Thermal spray coatings for high temperature corrosion protection of advanced power plants -performance and feasibility studies in a biomass-fired boiler

Research output: Chapter in Book/Report/Conference proceedingConference article in proceedingsScientificpeer-review

Abstract

The goal of carbon dioxide (CO2) reduction in energy production has lead power plant operators to increase the efficiency by higher process parameters and to use alternative fuels instead of fossil fuels.
Maintenance of power plant boilers experience great challenges due to use of difficult biomass and recycled fuels, which can cause severe corrosion damage to different boiler components and decrease lifetime of the metallic components.
Investigation on suitable material solution to encounter the corrosion problems in even higher process temperatures is thus needed. Thermal spray coatings to be applied up to 750 °C in biomass boiler conditions were sprayed and their high temperature corrosion resistance was validated in a 550 MWth circulating fluidized bed (CFB) burning mainly biomass.
Three test campaigns were performed with controlled probe measurements, their duration varying from 1300 hours to 5900 hours.
Two material test temperatures were set by the water and air controlled probe: 550 °C and 750 °C. The coatings were high velocity oxy-fuel (HVOF) sprayed nickel- and iron-based NiCr, Ni-21Cr, IN625, NiCrAlY, FeCr and arc sprayed NiCrTi.
Two spray guns were applied to spray the metallic HVOF coatings in order to compare the effect of coating structure and oxygen content on the corrosion resistance.
Applicability and performance of one ceramic coating Al2O3 with bond coat NiCrAlY was also tested.
Reference tube materials were ferritic steel T92 and nickel super alloys A263 and A740.
Most of the coatings showed excellent corrosion performance both at lower and higher test temperature.
However, Ni-21Cr and IN625 corroded strongly at higher temperature and cannot be applied with high chlorine containing
fuels such as biomass at temperatures as high as 750 °C.
According to this study, corrosion performance validation of materials suitable for advanced power plants
with higher steam and material temperatures is possible with temperature controlled probe exposure
in real boiler conditions.
Original languageEnglish
Title of host publicationProceedings
Subtitle of host publicationMaterials for Advanced Power Engineering 2014
Pages727-736
Volume234
Publication statusPublished - 2014
MoE publication typeA4 Article in a conference publication
Event10th Liege Conference on Materials for Advanced Power Engineering - Liege, Belgium
Duration: 14 Sep 201417 Sep 2014
Conference number: 10

Publication series

SeriesSchriften des Forschungszentrums Jülich: Reihe Energie & Umwelt/Energy & Environment
ISSN1866-1793

Conference

Conference10th Liege Conference on Materials for Advanced Power Engineering
CountryBelgium
CityLiege
Period14/09/1417/09/14

Fingerprint

Corrosion protection
Boilers
Power plants
Biomass
Coatings
Corrosion
Temperature
Corrosion resistance
Nickel
Spray guns
Ceramic coatings
Hot Temperature
Alternative fuels
Ferritic steel
Fossil fuels
Fluidized beds
Chlorine
Carbon dioxide
Steam
Iron

Keywords

  • biomass
  • boiler
  • co-firing
  • thermal spray
  • coating
  • high temperature corrosion

Cite this

Oksa, M., Kärki, J., & Metsäjoki, J. (2014). Thermal spray coatings for high temperature corrosion protection of advanced power plants -performance and feasibility studies in a biomass-fired boiler. In Proceedings: Materials for Advanced Power Engineering 2014 (Vol. 234, pp. 727-736). Schriften des Forschungszentrums Jülich: Reihe Energie & Umwelt/Energy & Environment
Oksa, Maria ; Kärki, Janne ; Metsäjoki, Jarkko. / Thermal spray coatings for high temperature corrosion protection of advanced power plants -performance and feasibility studies in a biomass-fired boiler. Proceedings: Materials for Advanced Power Engineering 2014. Vol. 234 2014. pp. 727-736 (Schriften des Forschungszentrums Jülich: Reihe Energie & Umwelt/Energy & Environment).
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Oksa, M, Kärki, J & Metsäjoki, J 2014, Thermal spray coatings for high temperature corrosion protection of advanced power plants -performance and feasibility studies in a biomass-fired boiler. in Proceedings: Materials for Advanced Power Engineering 2014. vol. 234, Schriften des Forschungszentrums Jülich: Reihe Energie & Umwelt/Energy & Environment, pp. 727-736, 10th Liege Conference on Materials for Advanced Power Engineering, Liege, Belgium, 14/09/14.

Thermal spray coatings for high temperature corrosion protection of advanced power plants -performance and feasibility studies in a biomass-fired boiler. / Oksa, Maria; Kärki, Janne; Metsäjoki, Jarkko.

Proceedings: Materials for Advanced Power Engineering 2014. Vol. 234 2014. p. 727-736 (Schriften des Forschungszentrums Jülich: Reihe Energie & Umwelt/Energy & Environment).

Research output: Chapter in Book/Report/Conference proceedingConference article in proceedingsScientificpeer-review

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N2 - The goal of carbon dioxide (CO2) reduction in energy production has lead power plant operators to increase the efficiency by higher process parameters and to use alternative fuels instead of fossil fuels. Maintenance of power plant boilers experience great challenges due to use of difficult biomass and recycled fuels, which can cause severe corrosion damage to different boiler components and decrease lifetime of the metallic components. Investigation on suitable material solution to encounter the corrosion problems in even higher process temperatures is thus needed. Thermal spray coatings to be applied up to 750 °C in biomass boiler conditions were sprayed and their high temperature corrosion resistance was validated in a 550 MWth circulating fluidized bed (CFB) burning mainly biomass. Three test campaigns were performed with controlled probe measurements, their duration varying from 1300 hours to 5900 hours. Two material test temperatures were set by the water and air controlled probe: 550 °C and 750 °C. The coatings were high velocity oxy-fuel (HVOF) sprayed nickel- and iron-based NiCr, Ni-21Cr, IN625, NiCrAlY, FeCr and arc sprayed NiCrTi. Two spray guns were applied to spray the metallic HVOF coatings in order to compare the effect of coating structure and oxygen content on the corrosion resistance. Applicability and performance of one ceramic coating Al2O3 with bond coat NiCrAlY was also tested. Reference tube materials were ferritic steel T92 and nickel super alloys A263 and A740. Most of the coatings showed excellent corrosion performance both at lower and higher test temperature. However, Ni-21Cr and IN625 corroded strongly at higher temperature and cannot be applied with high chlorine containing fuels such as biomass at temperatures as high as 750 °C. According to this study, corrosion performance validation of materials suitable for advanced power plants with higher steam and material temperatures is possible with temperature controlled probe exposure in real boiler conditions.

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KW - biomass

KW - boiler

KW - co-firing

KW - thermal spray

KW - coating

KW - high temperature corrosion

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Oksa M, Kärki J, Metsäjoki J. Thermal spray coatings for high temperature corrosion protection of advanced power plants -performance and feasibility studies in a biomass-fired boiler. In Proceedings: Materials for Advanced Power Engineering 2014. Vol. 234. 2014. p. 727-736. (Schriften des Forschungszentrums Jülich: Reihe Energie & Umwelt/Energy & Environment).