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Key technologies and industrialization for preparation of metal-matrix enamel composites for corrosion-resistant heat exchangers
High-performance corrosion-resistant enamel elements efficiently recover waste heat from power plants, save energy and reduce emissions, which is the first in China.
Type
Equipment
Tags
Industrial energy conservation
Composites
Product application-related engineering and technology
Chemical engineering
Heat exchange element
Corrosion-resistant enamel
Metal-based enamel
Solution maturity
Mass promotion / Mass production
Cooperation methods
Joint venture cooperation
Face-to-face consultation
Applicable industry
Manufacturing
Applications
Energy conservation and emission reduction
Key innovations
The country is the first desulfurization and denitrification enamel heat exchange element, innovatively develops high-performance corrosion-resistant base glaze, low-carbon electrofusion preparation technology and ultra-high enamel pipe continuous manufacturing equipment, fills domestic gaps, has independent property rights, reaches the international advanced level, and effectively saves energy and increases efficiency.
Potential economic benefits
Extend product life, reduce energy consumption and manufacturing costs, improve production efficiency and product quality, replace imports, and create significant economic benefits for users.
Potential climate benefits
Power plant waste heat recovery significantly improves energy efficiency and directly reduces fuel carbon emissions. Electrofusion and continuous processes for enamel production reduce manufacturing energy consumption, extend product life and reduce carbon emissions.
Solution supplier
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Donghua University
Donghua University
Donghua University, a key university in the national "211 Project", focuses on textiles, materials, fashion and design, cultivates innovative talents, and serves the country's industrial upgrading and scientific and technological progress.
Shanghai,China
Solution details

The project mainly involves the field of new materials and power. Among them, enamel glaze belongs to the field of new materials, while desulfurization and denitrification enamel heat exchange elements are mainly used for pre-waste heat recovery of boiler flue gas in power plants, belonging to the field of power. This project is the first in China, filling the domestic technical gap and making significant contributions in replacing similar products. Metal substrates are often used in air preheaters in power plants with harsh working environments and are often corroded by high temperatures and acidic flue gases. Enamel coatings have excellent high temperature resistance and chemical stability, so the application of enamel coatings to metal substrates has become a hot research topic today. This project mainly includes three aspects of technological innovation and improvement. (1) Research and development of high-performance corrosion-resistant base glaze. Enamel coatings are suitable for use in high-temperature corrosive atmospheres. Effective resistance to smoke corrosion is the key to improving the life of enamel. First, the influence of different trace oxide components on the microstructure, mechanical properties and acid-resistant chemical properties of enamel composites was explored; secondly, the content and particle size of abrasive additives were systematically studied on the acid-resistant properties of enamel glazes; Third, the preparation of enamel glaze by doping fly ash from power plants was systematically studied. Through precise construction of components, acid-resistant enamel glaze with a fly ash content of 10-15% was successfully prepared. (2) Research and development of low-carbon and energy-saving preparation technology for high-performance enamel. Enamel glaze is generally opaque because it contains adhesives, opacifying agents, etc., so the enamel glaze has poor heat permeability, conventional flame melting consumes a lot of energy and causes serious pollution. Through glass electrofusion technology, the electrofusion preparation of acid-resistant enamel glaze is realized directly by using bottom insertion electrode technology. Through Donghua University's research technology in electric melting, the use of vertical electric melting furnace and bottom-inserted electrode electric melting furnace technology can not only effectively reduce the corrosion of enamel on kiln refractory materials, improve the melting uniformity of enamel glaze, but also greatly reduce the enamel glaze preparation energy consumption. Compared with flame furnaces, the melting energy consumption per kilogram of enamel glaze is reduced by about 0.5kwh. (3) Development of continuous manufacturing equipment for ultra-high enamel pipes. With the requirements of large-scale power plants, the size of enamel products for high-performance heat exchangers is getting larger and larger. The conventional intermittent well-furnace sintering process is used, which has high energy consumption, low yield and low quality. This project has designed and prepared the first domestic ultra-high enamel pipe tunnel kiln production line that integrates online spraying, drying and sintering processes. Currently, the production line has been put into production and can achieve the online production of more than 2000 6-8-meter-long enamel pipes per day. The integrated process of coating, drying and sintering processes produces excellent quality products, low energy consumption, and greatly reduced labor intensity. This product has currently applied for relevant patents. The products developed in this project have completely independent intellectual property rights and have successfully realized the integrated independent intellectual property rights of acid-resistant enamel glaze from glaze, glaze slurry to enamel product production lines. In addition, this project successfully exceeded 6 meters in length for the first time (the domestic average level is about 4 meters), filling the domestic technical gap and reaching the domestic leading and international advanced level. It has laid a solid foundation for further promoting the development of corrosion-resistant enamel products in my country. This project has been successfully promoted and applied to Jinan Qiquan Thermal Power Co., Ltd., Jinan Weiquan Biological Power Generation Co., Ltd. and other companies. The results show that the high-performance enamel products developed in this project have the characteristics of good acid resistance and long service life, and have also brought benefits to the application units. Good economic and social benefits.

Last updated
09:41:16, Nov 05, 2025
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