Chimney Flue Lining Materials

1.0 Introduction

In order to minimize the adverse effects of SO2 and SO3 on the

environment, many power plants and industrial facilities use flue gas
desulphurisation (FGD) scrubbers to remove SO2 and SO3 from combustion
gases. In a 100% FGD plant total flue gas is treated. However in order to
economise, depending on control of pollutants emissions permitted, part capacity
FGD plants are also installed. The outlet gas from FGD plant would still be
corrosive because of presence of SO2, SO3 and moisture. Therefore, to reduce
the corrosion effects, for outlet ducts from FGD plants and chimney flues, acid
resistant internal liners are used. Typically, the acid dewpoint of a flue gas will lie
between 120 and 160 °C, depending on SO3 and water content of the flue gas.

2.0 Pennguard (Borosilicate Glass) Liners

Nowadays, Pennguard liners are widely used as lining materials for flue
gas ducts and chimney flues. Pennguard is a registered trademark of Henkel
Surface Technologies, USA, and is distributed and fitted by Hadek Protective
Systems, Netherlands. Pennguard block lining is composed of silica glass of
closed cell structure (celluar borosilicate glass block).

The advantages of a Pennguard lining could be summarized as follows:

a) An excellent corrosion barrier, with full resistance to sulfuric acid

condensate
b) A robust lining system, with a thickness of 38 mm (1 1/2 inch) or
more, yet also lightweight (about 13 kg / m2) and does not require
any anchors
c) A lining system, which can be applied to steel, concrete and brick
substrata, using uncomplicated installation procedures
d) A lining system, which is suitable for new construction projects and
also offers unique options for economical, time saving modifications
of existing chimneys directly on concrete or on brick flues
e) A low maintenance lining system, which has proven reliable and
durable in a wide variety of flue gas environments

A list of power stations where Pennguard liners are used on steel flues in
concrete chimneys are given in Annexure - 1. Further a list of power stations
where Pennguard liners are used on brick liners in concrete chimneys, and the
power stations where Pennguard linings are used directly on concrete shells are
given in Annexure - 2 and Annexure – 3, respectively.
3.0 Metallic Liners

Nickel and titanium alloys are also used in the form of wallpaper. Another
coating solution is to metalize the interior of the stack by applying a pressurized
molten zinc or aluminum alloy onto the steel. Nickel alloys have also been used
in some cases . The disadvantage of this type of protection is their high costs.

4.0 Fiberglass ( FRP ) Liners

There are liner tubes made from structural fiberglass with embedded steel
stiffeners. Their use to-date is limited. They are cheaper compared to metallic
liners.

Information gathered by:

1) Amol J Bharamgonda (JE)
2) Rajkumar S R (JE)
Guided by:
O K Muthappa

Note:
Three technical publications on the subject mentioned below, are annexed for
more information.
1) Pha Lai 2 Power Station- Vietnam’s most modern coal fired power station
uses Pennguard chimney flue lining
2) Dunamenti Power Station- Pennguard protects steel chimney liners in a
heavy oil fired power plant
3) West Burton Power Station- Large coal fired power station in England uses
Pennguard linings for its new FGD chimney
 Annexure - 1

List of Power Stations with Concrete Chimneys with Steel Flues Lined with Borosilicate Glass ( Pennguard )

Sl. No. Name of Power Plant No. of Units Year Type of Fuel Flue Lining Material Supplier Manufacturer

1 Pha Lai 2 Power Station, 3 X 300 MW * Coal fired Pennguard ( Borosilicate Glass ) Hadek Protective Systems b.v. Henkel Surface Technologies
Vietnam The Netherlands North America
www.hadek.com
2 Dunamenti Power Station, 6 X 220 MW 1994 Oil fired Pennguard ( Borosilicate Glass ) -Do- Henkel surface technologies
Hungary North America

3 Sual Power Station, 2 X 609 MW 1999 Coal fired Borosilicate Glass * *

Philippines

4 West Burton Power Station, 4X 500 MW * Coal fired Pennguard ( Borosilicate Glass ) Hadek Protective Systems b.v. Henkel Surface Technologies
England The Netherlands North America

5 PHo -Ping Power Co . 2 X 600 MW 2001 Coal fired Pennguard 55 Hadek Protective Systems b.v. Henkel Surface Technologies
Ho -Ping Power Station,
Taiwan
6 Korea South East Power Corp., 4 x 500 MW 2003-04 Coal fired Pennguard 55 Hadek Protective Systems b.v. Henkel Surface Technologies
Samchonpo Power Station 1-4, ( Borosilicate Glass )
Korea

7 New Brunswick Power, 3 x 350 MW 2003/04 Oil fired Pennguard 55

Hadek Protective Systems b.v. Henkel Surface Technologies
Coleson Cove Generating St., ( Borosilicate Glass )
Canada

8 Electric Authority of Cyprus, 120 MW 2004 Oil fired Pennguard 55

Hadek Protective Systems b.v. Henkel Surface Technologies
Vasilicos Phase II, Unit 3, ( Borosilicate Glass )
Cyprus

9 Tanjung Bin Power Sdn Bhd, 3 x 700 MW Summer 2005 Coal fired Pennguard 55
Hadek Protective Systems b.v. Henkel Surface Technologies
Tanjung Bin Power Station, ( Borosilicate Glass )
Johor - Malaysia

10 Electricity of Vietnam ( EVN ), 1 x 300 MW Autumn 2005 Coal fired Pennguard 55

Hadek Protective Systems b.v. Henkel Surface Technologies
Uong Bi Power Plant, ( Borosilicate Glass )
Vietnam
 11 Jimah Energy Ventures SdnBd 2 x 700 MW Spring 2007 Coal fired Pennguard 55
Hadek Protective Systems b.v. Henkel Surface Technologies
Jimah Power Station, ( Borosilicate Glass )
Malaysia

12 AES Kilroot Power LTD, 2 x 220 MW 2007 Coal fired Pennguard 55

Hadek Protective Systems b.v. Henkel Surface Technologies
Kilroot Power Station, ( Borosilicate Glass )
Northen Ireland

13 International Power, 2 x 500 MW Spring 2007 Coal fired Pennguard 55

Hadek Protective Systems b.v. Henkel Surface Technologies
Rugeley Power Station, ( Borosilicate Glass )
Great Britain

14 AES/ Indianapolis Power&Light 400 MW + 230 MW 1995 Coal fired Pennguard 55

Hadek Protective Systems b.v. Henkel Surface Technologies
Petersburg Unit 1, ( Borosilicate Glass )
Indiana, USA

* Information not available.

 Annexure - 2

List of Power Stations with Concrete Chimneys with Internal Brick Lined with Pennguard

Sl. No. Name of Power Plant No. of Units Year Type of Fuel Flue Lining Material Supplier Manufacturer

1 Korea Southern Power Co. 2 X 500 MW 1997 Coal fired Pennguard 55 Hadek Protective Systems b.v. Henkel Surface Technologies
Hadong Power Station 1 & 2, (Borosilicate Glass ) The Netherlands North America
Korea www.hadek.com
2 Essent 640 MW 1997 Coal fired Pennguard 55 -Do- Henkel Surface Technologies
Amercentrale 9, (Borosilicate Glass ) North America
Natherlands
3 Korea Midland power co. 4 X 500 MW 1997-98 Coal fired Pennguard 55 -Do- Henkel Surface Technologies
Boryung Power station 3 & 6 (Borosilicate Glass ) North America
Korea
4 Korea Western Power Co., 4X 500 MW 1998/99 Coal fired Pennguard 55 Hadek Protective Systems b.v. Henkel Surface Technologies
Taean Power Station, (Borosilicate Glass ) The Netherlands North America
Korea
5 Endesea S.A., 3 x 350 MW 1999 Coal fired Pennguard 55 Hadek Protective Systems b.v. Henkel Surface Technologies
Terul Power Station (Borosilicate Glass )
Spain

6 Tri State Generations & 2 x 420 MW 2003/04 Coal fired Pennguard 55 Hadek Protective Systems b.v. Henkel Surface Technologies
Transmission Associations, (Borosilicate Glass )
Craig Generation Station,
Colorado, USA

7 RWE Innogy, 3 X 500 MW 004/2005/200 Coal fired Pennguard 55 Hadek Protective Systems b.v. Henkel Surface Technologies
Aberthaw Power Station, (Borosilicate Glass )
Great Britain

8 RWE Power AG 2 x 300 MW Autumn 2005 Gas fired Pennguard 55 Hadek Protective Systems b.v. Henkel Surface Technologies
KW Weisweiler Block G/H, (Borosilicate Glass )
Germany

9 CWLP, 199 MW Spring 2006 Coal fired Pennguard 55 Hadek Protective Systems b.v. Henkel Surface Technologies
Dallman Power Station Unit 33, (Borosilicate Glass )
Illionis, USA
10 Dayton Power & Light Co. 600 MW Spring 2006 Coal fired Pennguard 55 Hadek Protective Systems b.v. Henkel Surface Technologies
Killen station unit 2, (Borosilicate Glass )
Ohio, USA

11 AES Kilroot Power Ltd., 2 x 220 MW 2007 Coal fired Pennguard 55 Hadek Protective Systems b.v. Henkel Surface Technologies
Kilroot Power Station, (Borosilicate Glass )
Northen Ireland

12 Maritsa Iztok 2 TPP- EAD 2 x 215 MW Autumn 2006 Coal fired Pennguard 55 Hadek Protective Systems b.v. Henkel Surface Technologies
Maritsa East 2 Power Station, ( Lignite ) (Borosilicate Glass )
Bulgeria.

13 Duke Energy, 1x1300 MW Spring 2007 Coal fired Pennguard 55 Hadek Protective Systems b.v. Henkel Surface Technologies
W.H.Zimmer Generating Station, (Borosilicate Glass )
Ohio , USA

14 Ferry Bridge Power Station, 3 x 500 MW Spring 2007 Coal fired Pennguard 55 Hadek Protective Systems b.v. Henkel Surface Technologies
Units 2,3 & 4, (Borosilicate Glass )
Great Britain
 Annexure - 3

List of Power Stations with Pennguard Lining on Concrete Shell

Sl. No. Name of Power Plant No. of Units Year Type of Fuel Flue Lining Material Supplier Manufacturer

1 Korea Southern Power Co., 2 X 500 MW Autumn 1999 Coal fired Pennguard 55 Hadek Protective Systems b.v. Henkel Surface Technologies
Hadong Power Station 1 & 2 , (Borosilcate Glass ) The Netherlands North America
Korea
2 CONEL 400 MW Spring 2002 Coal fired Pennguard 55 -Do- Henkel Surface Technologies
CET Craiova Power Station, (Borosilcate Glass ) North America
Romania
3 EDF Energy, 4 X 500 MW 2005/06 Coal fired Pennguard 55 -Do- Henkel Surface Technologies
Cottom Power Station, (Borosilcate Glass ) North America
Great Britain