures compared with competitors. For example, the 22kW NOBEL 24 DVPM has an FAD performance delivering over 4500 l/min, which is almost 10% better than industry peers. 

The third metric considers the operating range of a variable-speed compressor. This factor is important in satisfying the fluctuating demands of production and in preventing the air compressor from entering an ‘idle’ state, which is extremely wasteful in energy. To avoid this situation, NOBEL DVPM models operate with a wide range of between 15% and 100% of available capacity. 

There are many reasons for the high-efficiency performance levels of NOBEL DVPM air compressors, not least the introduction of permanent magnet motors and high-performance inverters. These technologies help compressed air users to take advantage of IE4 ‘Super Premium’ class efficiency, the highest available according to IEC 60034-30-1. Further innovations include an efficient intake regulator and a minimum-pressure valve that minimises pressure loss to reduce energy consumption.

Notably, the volume of compressed air generated by the cutting-edge NOBEL PM series aligns exactly to system requirements, achieved by regulating the speed of the electric motor. In other words, the system provides a continuously adjusted air output to match actual usage, meaning that users only expend power, for the volume of air required. 

Such impressive performance offers incredibly fast ROI (return on investment), with NOBEL PM series compressors typically paying for themselves in circa 12-18 months, sometimes less, when replacing an equivalent fixed-speed compressor.

​​​​​​​​​​​​​​Continued ……

The high efficiency levels combine with a direct transmission system featuring a flexible coupling that minimises component wear and reduces noise, and optimised controls in the form of the new and intuitive LOGIN multicolour touchscreen controller. Featuring an internal memory card for data recovery, LOGIN is ideal for remote control and multi-compressor management for up to eight compressor and as part of IoT digitalisation/connectivity projects. 

These advanced technologies, alongside the use of latest-generation air-end units, has facilitated the creation of the most innovative and reliable compressor available. The result: maximum energy savings and a subsequent reduction in CO2 emissions. The extremely compact, Italian manufactured NOBEL PM series compressors are not only an ecological choice, but they also offer among the lowest noise values in their category – as low as 58 dB(A).

A full NOBEL PM range is available from 18.5 to 90 kW, with the 24, 39 and 45 DVPM models typically offering the best performance in their market segment. An optional refrigerated dryer is available with integrated inlet/outlet filters to deliver clean, dry compressed air. A five-year warranty is available subject to terms and conditions.

For further information please visit https://www.fps-compressors.co.uk/energy-saving-air-compressors

Further information is available from:

FPS Air Compressors Ltd, Unit 5, Tower Estate, Warpsgrove LaneChalgroveOxfordshire OX44 7XZ

Telephone: 01865 892 620                    ​​e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

www.fps-compressors.co.uk/energy-saving-air-compressorsAD00F725 45EA 4EB4 A042 CB95A274C095


This article also featured in the December/Jan issue below


AirBench are pleased to announce the launch of a new range of wet filtered downdraught benches.

AirBench WB is designed specifically for flammable dusts which produce sparks when worked – for example titanium. WB uses a unique double-pass system of baffles to quench sparks in the integral water bath; filtering dust by passing through multiple water sprays.

Airflow is generated using a high-efficiency centrifugal fan, selected specifically for the high pressure needed to induce a water spray.

To date, filtration of this grade has required ducted installations. WB is a huge step forward in that it can be installed by the user, in under an hour; simply position and join the two sections, connect to power and water, and work can begin.

The UK’s most advanced solution to titanium dust extraction, now available from AirBench Ltd.

Visit www.airbench.com/wb for more information, or contact AirBench Ltd to discuss your extraction issues



 This article also featured in the DecemberJan issue below 




A Unique Effective Cost Saving Solution to Oil Spills


At PVL and Industry Superstore we are pleased to announce our partnership with TEST1 in conjunction with marketing their highly effective Foamflex200 product ranges in the UK.

  • TEST1’s FoamFlex200 is an innovative patented absorption technology for hydrocarbons and their derivatives. The product is an open cell oleophilic polyurethane foam with hydrophobic effect. This allows intact recovery of spilled hydrocarbons without water.
  • Foam Flex200 can absorb, for about 30 times its own weight, any hydrocarbon. The added difference is (compared to other products in the marketplace) ids that by wringing it out, just like a normal sponge, it can be reused over 200 times.
  • One kilogram (1 kg) of FoamFlex200 can absorb about 6.000 Kg of hydrocarbons. FoamFlex200 allows an improvement in the performance of the reclamation activities in terms of costs, efficiency, effectiveness, timing, minimizing the environmental impact.
  • FoamFlex200 is a fast, versatile, easy to use response method. FoamFlex200 performs the absorption of tons of oil with a minimal amount of product.
  • Its compact stowage size and effectiveness in any condition makes it the ideal emergency equipment specification for confronting unexpected spills. The speed of deployment and rapid absorption characteristics of FoamFlex200 limits damage due to weathering phenomena: sedimentation, stain expansion, toxic exhalations.

Raise Efficiency & Lower Costs: Rubix Release New SKF Cooper Split E-Series Brochure




Rubix, the UK’s leading supplier of industrial maintenance, repair and overhaul (MRO) products and services, has released a new brochure, produced with bearings manufacturer SKF.

‘SKF Cooper Split E-Series Bearings’ is a 6-page brochure that highlights how to reduce downtime, enhance worker safety, and increase efficiency, particularly in harsh or inaccessible applications where mounting, dismantling or maintenance can be a challenge.

Replacing damaged or worn bearings in heavy machinery that requires servicing or maintenance can be a problematic. Often faced with complex dismantling and assembly procedures – involving costly production losses from machinery shut down - it can take more than one person many hours to change a solid bearing. In extreme cases, it may even be necessary to break and replace a piece of expensive equipment to remove a faulty solid bearing. 

These issues can be resolved with the latest range of SKF Cooper Split E-Series bearings, which can be easily and quickly replaced in situ, reducing mean time to repair (MTTR) by up to 70%.

Unlike solid bearings, which must be slid onto the shaft, SKF Cooper Split E-Series bearings are split to the shaft; a design that both simplifies and expedites installation and cuts downtime when compared to replacing solid bearings of the same size. 

Reducing many of the risks associated with heavy lifting, particularly at height, the latest range of SKF Cooper Split E-Series bearings also makes a significant contribution to overall worker safety.

Suitable for a wide range of industrial and marine applications including belt and screw conveyors, industrial fans, industrial drive shafts, water turbines, and propeller shafts, to name but a few, SKF Cooper Split E-Series bearings feature a unique and patented brass cage design, with an optimised roller complement, which delivers increased carrying capacity, greater safety margins, longer L10 rating life, and subsequent service life.

‘SKF Cooper Split E-Series Bearings’ can be downloaded from the dedicated SKF bearings section on the Rubix website. Here, you can also not only find useful information on SKF’s Cooper Split E-Series, but also sections dedicated to specific industry specific solutions.

Rubix is an SKF Authorised Distributor across Europe and has an in-depth knowledge of the manufacturer’s product range, along with early access to its latest technologies. For more information, go to uk.rubix.com

 This article was also featured in the December/Jan issue below




Kings are the UK’s largest and longest established international supplier of industrial Steam and Hot Water boilers for replacement, temporary hire and servicing.  


4C9E5431 C534 4483 A7A7 0E4C3B045787Kings have over 80 years’ experience in supplying boilers for all types of commercial and industrial applications, offering businesses a full range of services.

Steam Boiler Hire

Our fleet of temporary steam boilers range from 340kg/hr (750lb/hr) to 15,800 kg/hr (35,000lb/hr) comprisingtrailerised, containerised or staticboilers that are oil, gas or dual fuel with pressures up to 12 bar.  Available nationwide.

Hot Water Boiler Hire

Our fleet of temporary hot water boilers range from 94kW (320,000 btu) to 8,000 kW (27,000,000 btu) and include a range of containerised or static low-pressure units, with oil, gas or dual fuel. Available nationwide.

Steam and Hot Water Boilers for Purchase

Kings have boilers for sale for any size project with fast, nationwide delivery.We have an unrivalled choice of modern steam and hot water boilers in stock, ranging from 340kg/hr to 16,000kg/hr steam and 150kW to 7,500kW hot water with working pressures from 7bar to 18 bar. Our fully re-furbished boilers save businesses time and money over new.

In-house expert engineers

Kingsteam of in-house engineershave extensive knowledge and expertise in boiler installation, replacement, servicing and maintenance. Our highlyexperienced burner and combustion engineers carry out all aspects of servicing and repair to all popular makes and models of Oil, Gas & LPG fired commercial burners.

Long-standing relationships

Kings have relationships with many customers which span decades. We are extremely proud of our long-term relationships which are testament to the excellent service, great quality and value for money we provide.  Over the summer we provided boiler plant for Scotland's continually growing brewery and distillery industry, hiring a fully refurbished containerised boiler house with steam boiler unit comprising a 1,362 KG, 10 bar for client of 20 years.

Kings help to ensure essential services continue to run

Kingsengineers recently installed two temporary boilersto provide hot water and heating to a community centre whilst essential repair works are carried out, in Suffolk.

The project initially involved providing hot water to taps for direct hot water, however, due to winter weather coming our dedicated team of engineers ensured heating was supplied to enable the community centre to continue running throughout the cold winter months. 

The community centre, formerly an old middle school, now the hive of the town, offers essential facilities for local residents including a nursery, indoor sports facilities, meeting room space, work areas and NHS facilities.  

Kings are proud to help ensure essential services like these continue to run throughout the UK.   If your business needs to hire or to purchase boiler plant, please contact us today.

Contact us today:

+44 (0)1992 451629                www.kingsboilerhire.com


This article also featured in the December/Jan issue below







EngineeringUK responds to DfE apprenticeships data

In response to the Department for Education (DfE) releasing new apprenticeships data today, EngineeringUK has run an analysis on the data related to the engineering and technology sector.

Engineering-related apprenticeship starts have increased at a greater rate than all sector subject areas, increasing by 25.8% on 2020/21, compared to an 8.6% increase across all sector subject areas. However, engineering-related apprenticeship starts are still down by 5.5% since 2018/19, and down by 12.3% since 2016/17.

Beatrice Barleon, Head of Policy & Public Affairs at EngineeringUK, comments:

“Today’s apprenticeship data show a step in the right direction – with a positive uptick in apprenticeships starts as we emerge from the pandemic. Given the acute skills shortage and the pressing need for more engineers to support the UK’s net zero ambitions, it’s particularly encouraging to see the engineering and technology sector is ahead of others in attracting people into its fold.

"However, to meet future skills needs projections, we need to see exponential growth of apprenticeships starts (and finishes!) in the engineering sector, particularly in areas such as construction. Technicians will be particularly vital in making the UK a leading economic power in low carbon technology and we must ensure that we have enough people skilled to fulfil these roles.

"Importantly, the data also suggests that more needs to be done to enable younger people to enter the engineering sector via the apprenticeship route, with Level 2 and 3 apprenticeships still in decline compared to higher level apprenticeships. Improving the system must focus on growth across all levels of apprenticeships if we are to successfully address current and future skills shortages.”

The full analysis from EngineeringUK can be found on the EngineeringUK website.

SICK’s MPB10 Sensor Bolts-on for Continuous Condition Monitoring

SICK has announced the launch of its MPB10 Multi-Physics Box condition monitoring sensor, a pioneering and rugged bolt-on device designed to deliver real-time, continuous service data from industrial machines, including electric motors, pumps, fans and conveyor systems, even in the harshest industry environments. 

SICK’s first dedicated condition monitoring sensor, the MPB10 is an all-in-one device designed to make it easy to monitor and interpret vibration, shock and temperature measurement data delivered right from the heart of machines. The MPB10 provides service data to enable more cost-efficient predictive maintenance practices that can improve plant availability, maximise operating life, and protect product and process quality. 

Detecting Signs of Failure

The SICK MPB10 measures vibration, shocks and temperature that can be the tell-tale signs of approaching machine failure. Users are provided with pre-processed, concise and easy to interpret information that can be customised for the machine and process.

A stand-alone SICK MPB10 can transmit data over IO-Link to a machine control or output a simple alarm-based switching signal. With wide-ranging measurement parameters, the MPB10 can be set up according to the type of machine to alert, for example, when values exceed pre-configured thresholds. 

Dashboard Visualisation

Users also have the option to visualise real-time and historic data from the SICK MPB10 on easy-to-interpret, customisable dashboards using the SICK Monitoring Box digital service. Via the Monitoring Box, operators can also receive notifications via email, or provide data for integration into cloud-based applications.  

The SICK MPB10 detects vibrations (± 8 g) and shocks up to 200g in all 3 axes via the sensor’s MEMS elementsMulti-stage alerts can be set up to monitor vibration thresholds according to the requirements of DIN ISO 10816-3 in rotating machines such as electric motors, fans, turbines and generators. The indicative vibration values in the time and frequency range are significantly easier to interpret than raw data, helping to detect, for example, insufficient lubrication, bearing damage or motor imbalances. 


Protected by a rugged IP68 stainless-steel housing, the MPB10 delivers consistent contact temperature data between −40 °C and +80 °C, even in dusty or wet environments. Ideally fixed close to the bearings, the MPB10 can be mounted securely using a single M3 screw or fixed onto curved surfaces using the mounting plate supplied. Alternatively, it can be secured with epoxy glue or welded.  


Cost-Saving Benefits

David Hannaby, SICK’s Market Manager for Presence Detection, said: “The SICK MPB10 is a rugged little instrument with the potential to add huge value to industrial machines and processes. By bolting on an MPB10 to their machine, plant operators and managers can upgrade simply to predictive maintenance practices and identify problems early before any significant decrease in performance or failure. 

“By avoiding damaging temperatures, shocks or vibrations, the availability of the machine can be increased, product and process quality can be protected, and operators have more potential to extend the life of their machines. Maintenance effort and costs are reduced because reactive interventions can be avoided, and time-consuming routine preventive inspections can become less frequent.” 

For more information, please contact Andrea Hornby on 01727 831121 or email This email address is being protected from spambots. You need JavaScript enabled to view it..

 This article was also featured in the issue of a EMS below

New NSK ball screw for next-generation, high-accuracy machine tools

NSK has developed a new type of ball screw that exhibits reduced motion errors to deliver higher surface finish quality for machine tools used in mould and die machining and other surface-critical applications. By eliminating or reducing the time needed for secondary burnishing or polishing applications, the new ball screw also contributes to higher productivity, while simultaneously reducing the amount of drive torque to save energy.

In recent years, builders of machine tools such as five-axis milling machines have been demanding increased accuracy to produce higher quality mould and die surfaces, where the ball screws used in these machines must further improve motion accuracy.

When a ball screw reverses direction, sudden fluctuations in friction cause ‘quadrant glitch’ motion errors with two peaks, leaving streak marks on the machined surface and reducing surface quality. Numerous studies conducted on quadrant glitches show that it is possible to correct the first peak through numerical control (software-based servo controller compensation). Although it is more difficult to fully compensate for the second peak due to the combined effects of more factors (compared with the first peak), NSK can now present the machining industry with a solution to this problem.

Using real digital-twin simulation and friction analysis, NSK has developed a new ball screw with an optimised internal design. Key to this outcome was the company’s understanding of the underlying mechanism of friction fluctuations in ball screws.

Among its many features, the new ball screw stabilises drive torque and reduces friction fluctuations when reversing its direction of motion, thereby improving motion accuracy and reducing quadrant glitch motion errors. The result is a near elimination of the second peak. Indeed, up to 20% less friction fluctuations also contributes to reducing the height of the first peak.

Through a combination of NSK's new ball screw and software servo controller compensation, machine tool manufacturers can assure their customers of significant improvements in machined surface quality. Furthermore, the enhanced surface quality eliminates or reduces the need for any previously required burnishing or polishing processes, reducing lead times, while lower drive torque contributes to energy savings. All of these benefits provide machine tool builders with the opportunity to pitch unique selling points to potential customers.

PR Ref. L062022-N | 1/3


 To maximise convenience for machine tool manufacturers, the mountings of NSK ball screws with quadrant glitch control are fully interchangeable with those of conventional products, allowing adoption without costly equipment changes. The ball screw will be available in shaft diameters from 25 to 63mm, with leads from 5 to 30mm. Preload types will include: offset preload (Z preload), double nut preload (D preload) and spring-type double nut preload (J preload).


1) Motion error during circular interpolation machining (with servo controller compensation)






2) Enlarged view of machined surface (simulated image)





 This article also featured in the December/Jan issue below





Hi-Plex hybrid technology from Hi-line provides cost-effective, energy-efficient compressed-air drying

Estimates suggest that Class 4 moisture content according to ISO 8573-1 is acceptable in the majority of compressed air system applications, thus supporting the use of refrigeration dryer technology. However, where applications demand higher levels of moisture removal, desiccant tends to be the go-to technology. The long-standing problem here is the higher cost associated with desiccant dryers, which is why Hi-line Industries, a UK-based leader in the design, manufacture and installation of energy-efficient compressed air purification equipment, is addressing this issue with its new Hi-Plex dual technology dryers. This hybrid solution combines Hi-line’s established refrigeration and PSA (Pressure Swing Adsorption) air treatment technologies, creating an energy-efficient system at low capital cost compared with standard heat-regeneration desiccant air dryers. 

So how does Hi-Plex work? Well, a Hi-line Tundra refrigeration system first removes bulk moisture via zero loss auto-drains, after which it chills the air to +1°C in the heat exchanger, condensing out all water to a +3°C PDP (Pressure Dewpoint). From here, the pre-dried air passes into an energy-efficient HPSA (Hi-line Pressure Swing Adsorption) dryer where it is further dried via adsorption to lower dewpoints of between -20°C PDP and -70°C PDP depending on end-user requirements, meeting Class 2 moisture content in accordance with ISO8573.1. As a point of note, Hi-line can add an Activated Carbon Tower for Class 0 applications.

Hi-Plex regeneration takes place by deploying a vacuumed-assisted fan, which uses a reduced amount of purge air to cause a desorption effect within the desiccant beds. A side-channel vacuum pump removes the small amount of remaining water (via exhaust silencers) back to the atmosphere from where it came. This plug and play system is fully automatic: wet air in – dry air out.

​​​​​​​​​​​​​​Continued ……

Importantly, Hi-Plex high-performance dual technology dryers typically run at only 1-2% purge in comparison with 13-15% on a standard desiccant air dryer. Even more savings are achievable following the specification of Hi-line’s optional AEMS (Automatic Energy Management System) for dewpoint control. AEMS features a digital dewpoint readout, high-humidity alarm, and set and demand regeneration function. As a result, customers can ensure they only use a minimal amount of energy to achieve dewpoints at any given time. In total, energy savings of over 70% are achievable compared with a conventional desiccant dryer, offering far quicker return on investment (ROI).

Every Hi-Plex dual technology dryer is application-specific, but built from standard off-the-shelf Hi-line products. The company adds all the components, stainless steel pipework and filtration to a compact skid at its UK headquarters and manufacturing facility in Burton-upon-Trent. Hi-line will happily cater for any special requirements, such as even smaller footprint or lower height dimension to fit inside a low-ceiling compressor house, for example. The company can also facilitate connection to customer software or a BMS (Building Management System).


 This article also featured in the December/Jan issue below




How Waste-to-Energy and Biomass Plants Can Protect Boiler Tubes and Refractory from Corrosion Introduction

282FA2EA-B8D5-4B78-BBD7-88FD5A1CF1AE.jpgCorrosion and Erosion are major concerns for all Waste-to-Energy and Biomass facilities. Highly corrosive operating environments present maintenance challenges which, if left untreated, can lead to costly asset failures and unplanned outages.

The issue of corrosion and erosionbecomes more serious when mixed fuel environments create extreme atmospheres that can predispose equipment to damage. For example, fuels containing alkali metal, heavy metals, chlorine, and sulphur.
In combustion systems usingbiomass and municipal solid waste, the steam temperatures are kept lower than 450°C to keep corrosion to a minimum. However, this results in low overall plant efficiencies (approx. 25 - 30%). As a result, methods to control high-temperature corrosion in these types of plants must be investigated.

WtEBoiler Corrosion Mechanisms


Increasing the efficiency of WtE boilers means increasing pressure and temperature inside the boiler tubes. The combination of new fuel types containing higher levels of corrosive agents with these higher temperatures and pressures can lead to material softening. Accelerated fireside boiler corrosion starts on the unprotected steel heat exchange surfaces of the super-heaters and erosion resistance declines.

Most corrosion protection mechanisms consist of generating a corrosion barrier on the base metal by forming an oxide layer. The challenge inside WtE boilers is that this layer is quickly eroded forcing the formation of another layer and consequently leading to the erosion-corrosion phenomenon. Erosion-corrosion thinning can happen quickly when harsh conditions are combined with soft or poor erosion resistance materials.

WtE Boiler Corrosion and Erosion Protection

Refractory protection is the first defense against corrosive flue gases and can also have excellent erosion properties but has limited heat exchange properties as the thermal efficiency is low. Refractory alloys can be used, but due to the excessive material costs and limited erosion resistance, the implementation of the surface protection layer is often a more cost-effective solution.

The use of thin ceramic coatings seems like an attractive approach; however, the thermal expansion mismatch and the fragility of such coatings make this solution unreliable. The coatings tend to crack, and corrosion can develop underneath the protective layer which can then peel off.

Corrosion-resistant HVTS Metal Spray Coatings

Integrated Global Services (IGS) has successfully developed a High Velocity Thermal Spray (HVTS) coating which has provided protection in boiler corrosion applications for decades. HVTS has been designed to apply a metal layer with very low porosity and sealability to better protect the base metal in high corrosion environments. This technology allows the use of solid or cored wire, enabling easy material modification compared to technologies depending on the market available solid wire. Since the process does not generate any dilution with the base metal, the quality of the coating remains uncompromised.

In boiler applications, HVTS has been successfully applied under refractory tiles to protect boiler tubes from leaks and asset failure. 

Case Study #1HVTS Cladding Under Refractory Protects Boiler Tubes from Corrosionat Waste-to-Energy Plant


A Waste-to-Energy (WtE) plant in Italy consists of two 35.7 MW combustion lines, that can supply nominal electric power of 22.25 MW and thermal power of 43.5 MW.

The plant was suffering from corrosion and erosion behind the refractory tiles which was causing damage to the boiler tubes. HVTS was chosen to prevent costly unexpected leaks in the boiler.

The Solution

In September 2021, HVTS was applied to the first pass (behind the refractory) of the boiler. The total area that was cladded was approximately 100m2 with a nominal cladding thickness of 500μm. The application was completed within just four days and without any technical concessions or deviations. The project was also completed in accordance with ISO: 8503-1 (preparation of steel substrates before application of paints and related products).

HVTS was chosen as it is a proven technology which stops corrosion of the base metal. Thus, refractory contacts the tube sheet and is cooled as designed. Functioning to design conditions, fouling build-up on the refractory is mitigated.

The Inspection

An inspection took place in September 2022. The results showed that the coated areas were in excellent condition and do not have anomalies or any other visible damage 13 months after the installation of HVTS. There was also no accumulation of slag or ash on the affected area.

The condition of the overlying tiles was also evaluated and showed that the refractory was totally intact and in good condition which is an indication that the underlying cladding and the coated pegs are still in good condition.

The HVTS thickness values were recorded with an elcometer and were found to comply with IGS specifications.

The report states, “the refractory and HVTS are in perfect condition and have no major defects”.

Case Study #2: HVTS Cladding and New Refractory Protects Boiler Tubes at Biomass Plant


A biomass plant in southern Italy converts wine residue and other greener locally sourced deposits to steam to produce electricity. The plant operates a large boiler and refractory tiles regularly fall off during operation, exposing the boiler tubes. When boiler tubes are exposed, they are susceptible to corrosion which eventually leads to tube leaks and asset failure, which can be costly.

The Solution - Cladding and Refractory

HVTS Metal Alloy Cladding

Integrated Global Services (IGS) High Velocity Thermal Spray (HVTS) metal alloy cladding was applied behind the tiles to protect the tubes if the refractory became damaged allowing flue gas to enter the boiler tubes. 

A two-meter band at the top of the refractory area was removed in the boiler’s first pass. New hangers were then welded before the application of the HVTS cladding. As a result, IGS’ HVTS protects both the tubes and the tile hangers, with the latter commonly being the source of refractory failure. 

IGS worked in conjunction with COREF Engineering, which then installed the new refractory. The cladding is half a millimeter thick with a smooth surface which meant that the same tiles could be installed without any design modifications or other challenges.

The Inspection

After two years in service, a visual inspection of the cladding and refractory was performed. The IGS HVTS cladding was found to be in very good condition and is expected to greatly extend the life of the boiler.

 This article also featured in the December/Jan issue below



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