Superheater Tube Corrosion in Wood Gasifier Ash Deposits
The upper operating temperature of tubes in heat exchangers/steam generators is strongly influenced by the degradation that can occur because of the reaction of the exchanger/generator tubing with the deposits that accumulate on the surface of the tubes. In fact, severe corrosion has been observed in some biomass fired systems, particularly with elevated potassium and chlorine concentrations in the deposits. Wood gasifiers have recently been and are currently being constructed at several sites in North America. In these systems, the syngas is burned to produce steam and the performance of the heat exchanger tubes under ash deposits is of great concern. As temperatures of the heat exchangers are increased in an effort to increase their operating efficiency, the performance of the tubes is of greater interest. The corrosion behavior of alloy steel tubes as a function of temperature has been investigated by exposing samples of selected alloys to ash collected from the steam generator fired by syngas produced in wood gasifiers. This study compares corrosion rates from laboratory exposures of synthesis gas and ash at 500 C and 600 C. This study investigated the material performance of four ferritic steels and one austenitic steel exposed to conditions expected on the fireside of a wood gasifier. The purpose of this study was to identify an effective method for determining material performance for samples exposed to both the process gas and the fly ash that is typically observed within the steam generator for times up to 1000 hours. Mass changes were measured for all of the samples, but this information can be misleading concerning material performance due to the difficulty in sufficiently cleaning the samples after exposure in the ash. Therefore, small cross sections of the samples were collected and imaged using optical microscopy. Oxide thicknesses were measured along with metal losses. The metal loss information provides a clear indication of material performance. The metal loss rates for the ferritic steels at 500 C were almost half of those observed at 600 C and the rates decreased with increasing exposure time. It was also reported that the metal loss rates generally decrease with increasing chromium concentration.