Review on Erosion-wear and Protection of Heat Exchange Surface in Power Station Boilers

doi:10.11902/1005.4537.2022.282

Journal of Chinese Society for Corrosion and protection

2023, Vol. 43

Issue (5): 957-970 DOI: 10.11902/1005.4537.2022.282

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Review on Erosion-wear and Protection of Heat Exchange Surface in Power Station Boilers

LI Haiyan¹, LIU Huan¹(

), WANG Geyi¹, ZHANG Xiuju¹, CHEN Tongzhou², YU Yun¹, YAO Hong¹

^1.School of Energy and Power Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
^2.Wuhan Research Institute of Materials Protection, Wuhan 430030, China

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Abstract

Power plant boilers are the key equipment for thermal power generation. During the combustion process, under the impact of the gas-solid two-phase flow of flue gas and fly ash, the heat exchange tubes of the boiler are prone to erosion-wear damage. The deterioration or even explosion of tubes seriously threatens the safe and stable operation of the power plant. In this paper, the causes of erosion, failure mechanism of heat exchange surfaces and prediction models of erosion rate were reviewed, including the cutting wear/deformation wear caused by fly ash in the furnace and the calculation model of the corrosion rate by considering various erosion parameters. Based on this, according to the specific environment of heat exchange surfaces in boilers, the influence of fly ash characteristics (shape, particle size and hardness), tube materials (carbon steel/alloy steel), and the service environment of heat exchange surfaces (the flow rate of flue gas in furnace, erosion speed/angle of fly ash, tube surface temperature) on the erosion-wear damage was summarized in detail. It is believed that erosion speed and tube surface temperature are the most important factors affecting erosion damage. Furthermore, from the perspective of alleviating erosion-wear, the research status of adding anti-erosion components and erosion-resistant coating materials on heat exchange surfaces was also reviewed. It was proposed that the main development directions of anti-erosion measures were to optimize the structure of heat exchange surfaces through flow field simulation and to apply WC-Co/Cr₂C₃-NiCr cermet coatings. At the same time, it was also pointed out that to clearly understand the relationship between the cost and protection effect of coatings, and further to optimize the coating preparation process, so that to reduce costs could provide an important economic guidance for the utilization of coatings. This review can provide a reference for the research on erosion-wear of heat exchange surfaces in boilers, as well as the development and application of protective measures.

Key words: erosion abrasion mechanism factors affecting erosion anti-erosion coatings boiler heat exchange surface

Received: 21 September 2022 32134.14.1005.4537.2022.282

ZTFLH:

TG174.4

Fund: National Key Research and Development Program of China(2018YFC1901302)

Corresponding Authors: LIU Huan, E-mail: huanliu@hust.edu.cn

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Cite this article:

LI Haiyan, LIU Huan, WANG Geyi, ZHANG Xiuju, CHEN Tongzhou, YU Yun, YAO Hong. Review on Erosion-wear and Protection of Heat Exchange Surface in Power Station Boilers. Journal of Chinese Society for Corrosion and protection, 2023, 43(5): 957-970.

URL:

https://www.jcscp.org/EN/10.11902/1005.4537.2022.282 OR https://www.jcscp.org/EN/Y2023/V43/I5/957

Fig.1 Schematic diagrams of erosion wear mechanism^[45]: (a) cutting wear, (b) deformation wear

Number

Calculation formula

Meaning of symbols

References

E = K x 4.95 ρ m ρ p 1 / 2 V 3 s i n 3 β H v 3 / 2

K: erosion constant; x: mass fraction of Si in the ash;ρ_m : density of mild steel; ρ_p : average density of ash particles; V: ash particle velocity; β: impingement angle;H_v : Vickers hardness number.

[52]

E = ∑ j = 1 2 K j C p j f β j U i n j g (D p) h T h ω j

j

=1, 2, represent polygon-shaped and spherical particles, respectively; K: erosion constant;C_p : particulate concentration; β: impact angle, U_i: impact velocity; D_p : particle size; T_h : homologous temperature ratio; ω: chemical composition of fly-ash particles

[53]

$E α = s i n α n 1 (1 + H v 1 - s i n α) n 2 E 90$

$E 90 = K (a H v) k 1 b (v v') k 2 (D D') k 3$

α: impact angle; H_v : Vickers hardness number; n₁、n₂、K、k₁、k₂、k₃ : indices and constants determined by the target material hardness, particle characteristics and erosion conditions.

[54, 55]

Table 1 Prediction models of erosion and wear

Fig.2 Geometrical morphologies of fly ash particles: (a) rod-shaped, (b) polygon-shaped, (c) near-spherical

Table 2 Compositions of coal fly ash and MSWI fly ash

Fig.3 Variations of erosion rate with particle velocity during 30° erosion and 90° erosion^[79]

Fig.4 Correlation between erosion rate and wall temperature^[103]

Fig.5 Velocity vector distributions of particles around the anti-wear beam at various h₀-h_s-S (mm): (a) 20-14-3; (b) 20-14-9; (c) 20-14-15 (h₀-height of the anti-wear beam on the wall; h_s-height of the anti-wear beam in the furnace; S-width of the anti-wear beam)^[20]

Fig.6 Morphologies of heat exchange tubes: (a) the damaged wall by erosion; (b) top surface of FMI-3 coating (FeAlCrB) after 13 a period of exposure^[118]

Fig.7 Proportions of materials and preparation techno-logies of anti-wear coatings: (a) materials; (b) technologies^{[4, 11, 24, 121~143]}

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