Alloy 740 as Superheater Tubing in Coal Fired Ultra Supercritical Boilers.pdfVIP

Corrosion Resistance of Alloy 740 as Superheater Tubing in Coal-Fired Ultra-Supercritical Boilers Brian A. Baker and Gaylord D. Smith Special Metals Corporation 3200 Riverside Drive Huntington, WV 25705-1771 ABSTRACT The nature of coal ash corrosion and factors affecting its severity are examined. Laboratory results for iron- and nickel-base alloys from a number of sources are compared. Flue gas composition SO2 content , coal ash alkali sulfate content, surface temperature and alloy composition are related to corrosion behavior. Results from in situ plant exposures will also be discussed; the role of key alloying elements will be addressed. Keywords: coal ash corrosion, oxidation, sulfidation, alkali sulfates, laboratory testing, field exposure, alloying elements, ferritic steels, austenitic stainless steels, nickel-containing alloys INTRODUCTION The goal of increasing efficiency of future coal-fired power plants necessitates the use of materials having strength and corrosion properties which are greatly improved over those more commonly used ferritic and austenitic steels. Operating conditions for the next generation of ultra-supercritical boiler o steam superheaters are expected to have surface temperatures on the order of 700-750 C with 375 bar steam pressure. Alloys selected for use in the form of superheater tubing would thus need to possess o high creep rupture strength 100,000 hours rupture life at 100 MPa stress at 750 C . In addition to the strength requirement, the required maximum corrosion loss should be less than 1mm in 100,000 hours. Nickel-base superalloys are being considered in the interest of meeting these stringent demands. Figure ? 1 shows a compilation of stress rupture data for INCONEL alloy 740 hot-rolled solution-annealed and aged bar and plate, representing data gathered at temperatures from 700°C to 800°C. Using the fitted po