Abrasion and Erosion Testing of Materials Used in Power Production From Coal

ABSTRACT The Albany Research Center (ARC) has a long history of studying abrasive wear, related to mineral testing, handling, and processing. The center has also been instrumental in the design and development of wear test procedures and equipment. Research capabilities at ARC include Pin-on-Drum, Pin-on-Disk, and Dry Sand/Rubber Wheel abrasion tests, Jaw Crusher gouging test, Ball-on-Ball Impact test, and Jet erosion tests. Abrasive and erosive wear studies have been used to develop both new alloys and improved heat treatments of commercial alloys. As part of ARC's newest iteration on wear testing to evaluate materials for use in new and existing pulverized coal combustion and gasifier power systems, the ARC has designed and constructed a new High Temperature Hostile Atmosphere Erosion Wear Test (HAET). This new piece of test apparatus is designed for erosive particle velocities of 10-40 m/sec and temperatures from room temperature (238C) to 800+°C, with special control over the gas atmosphere. A variable speed whirling arm design is used to vary the impact energy of the gravity fed erosive particles. The specimens are mounted at the edge of a disk and allow a full range of impingement angles to be selected. An electric furnace heats the specimens in an enclosed retort to the selected temperature. Tests include both oxidizing conditions and reducing conditions. A range of gases, including CO, CO 2 , CH 4 , H 2 , H 2 S, HCl, N 2 , O 2 , and SO 2 can be mixed and delivered to the retort. During the erosion testing a stream of abrasive powder is delivered in front of the specimens. This apparatus is designed to use low abrasive fluxes, which simulate real operating conditions in commercial power plants. Currently ~270 µm SiO 2 particles are being used to simulate the abrasive impurities typically found in coal. Since operators are always striving for longer lifetimes and higher operating temperatures, this apparatus can help elucidate mechanisms of wastage and identify superior materials. This talk will present some initial results from this new environmentally controllable erosion test apparatus

Simulated fireside corrosion of T91 in oxy-combustion systems with an emphasis on coal/biomass environments

Oxy-combustion is the burning of a fuel in oxygen rather than air for the ease of capture of CO2 for reuse or sequestration. Corrosion issues associated with the change in heat exchanger tube operating environment (replacement of most of the N2 with CO2 and potentially higher SOx levels) from air- to oxy-combustion were examined. The ferritic-martensitic alloy T91 was used in accelerated fireside corrosion tests using several different gas compositions and ash deposit overcoats to simulate air-fired, oxy-fired coal, and oxy-fired co-fired coal/biomass conditions. Initial corrosion was observed after 240 h of exposure by examining cross-sections with retained ash. Metal section losses were determined after exposures of up to 1440 h at 600–700°C. Severe corrosion was observed, and a corrosion response with respect to ash deposit chemistry was observed. Corrosion response differences with respect to gas phase chemistry were minimal. Alloy-oxide scale-ash morphologies were consistent with oxide fluxing mechanisms

Fireside Corrosion USC Steering

Oxy-Fuel Fireside Research goals are: (1) Determine the effect of oxy-fuel combustion on fireside corrosion - (a) Flue gas recycle choice, Staged combustion ramifications, (c) JCOAL Collaboration; and (2) Develop methods to use chromia solubility in ash as an 'ash corrosivity' measurement - (a) Synthetic ashes at first, then boiler and burner rig ashes, (b) Applicable to SH/RH conditions

Correlating abrasive wear to alloy additions in low-alloy steels /

Bibliography: p. 10.Mode of access: Internet

Materials Performance in USC Steam Portland

Goals of the U.S. Department of Energy's Advanced Power Systems Initiatives include power generation from coal at 60% efficiency, which requires steam conditions of up to 760 C and 340 atm, co-called advanced ultrasupercritical (A-USC) steam conditions. A limitation to achieving the goal is a lack of cost-effective metallic materials that can perform at these temperatures and pressures. Some of the more important performance limitations are high-temperature creep strength, fire-side corrosion resistance, and steam-side oxidation resistance. Nickel-base superalloys are expected to be the materials best suited for steam boiler and turbine applications above about 675 C. Specific alloys of interest include Haynes 230 and 282, Inconel 617, 625 and 740, and Nimonic 263. Further validation of a previously developed chromia evaporation model is shown by examining the reactive evaporation effects resulting from exposure of Haynes 230 and Haynes 282 to moist air environments as a function of flow rate and water content. These two alloys differ in Ti and Mn contents, which may form outer layers of TiO{sub 2} or Cr-Mn spinels. This would in theory decrease the evaporation of Cr{sub 2}O{sub 3} from the scale by decreasing the activity of chromia at the scale surface, and be somewhat self-correcting as chromia evaporation concentrates the Ti and Mn phases. The apparent approximate chromia activity was found for each condition and alloy that showed chromia evaporation kinetics. As expected, it was found that increasing the gas flow rate led to increased chromia evaporation and decreased chromia activity. However, increasing the water content in moist air increased the evaporation, but results were mixed with its effect on chromia activity

Task 1 Steam Oxidation (NETL-US)

Some conclusions are: (1) Increased flow rates can lower chromia activity in alloys with Ti and Mn - (a) Reduced chromia activity reduces equilibrium CrO{sub 2}(OH){sub 2}(g) vapor pressures; (2) Model is very sensitive to small decreases in chromia activity at the HP turbine - (a) Upstream partial saturation of the gas phase with CrO{sub 2}(OH){sub 2}(g) can become nearly or fully saturated at the HP turbine, (b) Can radically change breakaway oxidation times from less than a year to never happening; and (3) Thus even small chromia activity reductions from Ti and Mn additions can make evaporation issues self-correcting

Laboratory tests of spalling, breaking, and abrasion of wear-resistant alloys used in mining and mineral processing /

Bibliography: p. 17.Mode of access: Internet

Surface and Electrochemical Behavior of HSLA in Supercritical CO2-H2O Environment

General corrosion was observed on high strength low alloy carbon steel after electrochemical impedance spectroscopy experiments (EIS) performed in H{sub 2}O saturated with CO{sub 2} at 50 C and 15.2 MPa. However, general and localized were observed on the same material surfaces after the EIS experiments performed in supercritical CO{sub 2} containing approximately 6100 ppmv H{sub 2}O at 50 C and 15.2 MPa. The general corrosion areas were uniformly covered by the FeCO{sub 3}-like phase identified by X-ray diffraction (XRD). In the area of localized corrosion, XRD also revealed FeCO{sub 3}-rich islands embedded in {alpha}-iron. The energy dispersive X-ray (EDX) analysis revealed high concentrations of iron, carbon, and oxygen in the area affected by general corrosion and in the islands formed in the area of localized corrosion. The real and imaginary impedances were lower in H{sub 2}O saturated with CO{sub 2} than those in the supercritical CO{sub 2} containing the aqueous phase indicating faster corrosion kinetics in the former