N.J. Simms

Smart overlay coatings — concept and practice

Smart overlay coatings are a functionally gradient coating system designed to provide high temperature corrosion protection over a wide range of operating conditions. The SMARTCOAT design consists of a MCrAlY base, enriched first in chromium, then aluminium to provide a chemically graded structure. At elevated temperatures, above 900°C (1650°F), the coating oxidises to form a protective alumina scale. However, at lower temperatures this alumina scale does not reform rapidly enough to confer protection under type II hot corrosion conditions. The coating is therefore designed with an intermediate chromium-rich interlayer, which permits the rapid formation of chromia healing areas of type II corrosion damage. Laboratory and burner rig tests have been carried out on a series of developmental smart overlay coatings. These have shown that the development of an intermediate chromium-rich phase provides protection under low temperature hot corrosion conditions, while the aluminium-rich surface layer provides resistance to high temperature oxidation and type I hot corrosion. Thus, the single application of SMARTCOAT permits operation over a broad range of industrial and marine turbine conditions.

An integrated appraisal of energy recovery options in the United Kingdom using solid recovered fuel derived from municipal solid waste

This paper reports an integrated appraisal of options for utilising solid recovered fuels (SRF) (derived from municipal solid waste, MSW) in energy intensive industries within the United Kingdom (UK). Four potential co-combustion scenarios have been identified following discussions with industry stakeholders. These scenarios have been evaluated using (a) an existing energy and mass flow framework model, (b) a semi-quantitative risk analysis, (c) an environmental assessment and (d) a financial assessment. A summary of results from these evaluations for the four different scenarios is presented. For the given ranges of assumptions; SRF co-combustion with coal in cement kilns was found to be the optimal scenario followed by co-combustion of SRF in coal-fired power plants. The biogenic fraction in SRF (ca. 70%) reduces greenhouse gas (GHG) emissions significantly ( approximately 2500 g CO(2) eqvt./kg DS SRF in co-fired cement kilns and approximately 1500 g CO(2) eqvt./kg DS SRF in co-fired power plants). Potential reductions in electricity or heat production occurred through using a lower calorific value (CV) fuel. This could be compensated for by savings in fuel costs (from SRF having a gate fee) and grants aimed at reducing GHG emission to encourage the use of fuels with high biomass fractions. Total revenues generated from coal-fired power plants appear to be the highest ( 95 pounds/t SRF) from the four scenarios. However overall, cement kilns appear to be the best option due to the low technological risks, environmental emissions and fuel cost. Additionally, cement kiln operators have good experience of handling waste derived fuels. The scenarios involving co-combustion of SRF with MSW and biomass were less favourable due to higher environmental risks and technical issues.

Comparison of coal/solid recovered fuel (SRF) with coal/refuse derived fuel (RDF) in a fluidised bed reactor

An experimental study was undertaken to compare the differences between municipal solid waste (MSW) derived solid recovered fuel (SRF) (complying with CEN standards) and refuse derived fuel (RDF). Both fuels were co-combusted with coal in a 50 kW fluidized bed combustor and the metal emissions were compared. Synthetic SRF was prepared in the laboratory by grinding major constituents of MSW such as paper, plastic, textile and wood. RDF was obtained from a local mechanical treatment plant. Heavy metal emissions in flue gas and ash samples from the (coal+10% SRF) fuel mixture were found to be within the acceptable range and were generally lower than that obtained for coal+10% RDF fuel mixture. The relative distribution of heavy metals in ash components and the flue gas stream shows the presence of a large fraction (up to 98%) of most of the metals in the ash (except Hg and As). Thermo-gravimetric (TG) analysis of SRF constituents was performed to understand the behaviour of fuel mixtures in the absence and presence of air. The results obtained from the experimental study will enhance the confidence of fuel users towards using MSW-derived SRF as an alternative fuel.

Gas turbines: gas cleaning requirements for biomass-fired systems

Increased interest in the development of renewable energy technologies has been hencouraged by the introduction of legislative measures in Europe to reduce CO2 emissions from power generation in response to the potential threat of global warming. Of these technologies, biomass-firing represents a high priority because of the modest risk involved and the availability of waste biomass in many countries. Options based on farmed biomass are also under development. This paper reviews the challenges facing these technologies if they are to be cost competitive while delivering the supposed environmental benefits. In particular, it focuses on the use of biomass in gasification-based systems using gas turbines to deliver increased efficiencies. Results from recent studies in a European programme are presented. For these technologies to be successful, an optimal balance has to be achieved between the high cost of cleaning fuel gases, the reliability of the gas turbine and the fuel flexibility of the overall system. Such optimisation is necessary on a case-by-case basis, as local considerations can play a significant part.

Fireside issues in advanced power generation systems

Abstract The requirements to supply increasing quantities of electricity and simultaneously to reduce the environmental impact of its production are currently major issues for the power generation industry. Routes to meeting these challenges include the development and use of power plants with ever increasing efficiencies coupled with the use of both a wider range of fuels and technologies designed to minimise CO2 emissions. For fireside hot gas path components, issues of concern include deposition, erosion and corrosion in novel operating environments and increased operating temperatures. The novel operating environments will be produced both by the use of new fuel mixes and by the development of more complex gas pathways (e.g. in various oxyfired or gasification systems). Higher rates of deposition could significantly reduce heat transfer and increase the need for component cleaning. However, degradation of component surfaces has the potential to be life limiting, and so such effects need to be minimised. Materials and operational issues related to these objectives are reviewed.

Degradation of heat exchanger materials under biomass co-firing conditions

Abstract Co-firing biomass in conventional pulverised coal fired power stations offers a means to rapidly introduce renewable and CO2 neutral biomass fuels into the power generation market. Existing coalfired power stations are both much larger and more efficient than current designs of new biomass combustion systems, so feeding a few percent of biomass feed into an existing large coal fired station will give more biomass derived power than a new dedicated biomass station. Co-firing levels started at ∼2% biomass, but this has increased to ∼5–10% biomass, with higher levels of biomass co-firing being investigated, although supply of biomass becomes an issue with increasing co-firing levels. The lower levels of biomass co-firing (up to ∼5%) can be achieved with relatively minor modifications to existing plants, so avoiding the large capital costs and risks of building new biomass-only fired power systems. However higher levels of co-firing are more difficult to achieve, requiring dedicated biomass supply systems and burners. For existing coal-fired power stations, the co-firing of biomass causes some practical problems, e.g.: the control of co-firing two fuels; changes to bottom/fly ash chemistry; changes to deposition (fouling and slagging) within the boiler; reduced reliability of key high temperature components (e.g. heat exchangers) due to increased corrosion problems relative to those experienced with coal alone. This paper reports the results of assessments carried out to evaluate the potential operating conditions of heat exchangers in combustion systems with biomass (wood or straw) and coal cofiring, as well as laboratory corrosion tests that have been carried out to give an initial assessment of potential effects of biomass-co-firing. The corrosion tests have been carried out using the deposit recoat method in controlled atmosphere furnaces. A series of 1000 hour tests have been carried out at typical superheater and evaporator metal temperatures using simulated deposit compositions and gaseous environments (selected on the basis of plant experience and potential fuel compositions). Five materials were exposed in these tests: 1Cr steel, T22 steel, X20CrMoV121, TP347HFG and alloy 625. In order to produce statistically valid data on the actual metal loss from the materials, the performance of the materials in these tests was determined from dimensional metrology before and after exposure. For each material, these data have been used to determine the sensitivity of the corrosion damage to changes in the exposure conditions (e.g. deposit composition, gas composition) thereby producing initial models of the corrosion performance of the materials. The corrosion data and model outputs have been compared with data available from power plants operating on coal, straw or wood fuels.

Modelling hot corrosion in industrial gas turbines

Abstract Gas turbines are a critical component within combined cycle power systems that are being developed to generate electricity more cleanly and efficiently from solid fuel sources, that include coal and biomass. The use of such fuels, to produce fuel gases, increases the potential for significant corrosion and erosion damage to gas turbine blades and vanes. This paper addresses the modelling and prediction of type II hot corrosion in industrial gas turbines within the aim of given acceptable and predictable lifetimes. A matrix of corrosion tests have been undertaken using the ‘deposit recoat’ test procedure, with samples cooled periodically to re-apply controlled amounts of salt deposit. Deposited salt was 4/1 mole fraction of Na2SO4 and K2SO4, with deposited fluxes of 0, 1.5, 5.0 and 15.0 μg/cm2/h. Samples of polycrystalline (IN738 and IN792) and single crystal superalloys (CMSX4 and SC2B) were exposed for test durations of 500 and 1000 h at 700°C in a variety of gas compositions, consisting of air+50–500 vppm SO2+0–500 vppm HCl+0–5 vol% H2O. Section loss data has been measured, using precision optical metrology and analysed statistically. Models have been developed that predict section loss as a function of salt deposition rate and gas composition to precisions of ±20 mm loss, with 95% confidence (2×standard deviation).

Evaluation of oxidation related damage caused to a gas turbine disc alloy between 700 and 800°C

Abstract This paper presents the results of a study targeted at characterising the oxidation behaviour of a new nickel based disc alloy (RR1000) at intermediate temperatures. Isothermal exposures were carried out using a thermo-microbalance at temperatures in the range 700 – 800°C for exposures up to 200 hours. Cyclic oxidation exposures were carried out at, 700 and 750°C for up to 1000 hours with 100 hour cycles, using mass change to monitor the materials performance. The mass gain data obtained have been used to derive oxidation reaction rate parameters, using established methodologies, with parabolic rate constants varying between 1.4×10–5 mg2/cm4/h at 700°C and 8.4×10–4 mg2/cm4/h at 800°C. Surface oxides were initially analysed using scanning electron microscope/energy dispersive X-ray analysis (SEM/EDX) and X-ray diffraction (XRD) techniques. The results showed that slowly-growing chromium-rich oxide scales had formed on the surface of the samples during these exposures. A more detailed study of cross-sections through the oxide layers and underlying alloy was undertaken using a focused ion beam (FIB) system. Measurements of the thin oxides observed showed ranges of thicknesses from 0.08μm up to 1.9μm, that were consistent with the mass change data gathered. However, the FIB examinations also revealed significant sub-surface damage that contained a mixture of grain boundary pores, a second phase depletion zone, and grain recrystallisation. The depth of these sub-surface damage zones was greater than the thickness of the oxide layers and is believed to have a major impact on the fatigue performance of this disc alloy. The use of the FIB system has enabled characterisation of the development of both the oxide layers and sub-surface damage zones as a function of exposure time and temperature.

High-temperature oxidation of Fe-2 1 4 Cr-1Mo in oxygen

The oxidation of a 214Cr-1Mo steel in dry flowing oxygen has been studied in the temperature range 550–700°C for periods of up to 100 hr. A detailed low-resolution microstructural investigation revealed a layered oxide consisting of a very fine-grained and finely pored innermost layer of doped spinel, a central columnar-grained relatively coarsely pored layer of magnetite, and an outer fine-grained hematite layer with fine pores and covered with whiskers of α-Fe2O3. This structure is compared with previous results on Fe and model Fe-Cr alloys, as are the kinetics of the oxidation reaction.

Erosion-corrosion modelling of gas turbine materials for coal-fired combined cycle power generation

Abstract The development of coal-fired combined cycle power generation systems is receiving considerable worldwide interest. The successful development and commercialisation of these new systems require that all the component parts are manufactured from appropriate materials and that these materials give predictable in-service performance. Corrosion and erosion-corrosion, resulting from coal derived particulates, deposition and gaseous species, have been identified as potential life limiting factors for these systems. Models to predict these modes of materials degradation are under active development. This paper outlines the development and testing of models suitable for use in gas turbine environments. The complexity of the corrosion processes means that an empirical approach to model development is required whereas a more mechanistic approach can be applied to erosion processes. For hot corrosion conditions, statistically based corrosion models have been produced using laboratory tests for two coatings and a base alloy at typical type I and type II hot corrosion temperatures (900 and 700°C). These models use the parameters of alkali sulphate deposition flux and SO x partial pressure (at each temperature and for set HCl partial pressures), to predict the rate of the most likely localised damage associated with hot corrosion reactions. For erosion-corrosion modelling, a series of laboratory tests have been carried out to investigate erosion behaviour in corrosive conditions appropriate to coal-fired gas turbines. Materials performance data have been obtained from samples located in the hot gas path of the Grimethorpe PFBC pilot plant, under well characterised conditions, for testing the corrosion and erosion-corrosion models. The models successfully predict the materials damage observed in the pilot plant environments.