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Thermal Spray Coatings for High-Temperature Corrosion Protection in Biomass Co-Fired Boilers

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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. Many of them encounter 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 applied for corrosion protection of heat exchanger surfaces in biomass and waste-to-energy power plant boilers. Four HVOF coatings and one arc sprayed coating were exposed to actual biomass co-fired boiler conditions in superheater area with a probe measurement installation for 5900 h at 550 and 750 °C. The coating materials were Ni-Cr, IN625, Fe-Cr-W-Nb-Mo, and Ni-Cr-Ti. CJS and DJ Hybrid spray guns were used for HVOF spraying to compare the corrosion resistance of Ni-Cr coating structures. Reference materials were ferritic steel T92 and nickel super alloy A263. The circulating fluidized bed boiler burnt a mixture of wood, peat and coal. 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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Acknowledgments

This work was performed in the FP7 EU project NextGenPower—Efficiency increases in existing and new build pulverized coal power plants with a view to CCS. The authors would like to thank Alholmens Kraft Ab for the opportunity for performing the testing in the power plant.

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Authors and Affiliations

  1. Materials and Manufacturing, VTT Technical Research Centre of Finland, Espoo, Finland

    M. Oksa & J. Metsäjoki

  2. Biofuels and Bioenergy, VTT Technical Research Centre of Finland, Jyväskylä, Finland

    J. Kärki

Authors
  1. M. Oksa
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  2. J. Metsäjoki
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  3. J. Kärki
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Correspondence to M. Oksa.

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Oksa, M., Metsäjoki, J. & Kärki, J. Thermal Spray Coatings for High-Temperature Corrosion Protection in Biomass Co-Fired Boilers. J Therm Spray Tech 24, 194–205 (2015). https://doi.org/10.1007/s11666-014-0155-5

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  • DOI: https://doi.org/10.1007/s11666-014-0155-5

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