Enhancement of Service Life of Steam Generating Tubes in Oil-Fired Boiler for Power Generation Employing Plasma Spray Technology

Abstract

The effects of Ni-50 mass% Cr alloy coating, that is plasma-sprayed onto the fire-side of steam generating tubes in a heavy oil-fired boiler, on the high temperature corrosion resistance were examined. One of the severe environments in the industrial manufacturing facilities, where thermal sprayed coatings are employed, is the high temperature corrosion such as the oxidation, sulfidation, and low melting fuel ash corrosion in the fire-side of boiler tubes. In the fossil fuel-fired steam generating boiler facilities, the degradation or failure of steam generating tubes that were derived from the contaminants in a lower grade fuel have often occurred. The situation of degradation of the water evaporator and superheater tubes and corrosion-preventing effects of plasma sprayed coating are described. The enhanced effects of plasma sprayed Ni-50 mass% Cr alloy coating for the suppression of hot corrosion failure of the steam generating tubes of boiler are summarized.

D.C. Plasma Spraying

“…Some abradable coatings are also sprayed. Tani and Harada [205] have plasma sprayed, onto the combustion facing surface of steam generating tubes in a heavy oil-fired boiler, Ni-50 mass % Cr alloy coatings for their corrosion resistance. The Ni-50 mass% Cr alloy coating was successful for the suppression of hot corrosion failure of the steam generating tubes of the boiler.…”