Nickel-based HVOF coatings promoting high temperature corrosion resistance of biomass-fired power plant boilers

Maria Oksa (Corresponding Author), Pertti Auerkari, Jorma Salonen, Tommi Varis

Research output: Contribution to journalArticleScientificpeer-review

28 Citations (Scopus)

Abstract

There are over 1000 biomass boilers in Europe, and the number is increasing due to actions for reducing greenhouse gas emissions. Biomass boilers often experience strong corrosion due to harmful elements in fuels. In biomass burning, detrimental components include especially chlorine, potassium and heavy metals, which can cause chlorine-induced active oxidation or hot corrosion by molten phases even at fairly low temperatures. In order to increase the corrosion resistance of heat exchanger components, either more alloyed steels or protective coatings should be applied. High velocity oxy-fuel (HVOF) sprayed coatings may provide corrosion protection for low alloy tube materials. Three nickel based thermal spray coatings (Ni–24Cr–16.5Mo, Ni–22Cr<5Fe–9Mo–4Nb and Ni–22Cr–10Al–1Y) were tested for two years in a 40 MW circulating fluidized boiler (CFB), which had experienced severe corrosion and a tube failure. The coated tubes were installed to the cold and the hot economizer. After the exposure the coatings and the substrate materials were analyzed with SEM–EDX. The uncoated boiler tubes corroded strongly, whereas the thermal spray coatings exhibited excellent corrosion performance. This paper presents the tube failure at the cold economizer, exposure conditions, the analysis of the coated and uncoated samples, and the corrosion mechanisms of the steel tubes.
Original languageEnglish
Pages (from-to)236-245
Number of pages10
JournalFuel Processing Technology
Volume125
DOIs
Publication statusPublished - 2014
MoE publication typeA1 Journal article-refereed

Fingerprint

Nickel
Boilers
Corrosion resistance
Power plants
Biomass
Corrosion
Coatings
Economizers
Steel
Chlorine
Temperature
Sprayed coatings
Protective coatings
Corrosion protection
Heavy Metals
Gas emissions
Greenhouse gases
Heavy metals
Heat exchangers
Potassium

Keywords

  • Biomass combustion
  • chlorine induced corrosion
  • corrosion protection
  • high temperature corrosion
  • HVOF
  • thermal spray coating

Cite this

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title = "Nickel-based HVOF coatings promoting high temperature corrosion resistance of biomass-fired power plant boilers",
abstract = "There are over 1000 biomass boilers in Europe, and the number is increasing due to actions for reducing greenhouse gas emissions. Biomass boilers often experience strong corrosion due to harmful elements in fuels. In biomass burning, detrimental components include especially chlorine, potassium and heavy metals, which can cause chlorine-induced active oxidation or hot corrosion by molten phases even at fairly low temperatures. In order to increase the corrosion resistance of heat exchanger components, either more alloyed steels or protective coatings should be applied. High velocity oxy-fuel (HVOF) sprayed coatings may provide corrosion protection for low alloy tube materials. Three nickel based thermal spray coatings (Ni–24Cr–16.5Mo, Ni–22Cr<5Fe–9Mo–4Nb and Ni–22Cr–10Al–1Y) were tested for two years in a 40 MW circulating fluidized boiler (CFB), which had experienced severe corrosion and a tube failure. The coated tubes were installed to the cold and the hot economizer. After the exposure the coatings and the substrate materials were analyzed with SEM–EDX. The uncoated boiler tubes corroded strongly, whereas the thermal spray coatings exhibited excellent corrosion performance. This paper presents the tube failure at the cold economizer, exposure conditions, the analysis of the coated and uncoated samples, and the corrosion mechanisms of the steel tubes.",
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Nickel-based HVOF coatings promoting high temperature corrosion resistance of biomass-fired power plant boilers. / Oksa, Maria (Corresponding Author); Auerkari, Pertti; Salonen, Jorma; Varis, Tommi.

In: Fuel Processing Technology, Vol. 125, 2014, p. 236-245.

Research output: Contribution to journalArticleScientificpeer-review

TY - JOUR

T1 - Nickel-based HVOF coatings promoting high temperature corrosion resistance of biomass-fired power plant boilers

AU - Oksa, Maria

AU - Auerkari, Pertti

AU - Salonen, Jorma

AU - Varis, Tommi

PY - 2014

Y1 - 2014

N2 - There are over 1000 biomass boilers in Europe, and the number is increasing due to actions for reducing greenhouse gas emissions. Biomass boilers often experience strong corrosion due to harmful elements in fuels. In biomass burning, detrimental components include especially chlorine, potassium and heavy metals, which can cause chlorine-induced active oxidation or hot corrosion by molten phases even at fairly low temperatures. In order to increase the corrosion resistance of heat exchanger components, either more alloyed steels or protective coatings should be applied. High velocity oxy-fuel (HVOF) sprayed coatings may provide corrosion protection for low alloy tube materials. Three nickel based thermal spray coatings (Ni–24Cr–16.5Mo, Ni–22Cr<5Fe–9Mo–4Nb and Ni–22Cr–10Al–1Y) were tested for two years in a 40 MW circulating fluidized boiler (CFB), which had experienced severe corrosion and a tube failure. The coated tubes were installed to the cold and the hot economizer. After the exposure the coatings and the substrate materials were analyzed with SEM–EDX. The uncoated boiler tubes corroded strongly, whereas the thermal spray coatings exhibited excellent corrosion performance. This paper presents the tube failure at the cold economizer, exposure conditions, the analysis of the coated and uncoated samples, and the corrosion mechanisms of the steel tubes.

AB - There are over 1000 biomass boilers in Europe, and the number is increasing due to actions for reducing greenhouse gas emissions. Biomass boilers often experience strong corrosion due to harmful elements in fuels. In biomass burning, detrimental components include especially chlorine, potassium and heavy metals, which can cause chlorine-induced active oxidation or hot corrosion by molten phases even at fairly low temperatures. In order to increase the corrosion resistance of heat exchanger components, either more alloyed steels or protective coatings should be applied. High velocity oxy-fuel (HVOF) sprayed coatings may provide corrosion protection for low alloy tube materials. Three nickel based thermal spray coatings (Ni–24Cr–16.5Mo, Ni–22Cr<5Fe–9Mo–4Nb and Ni–22Cr–10Al–1Y) were tested for two years in a 40 MW circulating fluidized boiler (CFB), which had experienced severe corrosion and a tube failure. The coated tubes were installed to the cold and the hot economizer. After the exposure the coatings and the substrate materials were analyzed with SEM–EDX. The uncoated boiler tubes corroded strongly, whereas the thermal spray coatings exhibited excellent corrosion performance. This paper presents the tube failure at the cold economizer, exposure conditions, the analysis of the coated and uncoated samples, and the corrosion mechanisms of the steel tubes.

KW - Biomass combustion

KW - chlorine induced corrosion

KW - corrosion protection

KW - high temperature corrosion

KW - HVOF

KW - thermal spray coating

U2 - 10.1016/j.fuproc.2014.04.006

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