High-Temperature Corrosion in Fossil Fuel Power Generation: Present and Future

Pint, Bruce A.

doi:10.1007/s11837-013-0642-z

Cited by 44 publications

(16 citation statements)

References 45 publications

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“…Along with low natural gas prices, increased emissions regulations in the U.S. have resulted in the closure of many smaller, older coal-fired power plants and less utilization of the entire fleet in the past 7 years [1]. When new U.S. coal-fired generation is built, new technology will be required to reduce Hg, SO x , NO x and CO 2 emissions.…”

Section: Introductionmentioning

confidence: 99%

The effect of cycle frequency, H2O and CO2 on TBC lifetime with NiCoCrAlYHfSi bond coatings

Lance

Unocic

Haynes

et al. 2014

Surface and Coatings Technology

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a b s t r a c t a r t i c l e i n f o Available online xxxx Keywords: Photo-stimulated luminescence piezospectroscopy (PLPS) Water vapor Bond coating Alumina scale TBCFurnace cycle testing of superalloy 1483 and X4 substrates with high velocity oxygen fuel (HVOF) NiCoCrAlYHfSi bond coatings and air plasma sprayed (APS) yttria-stabilized zirconia (YSZ) top coatings was conducted at 1100°C in various environments. Average thermal barrier coating (TBC) lifetimes were 5-6 times longer when 100 h cycles were used to simulate base-load power generation operation, compared to the 1 h aero-engine standard cycle. Longer exposure times for 100 h cycles increased the interdiffusion resulting in no clear effects of H 2 O and CO 2 additions on average TBC lifetime for the 1483 substrates, contrary to the results with 1 h cycles where the addition of H 2 O reduced TBC lifetime. The lower Al content and perhaps the higher Ti content in 1483 compared to X4 resulted in lower TBC lifetimes for 1483. Photo-stimulated luminescence piezospectroscopy (PLPS) and 3D microscopy were used to measure residual stress in the alumina scale and surface roughness, respectively, on specimens with and without a YSZ top coating.

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Section: Introductionmentioning

confidence: 99%

The effect of cycle frequency, H2O and CO2 on TBC lifetime with NiCoCrAlYHfSi bond coatings

Lance

Unocic

Haynes

et al. 2014

Surface and Coatings Technology

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“…The mass gains in 17 bar steam were similar as in air, although there was more scatter in the results. Steam testing at 800°C was conducted in support of the U.S. Advanced Ultra-Supercritical (A-USC) steam boiler and turbine programs, which has the goal of increasing steam conditions in coal-fired boilers to ~350 bar (5,000psi) and 760°C [25,26] from current peak conditions of 250 bar/607°C [27]. To meet these goals and significantly improve efficiency, Ni-base alloys will be needed in both the boiler tubing and steam turbine.…”

Section: Resultsmentioning

confidence: 99%

Effect of Environment on the High Temperature Oxidation Behavior of 718 and 718Plus

Unocic¹,

Pint²

2014

8th International Symposium on Superalloy 718 and Derivatives (2014)

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Ni-base alloys 718 and 718Plus are widely used for high temperature components in aircraft and power generation turbines under various environment conditions. Laboratory experimental rigs were used to simulate turbine exhaust (air with 10%H2O), steam and laboratory air at 550°-800°C for up to 10,000 h and compared to oxidation in laboratory air. Because component lifetimes can be much longer than 10,000 h, the experiments at 800°C were performed in an attempt to simulate longer exposures at lower temperatures but there are concerns about 718 microstructural stability at this temperature. Oxidation in wet air resulted in net mass losses due to the formation of volatile CrO2(OH)2 but Cr depletion in the substrate was minimal, even at 800°C. The rate constants for 718Plus in air tended to be slightly lower than 718 but otherwise few differences in oxidation behavior were observed. The higher Al content in 718Plus or the finer grain size in these specimens may help to reduce the reaction rate.

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“…19 This leap in technology will require precipitation strengthened Ni-base alloys that have never been used in such applications. Relatively new alloys 740 20 and 282 21 are the current candidates but given the large steam tubing and piping requirements, even a small increase in high temperature properties or decrease in alloy cost 22 for a new alloy could result in a significant benefit for this application.…”

Section: Defining Requirementsmentioning

confidence: 99%

Critical Assessment 4: Challenges in developing high temperature materials

Pint

2014

Materials Science and Technology

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Materials are a key enabling feature for high efficiency engines for power generation or transportation. While significant research continues, progress in this century has certainly slowed compared to the previous century where modern materials science spawned a rapid advance in high temperature materials. One area that hampers new high temperature materials is a lack of inherent (i.e. uncoated) oxidation or environmental resistance, especially for the highest temperature applications such as Ni-base superalloys for turbomachinery. Thus, there appears to be more opportunity to develop materials for 600-1000uC applications than for higher temperatures. New materials requirements ranging from mechanical and environmental resistance to manufacturing and joining need to be clearly defined and experimental work focused on validating these properties for successful alloy development to proceed. For most applications the materials requirements have become so broad and complex that progress by single researchers is difficult. A teaming approach, especially among research institutions and industry, is needed to both define the critical needs and assemble experts in a range of disciplines to address these issues during the materials development process.

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High-Temperature Corrosion in Fossil Fuel Power Generation: Present and Future

Cited by 44 publications

References 45 publications

The effect of cycle frequency, H2O and CO2 on TBC lifetime with NiCoCrAlYHfSi bond coatings

The effect of cycle frequency, H2O and CO2 on TBC lifetime with NiCoCrAlYHfSi bond coatings

Effect of Environment on the High Temperature Oxidation Behavior of 718 and 718Plus

Critical Assessment 4: Challenges in developing high temperature materials

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