CFB Boiler · Dense Phase Zone
The dense-phase zone of a CFB boiler has the highest solid concentration and most intense fluidization velocity. High-temperature bed material (coal, limestone, ash) circulates at high speed, severely eroding the furnace-wall lining near the hearth bottom and air distributor—the worst wear zone of CFB linings.
Bed-material erosion: high particle concentration and velocity in the dense phase create continuous high-intensity abrasive wear, thinning the wall lining layer by layer. Pits and exposed anchors: uneven wear forms local pits; when wear depth passes the anchors they become exposed, further weakening the lining structure. Thermal shock and alkali attack: start/stop and load swings cause temperature changes; alkali metals and sulfides deposit locally and attack. Wear-spalling coupling: rough worn surfaces spall faster under gas impact, forming a vicious cycle.
Severe dense-phase wear thins furnace walls, exposes and even detaches anchors, raising local burn-through risk; worn fragments enter the bed and hurt fluidization quality; forced shutdown for repair reduces unit availability.
Select dense-phase lining for "high wear resistance + thermal-shock resistance":
Wear face layer: layer the wear-resistant working lining over the insulation layer with firm interface bonding. Vibration: vibrate fully and control water strictly for wear-layer density. Bake-out: follow the curve to prevent early spalling of the wear layer. Quality control: keep water at the datasheet lower limit—excess water is the main cause of lower wear resistance.
Monitor bed pressure and wall temperature; investigate on anomalies. At maintenance, measure dense-phase residual thickness and repair zones beyond limits with wear castable or precast blocks; build a wear-thickness ledger to optimize thickening design and repair cycles.
SiC wear-resistant castable with SiC≥50% aggregate offers extreme hardness and erosion resistance to 1600℃. High thermal conductivity promotes slag-coating self-protection. For CFB boiler cyclone barrels and cones, loop seals, copper flash furnace cones, launders and elbows under heavy wear.
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Wear-resistant castable with hard abrasion-resistant aggregate, Al₂O₃≥70%, 1500℃ max service and CCS≥90MPa. Dense matrix resists particulate erosion in gas-solid two-phase flow.
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Brown corundum castable based on dense fused alumina with Al₂O₃≥85%, 1750℃ max service and CCS≥90MPa. High hardness, refractoriness and excellent slag resistance. Used in steel ladle working linings and slag lines, main iron runners, converter mouth areas and CFB boiler cyclone wear zones.
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