Reducing chlorine corrosion to metals at high temperatures
is a big problem for many industrial processes. Some high Ni alloys
such as Hastelloy C-276 (Ni > 50 wt %) have been widely used for
this purpose. Chlorine and chlorides often coexisted in many industrial
processes at high temperatures, such as some industrial incinerators
and metallurgical furnaces. Thus, a comprehensive experimental investigation
regarding the effect of NaCl on the chlorination corrosion of metallic
nickel powder by chlorine at a high temperature was performed. It
was more convenient to investigate the intrinsic chlorination mechanisms
and kinetics of metallic Ni if Ni powder was used instead of a Ni
plate. It was found that there existed a critical chlorination temperature
of 450 °C for relative safe use of Ni-based alloy in the presence
NaCl. The Ni chlorination in the presence of NaCl was increased with
increasing temperature and reached a maximum of 97% at 700 °C,
which was about 21% higher than that in the absence of NaCl. An anhydrous
NiCl
2
was initially formed at about 700 °C during
the chlorination process and then immediately reacted with NaCl to
form a novel eutectic complex with a flaky shape, a melting point
of 585 °C, and a simplified molecular formula of NiNa
0.33
Cl
2.33
based on X-ray diffraction (XRD), differential
thermal analysis (DTA), scanning electronic microscopy (SEM), and
chemical analysis with inductively coupled plasma atomic emission
spectroscopy (ICP-AES). As a result, only the complex of NiNa
0.33
Cl
2.33
and NaCl was left in the chlorinated
product. At 700 °C, the chlorinated product evaporated only in
the form of complex NiNa
0.33
Cl
2.33
instead of
individual NiCl
2
or NaCl. The chlorination mechanisms of
metallic Ni at a high temperature, for example, 700 °C, in the
presence of NaCl were as follows. Step 1: Formation of initial chlorinated
solid product NiCl
2
(mp 1001 °C) at a high temperature;
step 2: The NiCl
2
reacted with solid additive NaCl (mp
801 °C) to form a final liquid product NiNa
0.33
Cl
2.33
(mp 585 °C); step 3: External Cl
2
(g) was
dissolved in the liquid product layer; step 4: The chlorine dissolved
in the liquid product of NiNa
0.33
Cl
2.33
reacted
with the unreacted Ni core. The external Cl
2
(g) passed
through the liquid product NiNa
0.33
Cl
2.33
layer
faster than the solid product NiCl
2
layer formed in the
absence of NaCl. This resulted in 21% more chlorination corrosion
of metallic Ni powder with NaCl addition than that without NaCl addition.