Development of SiO2/TiO2/Al2O3-based/TiO2 coating for preventing sulfide corrosion in thermal power plant boilers

Makoto Kawase, Akifumi Ido, Masahiro Morinaga

Research output: Contribution to journalArticle

Abstract

In thermal power generation equipment, wall thinning on boiler tubes due to sulfide corrosion has been a problem. The methods for resolving or preventing the problem are coating of a nickel-chromium film by plasma spraying, weld cladding, and replacement of water wall tubing. These methods are expensive and time consuming. Therefore, an economical and straightforward coating technique was developed for preventing sulfide corrosion on boiler tubes. The developed coating has a four-layered structure comprising, in order from the boiler tube substrate, thin films of (1) a SiO2 layer, (2) a TiO2 layer, (3) an Al2O3-based layer, and (4) a TiO2 layer. The coating reduced corrosion to 25% or less compared with an uncoated part under a simulated condition (Gas: CO2/H2/N2/CO/H2O = 12%/4%/67%/8%/9% H2S 330 ppm, Temperature: 500 °C). It was found that the coating on boiler tubes is exceptionally durable and continues to be effective for more than 2 years in actual power plants. This coating process can be applied to a large area, and the work period is short. When the coating area is 100 m2, the working time is 3 days and total spraying time is only 7 h.

Original languageEnglish
Pages (from-to)242-249
Number of pages8
JournalApplied Thermal Engineering
Volume153
DOIs
Publication statusPublished - 2019 May 5
Externally publishedYes

Fingerprint

Boilers
Power plants
Corrosion
Coatings
Coating techniques
Plasma spraying
Tubing
Spraying
Power generation
Sulfides
Hot Temperature
Chromium
Welds
Nickel
Thin films
Substrates
Gases
Water
Temperature

Keywords

  • Boiler tube
  • Coal
  • Liquid spray coating
  • Oil
  • Sulfide corrosion

ASJC Scopus subject areas

  • Energy Engineering and Power Technology
  • Industrial and Manufacturing Engineering

Cite this

Development of SiO2/TiO2/Al2O3-based/TiO2 coating for preventing sulfide corrosion in thermal power plant boilers. / Kawase, Makoto; Ido, Akifumi; Morinaga, Masahiro.

In: Applied Thermal Engineering, Vol. 153, 05.05.2019, p. 242-249.

Research output: Contribution to journalArticle

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