Thermal spray coatings in industrial boiler environments: A review.

Abstract

Fired Boilers are integral parts of modern Petroleum Refineries and Thermal Power Plants where their reliability directly impacts both the productivity and financial performance. The pressurized components of these boilers are susceptible to various corrosion mechanisms, which can affect the reliability of the boilers. Over the years, a range of corrosion mitigation strategies have been explored and implemented across the industry, yielding varying levels of success. Based on extensive research and field trials, thermal spray coatings have emerged as a promising solution, offering cost-effective corrosion protection. This paper offers a comprehensive overview of thermal spray coatings as an effective strategy for corrosion prevention in industrial boiler environments. Thermal conductivity considerations in the selection of coating materials is highlighted. © 2025 by authors.