Engineered Refractories for Slagging Gasifiers

Kwong, Kyei‐Sing; Bennett, James P.; Krabbe, Rick; Thomas, Hugh; Powell, Cynthia A.

doi:10.1002/9781118144091.ch28

Cited by 3 publications

(5 citation statements)

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“…From (A) to (E) in Figure 5, it is farther and farther away from the hot face, and the virgin microstructure is shown in Figure 5F. Consistent with previous studies, 6,12–14 it is typical slag penetration microstructure of high chromia brick in Figure 5A that the slag almost filled the pore of refractory, and the (Cr,Al) 2 O 3 solid solution was dismembered by the slag. And zirconia powders interspersed individually between the crystals of Cr 2 O 3 ‐Al 2 O 3 solid solution.…”

Section: Results and Analysissupporting

confidence: 84%

“…The refractories containing chromia have been used as corrosion resistant parts in many thermal devices because of their excellent slag resistance 9–11 . Cr 2 O 3 ‐Al 2 O 3 ‐ZrO 2 refractories, commonly known as high chromia bricks, have been used as lining of coal‐water slurry gasifier for about 30 years because of its outstanding corrosion resistance and good high temperature performance 12,13 . Because of its high price and troublesome replacement of gasifier lining, the longevity is important.…”

Section: Introductionmentioning

confidence: 99%

“…[9][10][11] Cr 2 O 3 -Al 2 O 3 -ZrO 2 refractories, commonly known as high chromia bricks, have been used as lining of coal-water slurry gasifier for about 30 years because of its outstanding corrosion resistance and good high temperature performance. 12,13 Because of its high price and troublesome replacement of gasifier lining, the longevity is important. Previous works of the degradation mechanism about the high chromia refractories used in gasifier considered that erosion, wear, and spalling were the causes of damage.…”

Section: Introductionmentioning

confidence: 99%

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Spalling degradation of Cr₂O₃‐Al₂O₃‐ZrO₂ refractories for coal‐water slurry gasifier linings: Role of phosphate

Sun

Geng

et al. 2022

Int J Applied Ceramic Tech

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Two kinds of high chromia bricks with and without phosphate as gasifier linings were postmortem analyzed during their whole service life. The effect of phosphate on the microstructure and phase composition of refractory sections was analyzed. The dense phosphate enrichment layer was observed between the slag penetration layer and the virgin layer, which was considered to reduce the damage of gasifier lining caused by spalling. Phosphate could decompose and migrate slowly under suitable temperature gradient existing in the bricks in service, which would result in the densification of the microstructure earlier than slag penetration. The phosphate in high chromia bricks reduced frequency of spalling due to penetration, which would lead to the lower early wear rate and longer lifetime.

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Section: Results and Analysissupporting

confidence: 84%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Spalling degradation of Cr₂O₃‐Al₂O₃‐ZrO₂ refractories for coal‐water slurry gasifier linings: Role of phosphate

Sun

Geng

et al. 2022

Int J Applied Ceramic Tech

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“…2 indicates spalling and dissolution of the refractory material on the surface and in a cross section of the refractory. These wear mechanisms have been previously discussed [1] and are not the subject of discussion in the paper. Phosphate additions to the refractory were found to virtually eliminate spalling of the refractory liner [2], with a wear mechanism of increasing slag viscosity responsible for the decreased slag penetration and spalling [3].…”

Section: Introductionmentioning

confidence: 94%

“…The entrained bed slagging gasifier currently used by industry is a temperature, high pressure reaction chamber originally developed by the petroleum industry in the late 1940's for processing natural gas and later modified to utilize by-products from the refinement of crude petroleum into a higher value product 1 . The petroleum by-product, a material called petroleum coke (petcoke), is processed in a reaction chamber (called a gasifier) using a process called gasification into thermal energy and a gas mixture of CO and H 2 , called synthesis gas (syngas), which is combusted to produce power or used as a feedstock material in chemical production.…”

Section: Introductionmentioning

confidence: 99%

Impact of Temperature and Oxygen Partial Pressure on Aluminum Phosphate in High Chrome Oxide Refractories

Bennett

Kwong

Nakano

et al. 2014

Advances in Science and Technology

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Gasifiers are reaction vessels used to process carbon feedstock such as coal and/or petcoke at elevated temperature, high pressure, and in a reducing atmosphere (low oxygen partial pressure) to form CO and H2, called synthesis gas or syngas. Syngas is used as a fuel in power generation or as a feedstock material in chemical production. By-products of the gasification process include unreacted carbon, gases such as CO2 and H2S, and slag formed from mineral impurities or organic metallic compounds in the carbon feedstock that liquefy during gasification. In the gasifier, slags interact with the high chrome oxide refractory liner, causing wear and eventual failure of the refractory lining by two primary means - spalling (structural and chemical) and chemical dissolution. Failure of the refractory lining causes the gasifier to be shut down for repair, with increased service time identified by users as important for greater usage of gasification as an industrial process. Phosphate additions to high chrome oxide refractories have been found to increase service life during commercial service by reducing spalling and lowering chemical dissolution of the refractory liner. The mechanism of how they improve service life is not well understood. The microstructure and physical properties of high chrome oxide refractories with and without phosphate additions removed from a commercial gasifier after approximately eight months of exposure to a coal slag are evaluated in this report, with the emphasis on evaluating slag/refractory interaction in refractory pores. Details of the investigation are presented and possible mechanisms of how phosphate additives improve wear resistance discussed.

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Ceramics for Molten Materials Containment, Transfer and Handling on the Lunar Surface

Standish

Stefanescu

Curreri

2009

47th AIAA Aerospace Sciences Meeting Including the New Horizons Forum and Aerospace Exposition

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As part of a project on Molten Materials Transfer and Handling on the Lunar Surface, molten materials containment samples of various ceramics were tested to determine their performance in contact with a melt of lunar regolith simulant. The test temperature was 1600 O C with contact times ranging h m 0 to 12 hours. Regolith simulant was pressed into cylinders with the approximate dimensions of 1.25 dia x 1.25cm height and then melted on ceramic substrates. The regolith-ceramic interface was examined after processing to determine the meltlceramic interaction. It was found that the molten regolith wetted all oxide ceramics tested extremely well which resulted in chemical reaction between the materials in each case. Alumina substrates were identified which withstood contact at the operating temperature of a molten regolith electrolysis cell (1600 OC) for eight hours with little interaction or deformation. This represents an improvement over alumina grades currently in use and will provide a lifetime adequate for electrolysis experiments lasting 24 hours or more. Two types of non-oxide ceramics were also tested. It was found that they interacted to a limited degree with the melt resulting in little corrosion. These ceramics, Sic and BN, were not wetted as well as the oxides by the melt, and so remain possible materials for molten regolith handling. Tests wing longer holding periods and larger volumes of regolith are necessary to determine the ultimate performance of the tested ceramics.

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Engineered Refractories for Slagging Gasifiers

Cited by 3 publications

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Spalling degradation of Cr₂O₃‐Al₂O₃‐ZrO₂ refractories for coal‐water slurry gasifier linings: Role of phosphate

Spalling degradation of Cr₂O₃‐Al₂O₃‐ZrO₂ refractories for coal‐water slurry gasifier linings: Role of phosphate

Impact of Temperature and Oxygen Partial Pressure on Aluminum Phosphate in High Chrome Oxide Refractories

Ceramics for Molten Materials Containment, Transfer and Handling on the Lunar Surface

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Engineered Refractories for Slagging Gasifiers

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Spalling degradation of Cr2O3‐Al2O3‐ZrO2 refractories for coal‐water slurry gasifier linings: Role of phosphate

Spalling degradation of Cr2O3‐Al2O3‐ZrO2 refractories for coal‐water slurry gasifier linings: Role of phosphate

Impact of Temperature and Oxygen Partial Pressure on Aluminum Phosphate in High Chrome Oxide Refractories

Ceramics for Molten Materials Containment, Transfer and Handling on the Lunar Surface

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Spalling degradation of Cr₂O₃‐Al₂O₃‐ZrO₂ refractories for coal‐water slurry gasifier linings: Role of phosphate

Spalling degradation of Cr₂O₃‐Al₂O₃‐ZrO₂ refractories for coal‐water slurry gasifier linings: Role of phosphate