Erosion protection shields, also known as boiler tube shields, anti-erosion shields, or anti-corrosion shields, are essential components designed to protect boiler tubes from the damaging effects of erosion, corrosion, and high-temperature flue gas abrasion in industrial boiler systems. These shields are critical 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 forming a robust protective barrier around boiler tubes, erosion protection shields significantly extend tube lifespan, minimize maintenance expenses, and enhance operational reliability by preventing premature tube failures.

These shields are manufactured from high-quality materials, including stainless steel (SS304, SS316, SS309, SS310) and alloy steels (A387 P11, A387 P22), selected for their durability and resistance to harsh environments. Advanced material grades like TP321 and TP310S provide exceptional corrosion resistance and can withstand temperatures up to 925°C, making them ideal for demanding applications. Erosion protection shields 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 production process for erosion protection shields employs 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 used, 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 protection shields are engineered to address critical user needs, such as reducing downtime and maintenance costs associated with 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 protection shields 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 protection shields 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.