Ceramic Coatings for Waste-to-Energy and Power Generation
Ceramic Coatings for Waste-to-Energy, Biomass, and Power Generation
ITC Coatings manufactures high-temperature ceramic coatings that protect metal structures, refractory linings, and heat recovery equipment in waste-to-energy (WTE), biomass, and power generation facilities. Our three-product coating system addresses the industry's most persistent problem — acid dew point corrosion from flue gas condensation — extending steel structure life 4–5x and reducing maintenance costs.
The Problem: Acid Dew Point Corrosion
Waste-to-energy plants, biomass facilities, and coal/gas-fired power plants all share a common destructive mechanism: acidic flue gas corrosion. When combustion exhaust gases cool below their acid dew point (typically 250–350°F depending on fuel chemistry), sulfuric acid, hydrochloric acid, and other corrosive compounds condense on metal surfaces. This condensation attacks:
• Steel shells of baghouses, scrubbers, and ductwork
• Heat recovery steam generator (HRSG) tubes and casings
• Spray dryer absorber (SDA) internals
• Economizer and air preheater surfaces
• Filter bags, cartridges, and support structures
The damage is progressive: corrosion weakens structural steel, perforates casings, destroys filter media, and eventually requires full component replacement — often at costs of hundreds of thousands of dollars.
The Solution: ITC Three-Product Coating System
ITC's complete coating system uses all three products working together:
Layer 1 — ITC 213 (Metal Protection): Applied directly to the steel surface. Creates an inorganic ceramic bond that prevents acid contact with the metal substrate.
Layer 2 — ITC 100HT (Thermal Barrier): Applied over ITC 213. Provides thermal insulation that raises the surface temperature above the acid dew point, preventing condensation from forming in the first place.
Layer 3 — ITC 296A (Chemical Barrier): Applied as the top coat. Resists chemical attack from flue gas constituents, slag, and particulate erosion.
This layered approach both prevents acid condensation (by keeping surfaces above dew point) and protects the metal even if condensation does occur (through the ceramic barrier).
Proven Results
TXI Cement, Texas — Baghouse
A 12-compartment baghouse (each compartment 20'x25'x60' high) was experiencing accelerated steel shell corrosion from acidic flue gas condensation. The full ITC three-product system was applied to all compartments. Steel shell life extended 4–5x. Filter bag and cartridge corrosion was also significantly reduced. This application uses all three ITC products, making it the highest-revenue installation type in the ITC product line.
Anchor Corrosion Testing — Alternative Fuel Environments
Laboratory testing simulated the corrosive conditions created by alternative fuels (waste-derived fuel, biomass, tires) that are increasingly used in WTE and power generation. ITC 213 was tested on 7 steel grades at 900°C for 5 hours in a NaSO₄/NaCl corrosive environment. Every steel grade improved at least one quality level. Most notably, ITC-coated AISI 316 improved from "Acceptable" to "Outstanding," and ITC-coated AISI 304 improved from "Excellent" to "Outstanding."
WTE and Power Generation Applications
Spray Dryer Absorbers (SDAs): ITC coatings protect internal metal surfaces from acid gas corrosion and abrasive particulate. SDAs are critical pollution control equipment where corrosion causes premature failure and expensive replacement.
Heat Recovery Steam Generators (HRSGs): ITC coatings on tube surfaces and casings prevent acid dew point corrosion and extend component life in combined cycle and WTE heat recovery systems.
Baghouses and Fabric Filters: The full ITC three-product system on steel shells, structural supports, and tube sheets. Prevents acid corrosion that destroys both the structure and the filter media it supports.
Waste Heat Recovery Units: ITC coatings on boiler tubes, ductwork, and economizer surfaces exposed to corrosive exhaust gases.
Boilers: ITC 100HT on refractory-lined surfaces and ITC 213 on metal surfaces in both watertube and firetube boiler configurations.
Frequently Asked Questions: ITC in WTE and Power
What is acid dew point corrosion?
Acid dew point corrosion occurs when combustion exhaust gases containing sulfur and chlorine compounds cool below their condensation temperature (acid dew point). The resulting liquid is highly acidic — primarily sulfuric acid and hydrochloric acid — and rapidly corrodes unprotected metal surfaces. It is the primary cause of structural failure in baghouses, scrubbers, economizers, and ductwork in WTE, biomass, and power plants.
How does ITC prevent acid dew point corrosion?
ITC's three-product system works in two ways: (1) ITC 100HT provides thermal insulation that raises surface temperatures above the acid dew point, preventing condensation from forming; and (2) ITC 213 and 296A create inorganic ceramic barriers that protect the metal even if condensation occurs. This dual-defense approach is why ITC extends structure life 4–5x.
Can ITC coatings handle alternative fuels?
Yes. Alternative fuels (waste-derived, biomass, tires) release alkali chlorides and sulphates that are more corrosive than traditional fossil fuels. ITC 213 has been tested specifically in these conditions at 900°C and demonstrated significant corrosion reduction on every steel grade tested.
Contact ITC Coatings to discuss your WTE or power generation application: info@itccoatings.com | 904.759.0152