Erosion shield tube boilers, commonly referred to as boiler tube shields, anti-erosion shields, or anti-corrosion shields, are specialized components designed to protect boiler tubes from the harsh effects of erosion, corrosion, and high-temperature flue gas abrasion in industrial boiler systems. These shields are crucial in industries such as power generation, petrochemical processing, and waste-to-energy plants, where boilers operate under extreme conditions involving high-pressure steam, abrasive fly ash, and corrosive chemical reactions. By providing a robust protective barrier around boiler tubes, erosion shield tube boilers significantly extend tube lifespan, minimize maintenance costs, and enhance operational reliability by preventing premature tube failures.

These shields are crafted from high-quality materials, including stainless steel (SS304, SS316, SS309, SS310) and alloy steels (A387 P11, A387 P22), selected for their ability to withstand severe environments. Advanced material grades like TP321 and TP310S offer exceptional resistance to corrosion and high temperatures, enduring up to 925°C, making them ideal for demanding applications. Erosion shield tube boilers are available in various configurations—straight, inner-curve, outer-curve, side-curve, and S-curve—to accommodate diverse tube geometries, such as finned tubes used in superheaters, reheaters, economizers, and water-cooled walls. The shields typically feature a semi-circular (180-degree) cross-section, with customizable wrap angles ranging from 90 to 240 degrees to meet specific operational requirements.

The manufacturing process for erosion shield tube boilers involves advanced techniques, such as high-pressure pressing and precision mold shaping, to ensure a smooth surface, excellent weldability, and a professional finish. For curved shields, specialized bending processes are employed, with technical drawings specifying parameters like tube outer diameter, bending radius, and angle. The inner diameter of the shield is designed to be 1-3mm larger than the tube’s outer diameter for a secure fit. Common tube sizes include 32mm, 38mm, 44.5mm, 57mm, and 63.5mm, with shield lengths ranging from 20mm to 3000mm, though 1000-2000mm is the most common range for industrial applications.

Erosion shield tube boilers are engineered to address critical user needs, such as reducing downtime and maintenance expenses caused by tube erosion or corrosion. They are particularly effective in protecting vital boiler components in fossil fuel-fired boilers, biomass power plants, and circulating fluidized bed (CFB) boilers. Positive Material Identification (PMI) is utilized during production to verify material quality and compliance with industry standards, ensuring reliability in challenging environments. Excess materials are often repurposed into snap rings, promoting cost-efficiency and sustainability. For extreme conditions, shields can be enhanced with chromium carbide coatings or manufactured from exotic alloys like Inconel for superior wear and corrosion resistance.

With a typical service life of 3-5 years, depending on boiler type and operating conditions, erosion shield tube boilers offer long-term reliability. Customizable features, such as variable wrap angles and end types (straight, belled, or flared), allow for precise adaptation to specific boiler configurations. By integrating these shields into boiler systems, operators can achieve enhanced durability, reduced maintenance frequency, and improved boiler efficiency, making them an essential solution for industrial boiler protection.

Additional Information

Applications: Erosion shield tube boilers are critical in fossil fuel-fired boilers, biomass power plants, and CFB boilers, protecting heating surfaces from high-temperature flue gas erosion.
Customization: Manufacturers like Sunny Steel provide bespoke solutions, producing shields for straight, curved, or finned tubes based on precise customer specifications.
Economic Benefits: By preventing tube erosion and corrosion, these shields reduce downtime and maintenance costs, ensuring uninterrupted boiler operations.
Material Versatility: Materials like TP321 for high corrosion resistance or 1Cr13 for lower-temperature applications ensure optimal performance across diverse conditions.