Corrosion-Erosion Mechanism and Research Prospect of Bare Materials and Protective Coatings for Power Generation Boiler

doi:10.11900/0412.1961.2021.00464

Acta Metall Sin

2022, Vol. 58

Issue (3): 272-294 DOI: 10.11900/0412.1961.2021.00464

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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.

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Abstract

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.

Key words: sulfur corrosion chlorine corrosion erosion-wear power generation boiler protective coating

Received: 28 October 2021

ZTFLH:

TG178

Fund: National Natural Science Foundation of China(52171058)

About author: ZHANG Shihong, professor, Tel: 13637101221, E-mail: zsh13637101221@163.com

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https://www.ams.org.cn/EN/10.11900/0412.1961.2021.00464 OR https://www.ams.org.cn/EN/Y2022/V58/I3/272

Fig.1 Schematic of the distribution of “boiler pipes” of power generating boiler^[57]

Table 1 Melting points (T_m) 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]

Table 2 Main alloy element chemical compositions and functions of steels for boiler^[62,96-100]

Table 3 Chemical compositions of high temperature alloy for boiler^[101-104]

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

Table 5 Comparison of hot corrosion rates for different alloy coatings^{[105,114-123]}

Table 6 Comparison of hot corrosion rates for different ceramic coatings^[124-131]

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

Table 8 Comparison of erosion wear rates for different thermal spray coatings^[146-153]

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