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

Content Provider	Springer Nature Link
Author	Hussain, T. Dudziak, T. Simms, N. J. Nicholls, J. R.
Copyright Year	2013
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 Na$_{2}$SO$_{4}$, K$_{2}$SO$_{4}$, and Fe$_{2}$O$_{3}$ 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.
Starting Page	797
Ending Page	807
Page Count	11
File Format	PDF
ISSN	10599630
Journal	Journal of Thermal Spray Technology
Volume Number	22
Issue Number	5
e-ISSN	15441016
Language	English
Publisher	Springer US
Publisher Date	2013-01-30
Publisher Place	Boston
Access Restriction	One Nation One Subscription (ONOS)
Subject Keyword	air-firing alloy 625 biomass/coal co-firing FeCrAl fireside corrosion HVOF coatings NiCr NiCrAlY plasma spraying superheater corrosion Triplex Surfaces and Interfaces, Thin Films Tribology, Corrosion and Coatings Characterization and Evaluation of Materials Operating Procedures, Materials Treatment Analytical Chemistry
Content Type	Text
Resource Type	Article
Subject	Surfaces, Coatings and Films Materials Chemistry Condensed Matter Physics

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