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1-6 of 6
Fireside corrosion
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Proceedings Papers
ITSC 2019, Thermal Spray 2019: Proceedings from the International Thermal Spray Conference, 109-114, May 26–29, 2019,
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Different surface protection technologies were investigated in a waste-wood fired fluidized bed boiler. This biomass fuel environment is more aggressive than those firing virgin wood due to the elevated presence of sodium, potassium, lead, and zinc, leading to the deposit of alkali metal chlorides in conjunction with ash on boiler tube surfaces. As laboratory tests are seldom representative of the complex firing, chemistry, temperature, and local heat flux encountered in actual operating conditions, five different commercial, near commercial, and development coatings were applied to a 1 m length of plain carbon steel tubing used in the furnace walls. The coatings were fully characterized and measured prior to installation and after exposure. Iron and nickel-based weld overlays, two high velocity thermal spray coatings, and a laser-clad nanosteel coating were tested. After exposure, the tube was extracted from the boiler and corrosion scales and material losses were evaluated in comparison to unprotected tube material.
Proceedings Papers
ITSC 2015, Thermal Spray 2015: Proceedings from the International Thermal Spray Conference, 1020-1025, May 11–14, 2015,
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Higher operating temperatures coupled with biomass-derived fuels can lead to aggressive corrosion damage to the superheater/reheater tubes in power plants. In this study, a HVOF sprayed NiCr coating was deposited onto a 9 % Cr substrate, which were exposed in simulated coal-biomass combustion gases with a screening deposit containing Na 2 SO 4 , K 2 SO 4 and Fe 2 O 3 at 700-750°C for 1000 h. The tests were carried out using the “deposit-recoat” test method and pre and post-exposure dimensional metrology was used to quantify the coating damage in terms of metal loss distributions. The exposed samples were also examined in a SEM/ EDX. The coatings developed a protective Cr 2 O 3 layer at the coatings/ deposit interface and a Cr depleted zone was observed underneath the oxide layer. NiCr coating provided suitable corrosion protection with a median metal loss of ~35μm in 1000h.
Proceedings Papers
ITSC2014, Thermal Spray 2014: Proceedings from the International Thermal Spray Conference, 546-550, May 21–23, 2014,
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This study assesses the fireside erosion-corrosion behavior of nanostructured NiCr coatings in a power plant boiler operating at 750 °C. In the experiments, Ni-20Cr nanocrystalline powder was synthesized by ball milling and deposited on T91 boiler steel substrates by HVOF spraying. Coated and uncoated steel specimens were thermally cycled in the superheater zone of a coal fired boiler. After 15 heating and cooling cycles, the specimens were examined and erosion-corrosion kinetics were established via weight-change and thickness-loss measurements. The results show that the nanostructured coatings reduced the erosion-corrosion rate of T91 steel by 85%.
Proceedings Papers
ITSC 2009, Thermal Spray 2009: Proceedings from the International Thermal Spray Conference, 691-694, May 4–7, 2009,
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This study evaluates Fe-Si intermetallic powders as an alternative to powders currently used to coat furnace walls in pulverized coal fired boilers. The developed powder mainly consists of Fe 2 Si, which has a relatively low melting point among iron silicides. The powders were deposited on CrMo steel substrates by HVOF and atmospheric plasma spraying and the resulting coatings were subjected to corrosion and erosion testing. Under conditions simulating the operating environment in a low NO X boiler, the HVOF sprayed Fe-Si coatings exhibited sulfidation resistance nearly equal to that of Cr-Ni layers, and in high-temperature erosion tests, the APS intermetallic coatings with boron additions were found to be more erosion resistant than conventional Cr 3 C 2 -NiCr coatings.
Proceedings Papers
ITSC1998, Thermal Spray 1998: Proceedings from the International Thermal Spray Conference, 151-155, May 25–29, 1998,
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The elevated temperature erosion resistance of experimental amorphous thermal spray coatings was determined in a laboratory elevated temperature erosion tester. Test conditions attempted to simulate the erosion conditions found at the combustor waterwall tubes in fossil fuel fired boilers. Erosion tests were conducted on four experimental amorphous thermal spray coatings, using the bed ash retrieved from an operating coal fired boiler. An experimental arcspray process was used to spray coatings. These results were compared with erosion test results of two common structural materials, two commercially available arc-sprayed coatings, and a proprietary HVOF coating. Test results indicated that the Duocor coating had the highest erosion resistance among the four experimental coatings, it showed equal resistance to the HVOF coating (DS-200). Compared to AISI 1018 steel, both Duocor and DS-200 coatings reduced material wastage by 26-fold. Other test results indicated that the XJ-16, 60T and Armacor M coatings had equal erosion resistance reducing material wastage approximately 7-fold, while Armacor CW reduced by 10-fold. Only slightly better than the unprotected 1018 steel, the X-20 coating performed poorly on erosion tests. The high erosion resistance of Duocor and DS-200 coatings was attributed to their high densities and fine splat structures.
Proceedings Papers
ITSC1998, Thermal Spray 1998: Proceedings from the International Thermal Spray Conference, 951-956, May 25–29, 1998,
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The unusual effects of plasma sprayed coating on the fire-side of evaporator tubes located in an oil-fired steam generating boiler are discussed. The main heat transfer surfaces are constructed by heat exchanger tubes, evaporator tubes and superheaters. Maintenance to prevent of the boiler failure or the preserve heat exchanger effectiveness is a very important factor in the operation of boiler facilities. In a boiler which employs heavy gravity oil as a fuel, plasma sprayed Ni-Cr alloy has often been applied to boiler tubes for the relief of hot corrosion by combustion gas. However, the circulation of boiler water causes an internal deposit to form on the inner wall of evaporator tubes. The internal deposit generates excess heat load against the tubes. As the overheating of the tubes often causes the evaporator tubes to fail, they are chemically cleaned periodically. In this paper, the influence of Ni-Cr plasma sprayed coating for the heat flux, which dominates the formation of the internal deposit, is investigated. Ni-Cr plasma sprayed coating is substitutionally hot corrosion resistant and is a composite coating into which the fuel ash containing a vanadium or sulfur compound are interstitially penetrated and solidified. It is derived that the existence of the coating on the fire-side of the evaporator tubes normalizes the heat load in their inner walls. Moreover, the suppression of internal deposit formation decreases the frequency of chemical cleaning for tubes. The dual effects of plasma sprayed coating for hot corrosion resistance in the fire side and the suppression of internal deposit on the water side of the tubes are reported.