Case Overview
A waste-to-energy plant operator replaced superheater tube bundles every 12-18 months because of chloride and sulfur corrosion from flue gas and ash deposits. Every replacement meant a costly shutdown. The operator sought corrosion-resistant overlay and coating materials to extend superheater service life toward a 3-year target.
DZX qualified with Inconel 625 overlay tubes and thermal-spray wire with verified chemistry and application support, helping the operator progress toward the 3-year life-extension target.
This case summarizes the application requirements, materials supplied by DZX and delivery value. For case-specific technical data, please contact our engineering team.
| Item | Details |
|---|---|
| Client Profile | Waste-to-energy plant operator / boiler service provider |
| Project Scale | Superheater replacement and protection program |
| Application | Superheater tubes, waterwall protection and repair coatings |
| Materials Supplied | Inconel 625 overlay tubes, thermal-spray wire and welding wire |
| Supply Forms | Tube, wire and plate |
| Lead Time | Standard grades: 3-4 weeks; project batches scheduled to plan |
| Project Country | Japan |
| Project Year | 2024 |
Our Solution
The operator’s life-extension program faced three material challenges:
- Chloride and sulfur corrosion: flue gas and ash deposits attacked superheater tubes above 400°C metal temperature, limiting unprotected life to 12-18 months.
- Overlay quality: overlays had to be dense and defect-free with controlled chemistry to create an effective corrosion barrier.
- Repair strategy: in-service waterwall and superheater repairs needed thermal-spray and welding materials with documented performance.
DZX built a protective-material package around the operator’s service-life target:
Inconel 625 overlay tubes were supplied for new and replacement superheaters, with controlled chemistry for chloride-rich flue-gas resistance. Thermal-spray wire and nickel-based welding wire covered waterwalls and repair projects. Every batch included chemistry, dimensional and application documentation supporting the operator’s overlay procedure qualification.
| Material | Representative Grades | Key Properties | Available Forms |
|---|---|---|---|
| Inconel | 625 | Chloride and sulfur corrosion resistance | Overlay tubes and wire |
| Thermal-spray wire | Nickel-based, selected by application | Waterwall and repair coatings | Wire |
| Welding wire | 625, Type 82 | Overlay and repair welding | Wire |
View Inconel Alloys → | View Thermal-Spray Wire → | View Welding Wire →
Superheater protection
Heating-surface coatings
Overlay and repair
Technical Specifications
Key technical parameters agreed before production. Contact us for grade-specific datasheets and tolerance-verification reports.
| Parameter | Agreed Specification | Verification Method |
|---|---|---|
| Overlay chemistry | Inconel 625, to ASTM B443/AMS | Batch chemical analysis |
| Tube substrate | To drawing (e.g. 38 mm × 4 mm) | Micrometer + wall-thickness inspection |
| Thermal-spray wire | Nickel-based, selected by application | Chemistry + spool documentation |
| Welding wire | 625 / Type 82, for overlays | Batch chemistry |
| Service-life target | 3-year superheater life-extension target | Application support + documentation |
Each supplied batch includes a quality inspection certificate with chemical analysis, meeting the applicable standard for each grade.
| Material | Applicable Standards |
|---|---|
| Inconel 625 | ASTM B443, B704 |
| Thermal-spray wire | To application specification |
| Welding wire | AWS A5.14 |
| Quality System | Mill quality certificate including chemical analysis |
Delivery and Quality Support
- Fast delivery: Sample and production lead times follow the project schedule; standard grades and sizes can be dispatched promptly from stock.
- Quality traceability: Every batch includes material certificates and inspection reports, with full heat and batch traceability.
- Technical support: Responsive support covers pre-sale material selection, drawing review and post-sale processing advice.
- Ongoing service: Regular follow-up after delivery tracks performance and addresses feedback promptly.
Customer Feedback
- Life extension enabled: Inconel 625 overlay supported the operator’s 3-year superheater life target
- Corrosion barrier: controlled overlay chemistry for chloride- and sulfur-bearing flue gas
- Repair capability: thermal-spray and welding wire for in-service protection programs
- Procedure qualification support: chemistry and application documentation for every batch
- Shutdown planning: project quantities scheduled to replacement windows
- One protection package: overlay tubes, spray wire and welding wire coordinated by one manufacturer
Our Capabilities
Jiangsu DZX Technology Co., Ltd. (Changzhou DLX Alloy) was founded in 2016. Its core team has worked in the field since 2002, with 24 years of precision-alloy R&D and production experience, operating a self-owned 12,000-square-meter modern factory with an ISO9001 system covering three inspection stages. Annual alloy output exceeds 1,200 tonnes, serving 1500+ business customers worldwide. The company operates integrated melting, drawing, annealing and precision-machining workshops, supporting volume customization of strip, wire, tube and bar. Every batch includes a chemical analysis report (MTC) for full delivery-quality traceability.
Related Products
Waste-to-Energy Applications
Boiler tubes, superheaters and flue-gas treatment systems
Energy Industry Applications
Boiler superheaters, nuclear steam generators and steam turbines
Industrial Applications
Furnace heating, heat treatment, machinery and wear-resistant parts
