Metguard Application in Haldia Power Plant: Mitigating Corrosion in Coal Handling Areas

Location: Haldia, West Bengal (50 km from Coastline)

Industry: Power Generation (Coal-Based Thermal Power Plant)

The thermal power plant located in the industrial town of Haldia, West Bengal, operates with a total capacity of 150 MW x 2 turbines, providing power to the state grid for rural supply. Despite the absence of a railway wagon line for coal transportation, the plant relies on dumpers, resulting in significant coal dust contamination in the atmosphere. This coal dust, combined with moisture, is a major contributor to sulfidic corrosion in the structures surrounding coal handling areas.

Corrosion Challenges in Thermal Power Plants

The power plant environment is filled with a variety of acidic oxides such as SOx, NOx, and other volatile compounds. When combined with the high moisture levels in the plant, these oxides lead to the formation of acids that accelerate corrosion in plant infrastructure. Key areas prone to corrosion include the Cooling Towers, Coal Handling Plant, Ash Handling Unit, ESP (Electrostatic Precipitator), and the DM (Demineralization) Plant. In particular, the Coal Stacker/Reclaimer, which handles coal in a moisture-rich environment, is highly susceptible to corrosion due to constant exposure to coal dust, moisture, and organic volatiles.

The plant’s proximity to the coast and surrounding industrial activities further exacerbates the corrosive environment, increasing the threat to infrastructure durability.

Metguard's Corrosion Protection in Power Plants

In such an aggressive environment, Metguard provides a robust solution for protecting critical infrastructure against both environmental and chemical corrosion. Here’s how Metguard was applied in the Haldia power plant:

• Sulfidic Corrosion Resistance: Metguard effectively prevents the destructive impact of H₂S and other sulfur compounds commonly found in coal dust and emissions, ensuring long-term protection of steel structures.
• Durability in Moisture-Rich Areas: Areas such as the Coal Stacker/Reclaimer, which are continuously exposed to moisture due to coal spraying, benefit from Metguard’s advanced corrosion-resistant properties.
• Protection Against Acidic Oxides: By neutralizing the effects of SOx, NOx, and other volatile compounds, Metguard safeguards key areas such as cooling towers and coal handling systems from acid-induced degradation.
• Thermoplastic Air-Drying Coating for Roofing Sheets: For roofing and side panels, Metguard's thermoplastic air-drying coating offers enhanced protection for Galvalume and galvanized sheets, ensuring superior durability in harsh environments like coal storage and acid pickling plants.

Conclusion

Metguard's application in the Haldia power plant has proven its effectiveness in protecting infrastructure against the severe corrosion challenges posed by coal dust, sulfur compounds, and other corrosive emissions. Its ability to provide long-term protection, especially in moisture-heavy environments, has helped enhance the durability of key plant structures and reduced maintenance costs, ensuring more efficient operations in this high-risk industrial setting.