Thermal spray coatings for high temperature corrosion protection in biomass co-fired boilers

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

Abstract

There are over 1000 biomass boilers and about 500 plants using waste as fuel in Europe, and the numbers are increasing. In many of them there are serious problems with high temperature corrosion due to detrimental elements such as chlorides, alkali metals and heavy metals. By HVOF spraying it is possible to produce very dense and well adhered coatings, which can be used as protection against severe material wastage of heat exchanger surfaces in biomass and waste-to-energy power plant boilers. Four HVOF coatings and one arc sprayed coating were manufactured on metallic test rings, which were exposed to actual biomass co-fired boiler conditions in superheater area with a probe measurement installation. The coating materials were Ni-Cr, IN625, Fe-Cr-W-Nb-Mo and Ni-Cr-Ti. Both CJS and DJ Hybrid spray guns were used for HVOF spraying to compare the corrosion resistance of Ni-50Cr coating structures. Substrate and reference materials were ferritic steel T92 for test temperature 550 °C and nickel super alloy A263 for 750 °C. The studied circulating fluidized bed (CFB) boiler used a mixture of wood, peat and coal as fuel. The duration of the measurement was 5900 hours. All the coatings showed excellent corrosion resistance at 550 °C compared to the ferritic steel. At higher temperature, NiCr sprayed with CJS had the best corrosion resistance. IN625 was consumed almost completely during the exposure at 750 °C.
Original languageEnglish
Title of host publicationInternational Tagungsband ITSC 2014 Thermal Spray Conference and Exposition
Place of PublicationDüsseldorf
Pages312-317
Publication statusPublished - 2014
MoE publication typeA4 Article in a conference publication
EventInternational Thermal Spray Conference, ITSC 2014 - Barcelona, Spain
Duration: 21 May 201423 May 2014

Publication series

NameDVS-Berichte
PublisherDVS Media GmbH
Volume302
ISSN (Print)0418-9639

Conference

ConferenceInternational Thermal Spray Conference, ITSC 2014
Abbreviated titleITSC 2014
CountrySpain
CityBarcelona
Period21/05/1423/05/14

Fingerprint

Corrosion protection
Boilers
Biomass
Coatings
Corrosion resistance
Ferritic steel
Spraying
Temperature
Spray guns
Superheaters
Sprayed coatings
Peat
Alkali metals
Fluidized beds
Heavy metals
Heat exchangers
Wood
Power plants
Nickel
Coal

Cite this

Oksa, M., Kärki, J., & Metsäjoki, J. (2014). Thermal spray coatings for high temperature corrosion protection in biomass co-fired boilers. In International Tagungsband ITSC 2014 Thermal Spray Conference and Exposition (pp. 312-317). Düsseldorf. DVS-Berichte, Vol.. 302
Oksa, Maria ; Kärki, Janne ; Metsäjoki, Jarkko. / Thermal spray coatings for high temperature corrosion protection in biomass co-fired boilers. International Tagungsband ITSC 2014 Thermal Spray Conference and Exposition. Düsseldorf, 2014. pp. 312-317 (DVS-Berichte, Vol. 302).
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abstract = "There are over 1000 biomass boilers and about 500 plants using waste as fuel in Europe, and the numbers are increasing. In many of them there are serious problems with high temperature corrosion due to detrimental elements such as chlorides, alkali metals and heavy metals. By HVOF spraying it is possible to produce very dense and well adhered coatings, which can be used as protection against severe material wastage of heat exchanger surfaces in biomass and waste-to-energy power plant boilers. Four HVOF coatings and one arc sprayed coating were manufactured on metallic test rings, which were exposed to actual biomass co-fired boiler conditions in superheater area with a probe measurement installation. The coating materials were Ni-Cr, IN625, Fe-Cr-W-Nb-Mo and Ni-Cr-Ti. Both CJS and DJ Hybrid spray guns were used for HVOF spraying to compare the corrosion resistance of Ni-50Cr coating structures. Substrate and reference materials were ferritic steel T92 for test temperature 550 °C and nickel super alloy A263 for 750 °C. The studied circulating fluidized bed (CFB) boiler used a mixture of wood, peat and coal as fuel. The duration of the measurement was 5900 hours. All the coatings showed excellent corrosion resistance at 550 °C compared to the ferritic steel. At higher temperature, NiCr sprayed with CJS had the best corrosion resistance. IN625 was consumed almost completely during the exposure at 750 °C.",
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Oksa, M, Kärki, J & Metsäjoki, J 2014, Thermal spray coatings for high temperature corrosion protection in biomass co-fired boilers. in International Tagungsband ITSC 2014 Thermal Spray Conference and Exposition. Düsseldorf, DVS-Berichte, vol. 302, pp. 312-317, International Thermal Spray Conference, ITSC 2014, Barcelona, Spain, 21/05/14.

Thermal spray coatings for high temperature corrosion protection in biomass co-fired boilers. / Oksa, Maria; Kärki, Janne; Metsäjoki, Jarkko.

International Tagungsband ITSC 2014 Thermal Spray Conference and Exposition. Düsseldorf, 2014. p. 312-317 (DVS-Berichte, Vol. 302).

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

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T1 - Thermal spray coatings for high temperature corrosion protection in biomass co-fired boilers

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N2 - There are over 1000 biomass boilers and about 500 plants using waste as fuel in Europe, and the numbers are increasing. In many of them there are serious problems with high temperature corrosion due to detrimental elements such as chlorides, alkali metals and heavy metals. By HVOF spraying it is possible to produce very dense and well adhered coatings, which can be used as protection against severe material wastage of heat exchanger surfaces in biomass and waste-to-energy power plant boilers. Four HVOF coatings and one arc sprayed coating were manufactured on metallic test rings, which were exposed to actual biomass co-fired boiler conditions in superheater area with a probe measurement installation. The coating materials were Ni-Cr, IN625, Fe-Cr-W-Nb-Mo and Ni-Cr-Ti. Both CJS and DJ Hybrid spray guns were used for HVOF spraying to compare the corrosion resistance of Ni-50Cr coating structures. Substrate and reference materials were ferritic steel T92 for test temperature 550 °C and nickel super alloy A263 for 750 °C. The studied circulating fluidized bed (CFB) boiler used a mixture of wood, peat and coal as fuel. The duration of the measurement was 5900 hours. All the coatings showed excellent corrosion resistance at 550 °C compared to the ferritic steel. At higher temperature, NiCr sprayed with CJS had the best corrosion resistance. IN625 was consumed almost completely during the exposure at 750 °C.

AB - There are over 1000 biomass boilers and about 500 plants using waste as fuel in Europe, and the numbers are increasing. In many of them there are serious problems with high temperature corrosion due to detrimental elements such as chlorides, alkali metals and heavy metals. By HVOF spraying it is possible to produce very dense and well adhered coatings, which can be used as protection against severe material wastage of heat exchanger surfaces in biomass and waste-to-energy power plant boilers. Four HVOF coatings and one arc sprayed coating were manufactured on metallic test rings, which were exposed to actual biomass co-fired boiler conditions in superheater area with a probe measurement installation. The coating materials were Ni-Cr, IN625, Fe-Cr-W-Nb-Mo and Ni-Cr-Ti. Both CJS and DJ Hybrid spray guns were used for HVOF spraying to compare the corrosion resistance of Ni-50Cr coating structures. Substrate and reference materials were ferritic steel T92 for test temperature 550 °C and nickel super alloy A263 for 750 °C. The studied circulating fluidized bed (CFB) boiler used a mixture of wood, peat and coal as fuel. The duration of the measurement was 5900 hours. All the coatings showed excellent corrosion resistance at 550 °C compared to the ferritic steel. At higher temperature, NiCr sprayed with CJS had the best corrosion resistance. IN625 was consumed almost completely during the exposure at 750 °C.

M3 - Conference article in proceedings

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BT - International Tagungsband ITSC 2014 Thermal Spray Conference and Exposition

CY - Düsseldorf

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Oksa M, Kärki J, Metsäjoki J. Thermal spray coatings for high temperature corrosion protection in biomass co-fired boilers. In International Tagungsband ITSC 2014 Thermal Spray Conference and Exposition. Düsseldorf. 2014. p. 312-317. (DVS-Berichte, Vol. 302).