Resistance of Coatings for Boiler Components of Waste-to-Energy Plants to Salt Melts Containing Copper Compounds

M.C. Galetz , J.T. Bauer, M. Schütze, M. Noguchi, H. Cho

Journal of Thermal Spray Technology 22 (2013), 828-837, DOI: 10.1007/s11666-013-9908-9

The accelerating effect of heavy metal compounds on the corrosive attack of boiler components like superheaters poses a severe problem in modern waste-to-energy plants (WTPs). Coatings are a possible solution to protect cheap, low alloyed steel substrates from heavy metal chloride and sulfate salts, which have a relatively low melting point. These salts dissolve many alloys, and therefore often are the limiting factor as far as the lifetime of superheater tubes is concerned. In this work the corrosion performance under artificial salt deposits of different coatings, manufactured by overlay welding, thermal spraying of self-fluxing as well as conventional systems was investigated. The results of our studies clearly demonstrate the importance of alloying elements such as molybdenum or silicon. Additionally, the coatings have to be dense and of a certain thickness in order to resist the corrosive attack under these severe conditions.

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