Coal-fired power plants in Europe are under continuous pressure to improve boiler efficiency, furnace sealing performance, and operational safety
The Polish customer planned a rear wall refurbishment project for an operating coal-fired boiler. The objective was to replace aging furnace components with membrane water wall panels that could enhance heat absorption, reduce air leakage, and extend boiler service life.
The customer is a thermal power plant operator in Poland, running a coal-fired unit equipped with a circulating fluidized bed (CFB) boiler.
Application scope:
- Boiler rear wall membrane water wall panels
- Furnace enclosure and evaporative heating surface
- High-temperature flame and flue gas heat absorption
The panels are vertically installed on the rear furnace wall and operate under high radiant heat conditions.
Based on the customer’s drawings and operating parameters, we supplied custom-manufactured membrane water wall rear panels, including:
- Carbon steel boiler-grade tubes
- Continuous flat steel fins welded between tubes
- Submerged Arc Welding (SAW) for uniform weld penetration
- Strict control of tube ovality and wall thinning in bent sections
- Post-weld straightening and dimensional inspection
Manufacturing process:
Tube preparation → Fin alignment → SAW membrane welding → Heat treatment → Panel straightening → Final inspection
- Product type: Membrane water wall rear panels
- Welding method: Submerged arc welding (SAW)
- Tube material: Carbon steel
- Structure: Tubes welded with continuous membrane fins
- Technical advantages:
- Excellent furnace gas-tightness
- Improved heat absorption compared to bare tubes
- High pressure resistance
- Reduced combustion air leakage
These features allow the boiler to achieve more stable combustion and higher thermal efficiency.
After final inspection, the panels were packed in reinforced steel-frame wooden crates
The customer expects the supplied membrane water wall panels to:
- Improve furnace sealing performance
- Reduce heat loss and air infiltration
- Shorten boiler startup and shutdown cooling time
- Support long-term, stable boiler operation
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