Performance testing of iron based thermally sprayed HVOF coatings in a biomass-fired fluidised bed boiler

Maria Oksa (Corresponding Author), Tommi Varis, Kimmo Ruusuvuori

    Research output: Contribution to journalArticleScientificpeer-review

    8 Citations (Scopus)

    Abstract

    Managing high temperature corrosion problems in biomass firing boilers has been challenging especially due to high amounts of chemically active compounds, in particular alkali chlorides. Thermally sprayed coatings with high chromium content can offer a solution for protecting low alloyed substrate materials in locations prone to high temperature corrosion. Two thermally sprayed (HVOF - high velocity oxy-fuel) iron based coatings (Fe-27Cr-11Ni-4Mo and Fe-19Cr-9W-7Nb-4Mo) were exposed to biomass boiler conditions for two years. The fluidised bed boiler for district heating used mainly wood-based fuels mixed with small amounts of peat. The coated tubes were located at the hot economiser of the boiler, where the estimated material temperature was about 200 °C maximum. After the exposure the coatings and the carbon steel St35.8 substrate material were analysed with SEM-EDX. It was detected that corrosion due to elements such as chlorine, potassium, zinc, lead and copper had caused severe material wastage in the biomass boiler with relatively low heat exchanger surface temperatures. The low alloyed boiler tubes had suffered severely with a corrosion rate as high as 2 mm/year, whereas dense thermal spray coatings offered excellent protection during the exposure.
    Original languageEnglish
    Pages (from-to)191-200
    Number of pages10
    JournalSurface and Coatings Technology
    Volume251
    DOIs
    Publication statusPublished - 2014
    MoE publication typeA1 Journal article-refereed

    Fingerprint

    boilers
    biomass
    Boilers
    beds
    Biomass
    Iron
    coatings
    iron
    Coatings
    corrosion
    Testing
    Corrosion
    Boiler firing
    Temperature
    District heating
    Sprayed coatings
    Peat
    tubes
    peat
    Chlorine

    Keywords

    • Biomass
    • chlorine corrion
    • corrosion protection
    • high temperature corrosion
    • HVOF
    • thermal spray coating

    Cite this

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    title = "Performance testing of iron based thermally sprayed HVOF coatings in a biomass-fired fluidised bed boiler",
    abstract = "Managing high temperature corrosion problems in biomass firing boilers has been challenging especially due to high amounts of chemically active compounds, in particular alkali chlorides. Thermally sprayed coatings with high chromium content can offer a solution for protecting low alloyed substrate materials in locations prone to high temperature corrosion. Two thermally sprayed (HVOF - high velocity oxy-fuel) iron based coatings (Fe-27Cr-11Ni-4Mo and Fe-19Cr-9W-7Nb-4Mo) were exposed to biomass boiler conditions for two years. The fluidised bed boiler for district heating used mainly wood-based fuels mixed with small amounts of peat. The coated tubes were located at the hot economiser of the boiler, where the estimated material temperature was about 200 °C maximum. After the exposure the coatings and the carbon steel St35.8 substrate material were analysed with SEM-EDX. It was detected that corrosion due to elements such as chlorine, potassium, zinc, lead and copper had caused severe material wastage in the biomass boiler with relatively low heat exchanger surface temperatures. The low alloyed boiler tubes had suffered severely with a corrosion rate as high as 2 mm/year, whereas dense thermal spray coatings offered excellent protection during the exposure.",
    keywords = "Biomass, chlorine corrion, corrosion protection, high temperature corrosion, HVOF, thermal spray coating",
    author = "Maria Oksa and Tommi Varis and Kimmo Ruusuvuori",
    year = "2014",
    doi = "10.1016/j.surfcoat.2014.04.025",
    language = "English",
    volume = "251",
    pages = "191--200",
    journal = "Surface and Coatings Technology",
    issn = "0257-8972",
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    }

    Performance testing of iron based thermally sprayed HVOF coatings in a biomass-fired fluidised bed boiler. / Oksa, Maria (Corresponding Author); Varis, Tommi; Ruusuvuori, Kimmo.

    In: Surface and Coatings Technology, Vol. 251, 2014, p. 191-200.

    Research output: Contribution to journalArticleScientificpeer-review

    TY - JOUR

    T1 - Performance testing of iron based thermally sprayed HVOF coatings in a biomass-fired fluidised bed boiler

    AU - Oksa, Maria

    AU - Varis, Tommi

    AU - Ruusuvuori, Kimmo

    PY - 2014

    Y1 - 2014

    N2 - Managing high temperature corrosion problems in biomass firing boilers has been challenging especially due to high amounts of chemically active compounds, in particular alkali chlorides. Thermally sprayed coatings with high chromium content can offer a solution for protecting low alloyed substrate materials in locations prone to high temperature corrosion. Two thermally sprayed (HVOF - high velocity oxy-fuel) iron based coatings (Fe-27Cr-11Ni-4Mo and Fe-19Cr-9W-7Nb-4Mo) were exposed to biomass boiler conditions for two years. The fluidised bed boiler for district heating used mainly wood-based fuels mixed with small amounts of peat. The coated tubes were located at the hot economiser of the boiler, where the estimated material temperature was about 200 °C maximum. After the exposure the coatings and the carbon steel St35.8 substrate material were analysed with SEM-EDX. It was detected that corrosion due to elements such as chlorine, potassium, zinc, lead and copper had caused severe material wastage in the biomass boiler with relatively low heat exchanger surface temperatures. The low alloyed boiler tubes had suffered severely with a corrosion rate as high as 2 mm/year, whereas dense thermal spray coatings offered excellent protection during the exposure.

    AB - Managing high temperature corrosion problems in biomass firing boilers has been challenging especially due to high amounts of chemically active compounds, in particular alkali chlorides. Thermally sprayed coatings with high chromium content can offer a solution for protecting low alloyed substrate materials in locations prone to high temperature corrosion. Two thermally sprayed (HVOF - high velocity oxy-fuel) iron based coatings (Fe-27Cr-11Ni-4Mo and Fe-19Cr-9W-7Nb-4Mo) were exposed to biomass boiler conditions for two years. The fluidised bed boiler for district heating used mainly wood-based fuels mixed with small amounts of peat. The coated tubes were located at the hot economiser of the boiler, where the estimated material temperature was about 200 °C maximum. After the exposure the coatings and the carbon steel St35.8 substrate material were analysed with SEM-EDX. It was detected that corrosion due to elements such as chlorine, potassium, zinc, lead and copper had caused severe material wastage in the biomass boiler with relatively low heat exchanger surface temperatures. The low alloyed boiler tubes had suffered severely with a corrosion rate as high as 2 mm/year, whereas dense thermal spray coatings offered excellent protection during the exposure.

    KW - Biomass

    KW - chlorine corrion

    KW - corrosion protection

    KW - high temperature corrosion

    KW - HVOF

    KW - thermal spray coating

    U2 - 10.1016/j.surfcoat.2014.04.025

    DO - 10.1016/j.surfcoat.2014.04.025

    M3 - Article

    VL - 251

    SP - 191

    EP - 200

    JO - Surface and Coatings Technology

    JF - Surface and Coatings Technology

    SN - 0257-8972

    ER -