Protecting upper furnace components with superheater, reheater, and economizer services

With over 30 years of experience, WSI is a leading expert in safeguarding upper furnace components subjected to harsh corrosive and erosive conditions. Our patented Unifuse 360^® technology provides unparalleled protection to superheaters, reheaters, and economizers. Backed by the industry’s largest installed base, this technology has a proven track record of reliability, successfully preserving hundreds of boilers worldwide.

A unique, cost-effective solution for superheater, reheater, and economizer repair

WSI’s Unifuse 360 technology features a fully fused welded bond between the corrosion-resistant overlay material and the tube base material. This patented welding process creates a fully tempered heat-affected zone, allowing the tube to be bent to its final configuration after the coating application. The bond quality achieved with Unifuse 360 is significantly superior to other methods, such as coextruded tubes and tubes heat-treated after overlay application.

Tailored manufacturing for maximum protection

Unifuse 360 can be manufactured in small batches using corrosion-resistant alloys specifically tailored to the corrosive environment of your boiler. That flexibility ensures that the protective overlays are optimized for each boiler’s unique conditions. The technology’s reliability has been proven over decades, offering successful protection for hundreds of boilers around the world.

Leading expert with automated weld overlay technology for upper furnace components

Upper furnace components in boilers face some of the most challenging erosive and corrosive environments. Exposed to flue gas corrosion products and higher operating temperatures than other components like waterwalls, these critical elements also endure high-velocity flue gas particulates due to the area reduction typically designed into the units.

Unifuse 360 technology provides the highest level of protection for your superheater, reheater, and economizer services, ensuring operational efficiency and longevity in the toughest environments. Proven expertise in superheater automated weld overlay, reheater machine weld overlay, and economizer weld overlay help prevent tube leaks and other common issues, offering comprehensive and reliable repair solutions.

The world’s largest installed base for waterwall services and fireside corrosion mitigation

Fireside corrosion of waterwall panels is one of the costliest issues for boiler operators, especially in coal-fired units where sulphidation is prevalent. WSI is globally recognized for its Unifuse180^® technology, the industry standard in fireside erosion and corrosion control. This technology has the world’s most extensive installed base for mitigating fireside corrosion in waterwall panels in both critical and sub-critical coal-fired units, offering protection for existing panels and new constructions. Our comprehensive waterwall services ensure the highest level of protection and longevity for your boiler components.

Since 1985, WSI has led the way in fireside corrosion mitigation for Waste to Energy (WTE) boilers with its innovative weld metal overlay using alloy 625. The robust barrier prevents damage from low-melting-point chlorides formed by heavy metal reactions with chlorine. Welded coating ensures a durable bond capable of withstanding thermal cycling and other stressors like soot blowers, effectively protecting against base metal damage. Unifuse 180, initially developed for WTE boilers, remains the most reliable method for mitigating fireside thinning.

State-of-the-art shop production services

Two state-of-the-art production facilities in the USA and Europe support Unifuse 180 weld metal overlay applications. Extensive resources and technical expertise enable handling of intricate and large-scale panel configurations for individual plant operators and boiler OEMs. We offer unparalleled fabrication capabilities for waterwall services, accommodating panels up to 18 m long and 2 m wide at a competitive cost per panel. Overlay thicknesses ranging from 1.2 to 3 mm or more can be applied, tailored to meet specific requirements.

Field production specialists and waterwall services

Field application specialists perform on-site waterwall overlay applications. As the largest provider of weld metal overlay globally, WSI has the industry’s largest fleet of equipment and highly trained personnel, capable of easily managing projects of any size.

Industry-leading solution for fireside corrosion mitigation with Unifuse 180 technology

Fireside corrosion presents a significant challenge for boiler operators due to its cost implications. Unifuse180 technology offers a highly effective solution, setting the industry standard for managing fireside erosion and corrosion in critical and sub-critical coal-fired units. It can be applied in the field to protect existing waterwall panels or in the shop for new constructions or replacements of damaged panels. Engineered to enhance boiler waterwall longevity, Unifuse 180 ensures excellent heat transfer efficiency, providing the longest reliable working life.