Corrosion-Erosion Mechanism and Research Prospect of Bare Materials and Protective Coatings for Power Generation Boiler
ZHANG Shihong1,2(), HU Kai1,2, LIU Xia1, YANG Yang1
1.Key Laboratory of Green Fabrication and Surface Technology of Advanced Metal Materials, Ministry of Education, Anhui University of Technology, Ma'anshan 243002, China 2.School of Materials Science and Engineering, Anhui University of Technology, Ma'anshan 243002, China
Cite this article:
ZHANG Shihong, HU Kai, LIU Xia, YANG Yang. Corrosion-Erosion Mechanism and Research Prospect of Bare Materials and Protective Coatings for Power Generation Boiler. Acta Metall Sin, 2022, 58(3): 272-294.
Since the “emission peak-carbon neutrality” goal was proposed, coal-fired boilers, which are major power supply equipment and CO2 emission sites, have been gradually developed to zero-carbon emission biomass and low-carbon coal/biomass cofired boiler. The corrosion and erosion behavior of the sulfur and chlorine components of coal and biomass poses a serious threat to the safety and long-term operation of boilers, and protective coatings have become a convenient and efficient way to improve the corrosion and erosion resistance of boilers. This paper reviews recent research progress on high-temperature corrosion and erosion of bare materials and protective coatings used in coal-fired, biomass, and coal/biomass cofired boilers. The mechanism of sulfur corrosion and alkali chlorine corrosion in coal-burning and biomass combustion environments is summarized. The ash deposition-impaction mechanism in coal/biomass cofired environments is described. The current application status of boiler bare materials is introduced, and the design principles, preparation processes, and application status of alloy, ceramic, and metal-ceramic coatings in corrosive and erosive environments are summarized. Based on the current findings, future research on corrosion and erosion of boilers should focus on imperfect hot corrosion mechanisms, accurate corrosion-wear prediction models and types of protective coatings. Finally, material genome engineering and machine learning are proposed to accelerate material research/development and study the corrosion-erosion mechanisms as well as multifactor coupling models. There is a need to integrate powder synthesis methods, coating structure designs, and in-service performance into the development of new protective coatings.
Fig.1 Schematic of the distribution of “boiler pipes” of power generating boiler[57]
Material
Tm / oC
Ref.
Na2SO4
884
[63]
K2SO4
1069
[63]
Na2S2O7
401
[63]
K2S2O7
325
[63]
Na3Fe(SO4)3
624
[63]
K3Fe(SO4)3
618
[63]
Na2SO4-CoSO4
575
[71]
Na2SO4-NiSO4
631
[71]
Table 1 Melting points (Tm) of various sulfate/pyrosulfate salts and eutectic salts[63,71]
Fig.2 Schematic of the process of hot corrosion induced by molten sulfate salts[63]
Fig.3 Ash corrosion of tubes in biomass boiler[29]
Fig.4 Schematics of hot corrosion process induced by KCl molten salt
Fig.5 Schematics of ash deposition-impaction mechanism on a heat transfer tube[43]
Steel
C
Cr
Mo
V
Nb
Ni
Other
20G[96]
0.17-0.24
-
-
-
-
-
-
12CrMoVG[96]
0.08-0.15
0.90-1.20
0.25-0.35
0.15-0.30
-
-
-
T11[98]
0.05-0.15
1.00-1.50
0.44-0.65
-
-
-
-
T23[98]
0.04-0.10
1.90-2.60
0.05-0.30
0.20-0.30
0.02-0.08
-
W (1.45-1.75)
Improve red-hardness and
heat resistance
T24[62]
0.05-0.10
2.20-2.60
0.90-1.10
-
-
Ti (0.05-0.10)
Refine the grain and reduce
cold shortness
T91[98]
0.08-0.12
8.00-9.50
0.85-1.05
0.18-0.25
0.06-0.10
-
-
T92[97]
0.07-0.13
8.50-9.50
0.30-0.60
0.15-0.25
0.04-0.09
-
W (1.50-2.00)
TP304[99]
≤ 0.08
18.00-20.00
-
-
-
8.00-11.00
-
TP347[99]
≤ 0.10
17.00-19.00
-
-
0.80-1.50
9.00-13.00
-
Super304H[97]
0.07-0.13
17.00-19.00
-
-
0.30-0.60
7.50-10.50
Cu (2.50-3.50)
Improve strength and
toughness and corrosion
resistance
HR3C[100]
≤ 0.10
24.00-26.00
-
-
0.20-0.60
19.00-22.00
-
Table 2 Main alloy element chemical compositions and functions of steels for boiler[62,96-100]
Alloy
Si
Cr
Al
Ti
W
Mo
Co
Ni
Fe
Superfer 800H[101]
0.60
19.50
0.34
0.44
-
-
-
30.80
Bal.
A 286[102]
0.50
13.60
0.25
1.99
-
1.18
0.32
24.10
Bal.
Inconel 718[103]
0.18
19.00
0.30
0.90
-
3.05
-
Bal.
18.50
Inconel 600[103]
-
15.50
-
-
-
-
-
Bal.
10.00
Superco 605[103]
0.30
20.00
-
-
-
-
Bal.
10.00
3.00
Stellite-6[104]
1.09
28.27
-
-
4.51
-
Bal.
2.80
2.66
Table 3 Chemical compositions of high temperature alloy for boiler[101-104]
Technology
Flame property
Coating property
Temperature / oC
Velocity / (m·s-1)
Porosity / %
Bonding strength / MPa
AS[32]
> 6000
50-100
10-20
25-50
PS[32]
10000-15000
300-1000
5-10
20-60
D-gun[113]
5500
> 2500
< 2
> 70
HVOF[113]
2500-5500
500-1200
< 2
> 70
CS[32]
0-700
300-1200
< 5
> 70
Table 4 Comparison of thermal spray technology in the field of boiler protective[32,113]
Fig.6 Relevant thermal spraying technology proportion in the field of boiler protection
Coating
Substrate
Coating
Corrosion
Cycle
Molten salt
Hot corrosion rate
preparation
temperature
time
composition
mg·cm-2
process
oC
h
(mass fraction)
Coating
Substrate
Ni-21Cr
304 s.s.
HVOF
650
100
NaCl + Na2SO4 +
35.00
-
Ni-15Cr
KCl + K2SO4
48.00
Ni-11Cr
56.50
Ni-7Cr[114]
65.50
FeCrAl[115]
T92
HVOF
700
1000
37.5%Na2SO4 +
37.5%K2SO4 +
25%Fe2O3
70
-
750
130
800
170
FeCrNiMoSi[116]
T91
PS
700
84
Na2SO4-30%K2SO4
8.0
-
Ti-50Al
Al-30Cr[117]
Superfer 800H
PS + Nitriding
900
50
Na2SO4-60%V2O5
8.5
24.5
12.0
NiCrBSi[118]
Inconel 600
HVOF
900
50
Na2SO4-60%V2O5
9.1
15.3
Inconel 601
10.5
26
Superfer 800H
9.2
46
Ni-Cr
T91
D-gun
900
100
Na2SO4-60%V2O5
66.3
73.0
Stellite-21[119]
67.2
NiCrAlY
Superfer 800H
PS
900
50
Na2SO4-60%V2O5
5.4
51.6
Ni-20Cr
10.2
Stellite-6
32.4
Ni3Al[120]
16.2
Ni-50Cr[121]
T22
Cold spray
900
50
Na2SO4-60%V2O5
48
218
SA 516
29
245
Ni-30Cr
20G
Arc spray
750
100
Na2SO4-30%K2SO4
4.3
-
Ni-45Cr
3.2
Ni-50Cr[122]
2.9
NiCr
Carbon steel
HVAF
600
168
KCl
11.32
-
NiAl[123]
2.49
NiCrAl
Carbon steel
HVAF
600
168
KCl
1.49
-
NiCrMoSi[105]
0.67
Table 5 Comparison of hot corrosion rates for different alloy coatings[105,114-123]
Coating
Substrate
Coating
Corrosion
Cycle
Molten salt
Hot corrosion rate
time
mg·cm-2
preparation
Temperature
composition
h
Coating
Substrate
process
oC
(mass fraction)
Al2O3[124]
304L
PS
900
168
Actualwaste
Peeling
-
energy furnace
Cr2O3[125]
T22
PS
850
25
Na2SO4-40%V2O5
50.93
65.16
Cr2O3[126]
T11
D-gun
900
50
Na2SO4-60%V2O5
24.00
25.00
NiCrAlCo-Y2O3 /
309 s.s.
PS
600
168
10.2%KCl +
-
-
ZrO2-8Y2O3[127]
11.5%Na2CO3 +
72.9%Na2SO4 +
4.4%K2SO4
NiCr/Cr2O3-50Al2O3[128]
T22
D-gun
900
50
Na2SO4-60%V2O5
10.50
364.17
Superfer 800H
21.55
26.58
NiCr/Al2O3-40TiO2[129]
Inconel 625
PS
800
50
K2SO4-60%NaCl
7.00
15.50
NiCr/Al2O3
T11
PS
900
1000
Actual coal boiler
113.27
135.96
NiCr/Al2O3-4CNT[130]
11.27
135.96
ZrO2-Y2O3-6CNT[131]
T91
PS
750
50
Na2SO4-60%V2O5
3.54
70.12
Table 6 Comparison of hot corrosion rates for different ceramic coatings[124-131]
Coating
Substrate
Coating
Corrosion
Cycle
Molten salt
Hot corrosion
time
rate / (mg·cm-2)
preparation
temperature
composition
process
oC
h
(mass fraction)
Coating
Substrate
Cr3C2-25NiCr
Superni 600
D-gun
900
100
Na2SO4-25%NaCl
5.0
-
Cr3C2-25NiCr-0.4%CeO2[132]
7.0
Cr3C2-NiCr-Zr[133]
Superni 600
D-gun
900
100
40%Na2SO4-
7.0
-
Superni 718
10%NaCl-40%K2SO4-
3.5
Superco 605
10%KCl
11.7
Cr3C2-25NiCr/WC-Co[134]
T22
HVOF
700
50
Na2SO4-82%Fe2(SO4)3
8.8
77.8
Ni-20Cr-TiC
T22
Cold spray
900
50
Na2SO4-60%V2O5
40
220
Ni-20Cr-TiC-Re[135]
20
FeCrNiAlMnB-Cr3C2 [136]
AISI 1020
Arc spray
750
100
Na2SO4 + 25%K2SO4
3.5
127.1
Na2SO4 + 25%NaCl
11.1
130.1
Cr3C2-NiCr[137]
T91
HVOF +
900
50
Na2SO4-60%V2O5
236
-
sealing + heat
25
treatment
68
NiCrBSi-TiB2[138]
Carbon steel
HVOF
800
200
Na2SO4-60%V2O5
7
-
Table 7 Comparison of hot corrosion rates for different metallic-ceramic coatings[132-138]
Fig.7 Schematics of preparation process of NiCrBSi-ZrB2 powder and coating
Fig.8 Hot corrosion and high temperature wear performances of NiCrBSi-ZrB2 coating
Coating
Substrate
Coating
Test
Cycle
Erodent
Impact
Thickness loss (mm) /
time
angle
Volume loss (mm3) /
preparation
temperature
material
min
(o)
Weight loss (mg) /
process
oC
Erosion wear rate
Coating
Substrate
NiCrBSi-Al2O3[146]
304 s.s.
PS
450
10
Al2O3
30
3.4 × 10-5
8.5 × 10-5
Cr2C3-NiCr
Carbon steel
HVAF
Room
10
Al2O3
30
0.69 mm3
-
Cr2C3-FeCr
temperature
0.68 mm3
-
Cr2C3-WC-MA[147]
0.52 mm3
-
NiCrAlY[148]
Superni 75
PS
540
60000
Actual coal
-
0.46 mm
0.46 mm
0.40 mm
0.49 mm
-
Superni 600
fired boiler
-
-
Superni 718
-
-
Superfer 800
-
-
Cr2C3-25NiCr
304 s.s.
HVOF
400
60
Al2O3
30
39 mg
-
WC-10Co4Cr[149]
51 mg
WC-Co
T12
D-gun
400
5
Al2O3
30
2.5 × 10-5
5.0 × 10-5
Stellite 6
2.5 × 10-5
Stellite 21[150]
2.4 × 10-5
Ni-20Cr
SA 516
Cold spray
700
90000
Actual coal
-
0.21 mm
0.50 mm
Ni-20Cr-TiC
fired boiler
0.12 mm
Ni-20Cr-TiC-Re[151]
0.11 mm
Ni-20Cr
T22
Arc spray
750
90000
Actual coal
-
0.06 mm
0.51 mm
Ni-5Al[152]
fired boiler
0.16 mm
Al2O3-3TiO2[153]
T11
D-gun
700
90000
Actual coal
-
0.25 mm
2.08 mm
T22
fired boiler
0.23 mm
1.71 mm
Table 8 Comparison of erosion wear rates for different thermal spray coatings[146-153]
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