Corrosion challenges in high and low temperature systems: Mechanisms and thermal spray coating advances
DOI:
https://doi.org/10.62638/ZasMat1565Abstract
Corrosion in boilers is now a major issue in thermal power generation industry, and it has a substantial effect on efficiency of equipments, maintenance expenses and life of the equipment. This study addresses the mechanisms of both high temperature and low temperature corrosion of boiler materials. The initiation of high-temperature oxidative attackis closely related to exposure to thetubes, deposition of slags and corrosive gases like H₂S and Cl₂ and causes severe degradation of water wall tubes and superheaters. The change in operating temperature would further promote the adventurous reactions between molten ash and sulphide species. Low-temperature corrosion generally arises from thecondensation of flue gases on colder surfaces like economizers and air preheaters, where sulphuric acid formation, alkali metal sulfates, deterioration of the oxide layer and thermal fatigue become more dominant below the dew point temperature. The situation is exacerbated by fly ash deposits that trap heat and tend to concentrate corrosive agents on the metal surface. Several of these have been investigated for corrosion protection using thermal spray technologies.Different types of thermal spray coatings have been investigated to overcome these problems. Coatings of CNT reinforced Cr₂O₃, Ni-based alloys and ZrO₂–Al₂O₃ composites have shown a very good resistance to corrosion and erosion under the harsh conditions of the boilers. These coatings are partly dependent on the deposition methods, including High-Velocity Oxy-Fuel (HVOF), Cold Spray processes and Atmospheric Plasma Spraying (APS). The developments of recent years with the use of nanoparticles and hydrophobic additives have further enhanced the durability of coatings and protection capabilities in harsh operating conditions. The application of advanced thermal spray coating material and optimized operation parameters to inhibit boiler corrosion, prolong the service life and increase the reliability of power generation equipment is highlighted in this study.
Keywords:
Low Temperature Corrosion, High Temperature Corrosion, Thermal Spray Coatings, Material ProtectionReferences
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