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Fireside Corrosion Behavior of HVOF and Plasma-Sprayed Coatings in Advanced Coal/Biomass Co-Fired Power Plants

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Abstract

This article presents a systematic evaluation of coatings for advanced fossil fuel plants and addresses fireside corrosion in coal/biomass-derived flue gases. A selection of four candidate coatings: alloy 625, NiCr, FeCrAl and NiCrAlY were deposited onto superheaters/reheaters alloy (T91) using high-velocity oxy-fuel (HVOF) and plasma spraying. A series of laboratory-based fireside corrosion exposures were carried out on these coated samples in furnaces under controlled atmosphere for 1000 h at 650 °C. The tests were carried out using the “deposit-recoat” test method to simulate the environment that was anticipated from air-firing 20 wt.% cereal co-product mixed with a UK coal. The exposures were carried out using a deposit containing Na2SO4, K2SO4, and Fe2O3 to produce alkali-iron tri-sulfates, which had been identified as the principal cause of fireside corrosion on superheaters/reheaters in pulverized coal-fired power plants. The exposed samples were examined in an ESEM with EDX analysis to characterize the damage. Pre- and post-exposure dimensional metrologies were used to quantify the metal damage in terms of metal loss distributions. The thermally sprayed coatings suffered significant corrosion attack from a combination of aggressive combustion gases and deposit mixtures. In this study, all the four plasma-sprayed coatings studied performed better than the HVOF-sprayed coatings because of a lower level of porosity. NiCr was found to be the best performing coating material with a median metal loss of ~87 μm (HVOF sprayed) and ~13 μm (plasma sprayed). In general, the median metal damage for coatings had the following ranking (in the descending order: most to the least damage): NiCrAlY > alloy 625 > FeCrAl > NiCr.

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Acknowledgments

The authors acknowledge the supports from the ASPECT project, which is a Technology Strategy Board (TSB)-funded project, and especially thank the following companies: Doosan Babcock, E.ON, the National Physical Laboratory, Sulzer Metco, Monitor Coatings, and RWE npower, for their valuable contributions to the project. The authors would also like to thank Dr Johannes Rauch from Sulzer Metco WOKA GmbH for his kind cooperation during this project.

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  1. Centre for Energy and Resource Technology, Cranfield University, Bedfordshire, MK43 0AL, UK

    T. Hussain, T. Dudziak, N. J. Simms & J. R. Nicholls

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  1. T. Hussain
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  4. J. R. Nicholls
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Correspondence to T. Hussain.

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Hussain, T., Dudziak, T., Simms, N.J. et al. Fireside Corrosion Behavior of HVOF and Plasma-Sprayed Coatings in Advanced Coal/Biomass Co-Fired Power Plants. J Therm Spray Tech 22, 797–807 (2013). https://doi.org/10.1007/s11666-013-9887-x

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  • DOI: https://doi.org/10.1007/s11666-013-9887-x

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