Wear protection & Anti-adhesion for coal-fired power plants
Preventing aerodynamic wear
Reduce leakage and unplanned shutdowns
Breakthrough wear protection using Kalcret-lined elbows at directional-change points and Abresist fused cast basalt-lined slag pipelines with a proven service life of over 12 years
Control wear at critical bottlenecks
Material handling systems in coal-fired power plants are exposed to aerodynamic wear from pulverized coal and fly ash, combined with hydraulic abrasion and chemical corrosion in bottom-ash and hydraulic-ash systems
INCORRECT APPROACHES
- Underestimating the wear potential of fly ash and pulverized coal. At gas velocities of 25–35 m/s, fine particles can cause severe erosion at elbows and directional-change points, rapidly wearing through carbon-steel pipes and causing dust leakage.
- Using conventional steel pipes for bottom-ash handling systems. Bottom ash contains SiO₂ and sharp particles carried by recirculating water, creating simultaneous mechanical abrasion and chemical corrosion that can rapidly degrade steel or cast-iron pipelines over time.
- Applying hardfacing directly to fan blades and classifier blades. Uneven hardfacing surfaces can increase aerodynamic drag and alter mass distribution, affecting fan efficiency and the dynamic balance of rotating equipment.
SOLUTION SELECTION PRINCIPLES
- Protect directional-change points with high wear-resistant materials. At elbows and three-way splitters, use jointless Kalcret hard compound linings to form a rigid protective layer and reduce the impact of high-velocity fine particles.
- Combine wear resistance with chemical resistance. Abresist fused cast basalt-lined steel pipes provide a smooth, chemically inert surface, reducing flow friction while protecting bottom-ash pipelines over extended operating periods.
- Prioritize lightweight linings for high-speed rotating equipment. 10mm Kalocer ceramic liners combined with heat-resistant Kalfix adhesive provide a thin, lightweight wear barrier that helps maintain system dynamic balance
Mapping wear hotspots in coal-fired power plants
GAC provides specialized lining solutions designed to address wear at each critical position throughout the material handling system
Pulverized coal pipes, elbows & three-way splitters
High-speed coal dust mixtures continuously erode pipe bends and splitters feeding the burners.
Solution: Line internally with 25mm-thick Kalcret BTX compound cast over expanded steel mesh, or utilize Kalocer weld-on ceramics. (Proven by 36 three-way splitters successfully retrofitted at Vinh Tan 2 Thermal Power Plant).
Bottom ash & slag disposal pipelines
Sharp slag quenched under the boiler is pumped as slurry to the ash ponds, wearing out standard steel lines in months.
Solution: Install steel pipe spools lined with 20–30mm Abresist Fused Cast Basalt. This solution has been operational at Uong Bi Thermal Power Plant since 2006, delivering over 12 years of maintenance-free service.
Coal mill classifiers & ID fans
Coarse coal particles erode classifier blades (such as in DH3 mills), and fly ash erodes flue-gas fan blades, causing structural decay and fineness loss.
Solution: Line static/dynamic blades with 10mm Kalocer High-Alumina Ceramics bonded with Kalfix E20 epoxy.
Raw coal silos & hoppers
Sticky, wet coal particles cling to the raw coal silo hopper walls, causing bridging and rat-holing that interrupts mill feed.
Solution: Line hopper cones with 12mm Wear-resistant welding consumables UHMW-PE (friction coefficient 0.08) to ensure smooth, uninterrupted coal flow.
European-standard workflow – solving plant downtime from end to end
GAC does more than supply materials. We take full responsibility for the actual operating performance of the wear protection system through documented commitments
On-site parameter mapping
We measure air flow velocity, fly ash density, raw coal moisture levels, and take 3D scans of pipelines and hoppers
Custom engineering & combined lining design
We compute optimum liner thicknesses and design asymmetric elbow walls (thicker on high-wear back curves) using custom CAD software
Advanced workshop fabrication
We perform Abresist pipe lining, pre-form steel skeletons for Kalcret casting, and CNC-cut Wear-resistant welding consumables at our workshop
Certified installation
Skilled GAC field technicians execute monolithic Kalcret casting, dán gốm (ceramic bonding), and weld-on Kalocer installations under factory-certified supervision
Commissioning, quality handover & performance warranty
We cure surfaces with Kalcure, hand over original European CO/CQ certificates, and issue a written performance warranty of up to 24–48 months
Plants successfully using Gia Anh's solutions
Wear protection for induced draft fan stationary blades – Vinh Tan 2 thermal power plant
On November 28, 2023, Gia Anh Investment Trading Co., Ltd. (GAC) completed the wear protection work for all 72 stationary vanes of the flue gas fan at Vinh Tan 2...
Wear protection project for coal conveying pipelines – Vinh Tan 2 thermal power plant
In October 2020, a wear protection project for the coal conveying pipelines was carried out at Vinh Tan 2 Thermal Power Plant. EVNGENCO 3 Power Service Company was responsible for...
Wear protection project for the static separator vanes of a coal mill
In January 2021, Gia Anh Investment Trading Co., Ltd. collaborated with Kalenborn to implement a wear protection solution for the coal mill separator guide vanes at VICEM Hai Phong Cement...
Wear protection project for a coal mill
In May 2021, Gia Anh Investment Trading Co., Ltd. carried out a wear protection project for the coal mill at VICEM Tam Diep Cement Plant. The scope of work covered...
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Products and services
Specialized aerodynamic-erosion, sliding-abrasion, and anti-sticking materials
Kalcret Silicon Carbide-Bonded Hard Compound (Germany): Mortar featuring silicon carbide aggregates, resisting up to 1,200°C with compressive strength >130 MPa, engineered to resist high-velocity fly ash erosion.
Abresist Fused Cast Basalt (Germany): Centrifugally cast spools (20-30mm thick) reaching a hardness of 8 Mohs with a permanently glass-smooth interior, fully chemically inert to acid/alkali corrosion.
Kalocer High-Alumina Wear-Resistant Ceramics: Dense tiles (Al₂O₃ >92%) in 10-25mm thicknesses featuring integrated mechanical weld-on holes for extreme vibration zones like ID fans and splitter gates.
Tivar 88-2 UHMW-PE Anti-Sticking Liners: Premium 12.7mm sheets designed to line raw coal bunkers, completely eliminating wet coal blockage and bridging.
On-site wear diagnostics & aerodynamic modeling
On-site parameter mapping of coal dust air flow velocity (25–35 m/s), fly ash concentration, raw coal moisture levels, and 3D Laser Scanning of eroded pipe wall thicknesses.
Finite Element Analysis (FEA) to compute peak stress concentration on the outer radius of elbows to engineer asymmetric-wall configurations.
Precision mechanical fabrication at GAC Hung Yen workshop
Fabricating steel pipe spools, welding structural anchor mesh, and performing Abresist centrifugally cast lining or Kalcret casting inside pipe elbows and three-way splitters.
CNC custom machining of Tivar 88-2 sheets with recessed countersunk recesses matched to the conical geometry of silo hoppers.
Certified monolithic installation & curing
Installing anchoring steel mesh to absorb curing stresses and applying jointless, monolithic Kalcret BTX/BTY wear linings on-site.
Bonding high-strength Kalocer ceramics using specialized heat-resistant Kalfix E20 epoxies.
Executing surface hydration spray curing with Kalcure compounds, allowing full commissioning within 24 to 48 hours.
Key Clients
Frequently Asked Questions
GAC uses TIVAR® 88-2 ultra-high molecular weight polyethylene (UHMW-PE), which features an extremely low coefficient of friction (0.08) and zero moisture absorption. It converts material flow into true mass flow, eliminating blockages without the need for hammering that can damage the silo structure.
Steel is not always the best solution.
In areas exposed to high-velocity material flow, severe abrasion, or aggressive chemical environments, non-metallic materials such as engineering ceramics, cast basalt, wear-resistant castable compounds, or engineering plastics can provide significantly longer service life while reducing maintenance costs.
The optimal material depends on multiple factors, including the type of conveyed material, flow velocity, operating temperature, mechanical loading, and the working environment. Rather than automatically specifying steel for every application, Gia Anh performs a comprehensive evaluation before recommending the most suitable solution.
Using KALCRET castable compound, GAC creates a completely jointless lining that eliminates adhesive joints—the weakest point in conventional lining systems. The result is a monolithic protective layer that provides exceptional durability against severe wear.
Yes. GAC provides ongoing technical support by monitoring system performance, evaluating equipment condition, and recommending optimization measures throughout the equipment’s operating life.
Request for solution consultation
Gia Anh's expert will contact you within 24 hours to analyze the problem and provide a suitable solution.
