Renewable EnergY – Hydropower
Efficiency and Longevity in Hydropower: Advanced Wear Protection for the Hydropower Plants of Tomorrow
Hydropower is a cornerstone of the global energy transition. As a primary renewable source, it accounts for approximately 20% of global electricity generation, making it an indispensable part of the renewable portfolio. However, operating modern hydropower plants places extreme demands on material integrity. Turbines, guide vanes, and runners are subjected to constant stress from abrasion, erosion, and cavitation.
With BOROCOAT®, BorTec offers an innovative solution to increase the operational efficiency of hydropower plants and sustainably reduce long-term maintenance costs.
Targeted Protection for Critical Components in hydropower
BOROCOAT® provides specialized protection exactly where hydropower technology reaches its physical limits:
Abrasive wear
Protection for turbine runners and wicket gates against sediment-heavy water.
Cavitation
Effective reduction of material fatigue in pumps and impellers through extreme surface hardness.
Corrosion Resistance:
Long-term preservation of component integrity, even in chemically aggressive or saline environments.
The Challenges of Hydropower Plants: Erosion and Cavitation
In high- and medium-head hydropower plants, materials are exposed to brutal conditions. Silt and sediment-heavy water act like sandpaper on components made of martensitic stainless steels (such as CF6NM, 1.4313/ AISI 415/F6NM, or 1.4418/X4CrNiMo16-5-1.). The consequences for plant operators are severe:
- Surge in Maintenance Costs: Approximately 2% of annual revenue is typically reinvested in maintenance, primarily driven by wear and tear.
- Loss of Efficiency: Surface degradation impairs hydrodynamic properties, leading to lower power output for the entire facility.
- Material Fatigue: Cavitation (imploding vapor bubbles) destroys even high-strength surfaces.
Looking to minimize downtime at your facility?
BOROCOAT®: The Game Changer for Hydropower Facilities
To meet these challenges, BorTec utilizes boriding, a thermochemical diffusion process. Unlike conventional coatings, BOROCOAT® does not apply a foreign material that could peel or flake off. Instead, boron atoms diffuse into the substrate surface, forming an extremely hard, integrated bond of metal borides.
Why choose Boriding for Hydropower Plant components?
Extreme Surface Hardness:
With a hardness of up to 2,000 HV (Vickers), the surface becomes more resistant to abrasive particles than any base material.
Cavitation Shield:
Boride layers significantly reduce cavitation effects. The high compressive residual stresses within the layer prevent material breakout.
Comprehensive Protection for Complex Geometries:
While spray processes (such as HVOF or Plasma) reach their limits with “line-of-sight” restrictions, BOROCOAT® reaches every internal contour. Even complex Francis runners or narrow internal pipe surfaces are protected uniformly.
Superior Adhesion:
Since the protective layer is formed within the component itself, an inseparable metallurgical bond is created. Risk of delamination, even under heavy impact, is eliminated.
Proven Solutions: Maximum Protection for Francis Runner Turbines
A prime example of BOROCOAT®’s effectiveness in utility-scale hydropower plants is the protection of Francis runners. These key components are the heart of the plant and endure the most extreme operational stresses.
Sustainability and Profitability through Innovation
Investing in BorTec technology pays off twice. By significantly extending the service life of turbine components, the frequency of repairs drops. This not only saves capital but also conserves valuable resources.
Furthermore, a smooth, borided surface minimizes flow losses. The result: Optimized efficiency for your hydropower plant and a higher energy yield from the power of water.
Our Services at a Glance:
✔️ Treatment of martensitic stainless steels (1.4313/AISI 415/F6NM, 1.4418/X4CrNiMo16-5-1, and more)
✔️ Precision finishing for optimal hydrodynamic performance
✔️ Coverage of complex internal geometries and undercuts
BorTec – Your Partner for Industrial Wear Protection
As a specialist in thermochemical diffusion processes, BorTec supports hydropower plant operators and manufacturers worldwide in making renewable energy even more competitive. With BOROCOAT®, you invest in a technology that combines technical superiority with environmental responsibility.
