CCS and Power Systems

Crosscutting Research - Plant Optimization Technologies

Development of Computational Capabilities to Predict the Corrosion Wastage of Boiler Tubes in Advanced Combustion Systems

Performer: Babcock & Wilcox Power Generation Group, Inc.

Project No: FC26-07NT43097

Project Description

For this project, B&W will characterize the realistic combustion conditions and products in boilers. Researchers will select eight common U.S. coals that represent a wide range of coal chemistry burned in utility boilers. These coals will be combusted in Brigham Young University’s burner flow reactor (BFR) to closely simulate actual staged combustion encountered in utility boilers. During the BFR runs, gas and ash/ slag deposit samples will be collected and analyzed for each coal at the waterwall and superheater/reheater locations.

Once the conditions are defined, a series of long-term (1,000-hour) laboratory corrosion tests will follow. Researchers will expose various alloys and weld overlays of a wide range of metal compositions to laboratory conditions resembling actual boiler operating environments. Relevant corrosion data from these tests will be used to generate models to aid in the development of materials for improving the performance of boiler tubes. The modeling will produce two predictive equations, one for waterwalls and one for superheaters/reheaters, which will be used to estimate the corrosion wastage of boiler tubes as a function of different key variables such as sulfur, chlorine, alkali, ash, pyrite, and metal temperature. Application of these predictive equations will be designed to be highly versatile and applicable to a variety of coals and boiler operations.

Project Details