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Corrosion Testing of Thermal Spray Coatings in a Biomass Co-Firing Power Plant
Open accessAbstract
Large-scale use of biomass and recycled fuel is increasing in energy production due to climate and energy targets. A 40% cut in greenhouse gas emission compared to 1990 levels and at least a 27% share of renewable energy consumption are set in EU Energy Strategy 2030. Burning fuels with high content of corrosive species such as chlorine and heavy metals causes deterioration of boiler components, shortened lifetime, limited availability of a plant and hence higher maintenance and investment costs and lower thermal and economic efficiency. Coatings can be applied to protect the critical boiler components against high temperature corrosion. In this study, five thermal spray coatings were tested in an actual biomass co-firing boiler for 1300 h with a measurement probe. The coatings were analyzed after the exposure by metallographic means and scanning electron microscope/energy-dispersive X-ray spectroscope (SEM/EDX). The deposits formed on the specimens were analyzed by X-ray fluorescence. At 550 °C, the coatings showed excellent corrosion performance compared to reference material ferritic steel T92. At 750 °C, tube material A263 together with NiCr and NiCrTi had the highest corrosion resistance. To conclude, thermal spray coatings can offer substantial corrosion protection in biomass and recycled fuel burning power plants.
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“A HVOF Ni-46Cr coating formed a protective Cr2O3 layer and showed superior corrosion resistance after 1300 h of exposure in a biomass co-fired boiler comparison to coatings with lower chromium content [101].”
From High Temperature Corrosion Resistant and Anti-slagging Coatings for Boilers: A Review (2024) · cites this paper as [101]
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Research works printed but not linked: 8
- Montgomery, 2011, Experiences with high temperature corrosion at straw-firing power plants in Denmark, Mater. Corros., 62, 593, 10.1002/maco.201005856 · DOI
- Montgomery, 2013, In situ corrosion testing of various nickel alloys at Måbjerg waste incineration plant, Mater. Corros., 64, 14, 10.1002/maco.201006019 · DOI
- Bankiewicz, 2012, High temperature corrosion of boiler waterwalls induced by chlorides and bromides—Part 2: Lab-scale corrosion tests and thermodynamic equilibrium modeling of ash and gaseous species, Fuel, 94, 240, 10.1016/j.fuel.2011.12.023 · DOI
- Enestam, 2013, Evaluation of the condensation behavior of lead and zinc in BFB combustion of recovered waste wood, Fuel Process. Technol., 105, 161, 10.1016/j.fuproc.2011.09.002 · DOI
- Oksa, 2014, Nickel-based HVOF coatings promoting high temperature corrosion resistance of biomass-fired power plant boilers, Fuel Process Technol., 125, 236, 10.1016/j.fuproc.2014.04.006 · DOI · Paper page
- Oksa, 2015, Optimizing NiCr and FeCr HVOF coating structure for high temperature corrosion protection applications, J. Therm. Spray. Technol., 24, 436, 10.1007/s11666-014-0192-0 · DOI
- Hussain, 2013, Fireside corrosion behavior of HVOF and plasma-sprayed coatings in advanced coal/biomass co-fired power plants, J. Therm. Spray. Technol., 22, 797, 10.1007/s11666-013-9887-x · DOI
- Oksa, 2013, Increased lifetime for biomass and waste to energy power plant boilers with HVOF coatings: High temperature corrosion testing under chlorine-containing molten salt, J. Therm. Spray. Technol., 22, 783, 10.1007/s11666-013-9928-5 · DOI
Cited by
Sorted by citations
High Temperature Corrosion Resistant and Anti-slagging Coatings for Boilers: A Review
Khantisopon, K., Singh, S., Jitputti, J., Berndt, C. C., & Ang, A. S. M. (2024) · High Temperature Corrosion of Materials · doi:10.1007/s11085-024-10251-0 · Cited by 30
Metadata
- Authors
- Oksa, M., Metsäjoki, J., & Kärki, J.
- Affiliations
- VTT Technical Research Centre of Finland (FI)
- Corresponding author
- Oksa, Maria
- ORCID
- Kärki, Janne
- Venue
- Coatings
- Publisher
- MDPI AG
- Published
- 2016-11-24
- Volume
- 6
- Issue
- 4
- Pages
- 65
- ISSN
- 2079-6412 (ISSN-L)
- OpenAlex
- W2556739207
- Cited by
- 17
- References
- 0
- Citations by year
- 2026: 1 · 2025: 3 · 2024: 1 · 2023: 1 · 2022: 5 · 2021: 3 · 2020: 2 · 2019: 1
- FWCI
- 0.41
- Type
- journal article
- Language
- en
- Open access
- gold
- doi.org
- Licence
- Locations
- Coatings (publishedVersion, cc-by)
- DOAJ (DOAJ: Directory of Open Access Journals) (submittedVersion)
- Funders
- European Commission (ENER/FP7EN/249745/”NEXTEGENPOWER")
- Topics
- Physical Sciences › Materials Science › Surfaces, Coatings and Films › High-Temperature Coating Behaviors
- Physical Sciences › Engineering › Mechanical Engineering › High Temperature Alloys and Creep
- Physical Sciences › Engineering › Mechanical Engineering › Surface Treatment and Coatings
- Keywords
- thermal spray coatings, high-temperature corrosion, biomass co-firing, boiler components, corrosion protection, Ni-Cr coatings, chloride-induced corrosion, coating degradation, power plants
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