Low-Temperature Corrosion in Biomass...
Transcript of Low-Temperature Corrosion in Biomass...
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Low-Temperature Corrosion in
Biomass Combustion
Emil Vainio
Chemistry in Energy Technology, 12.03.2019
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Total energy consumption by
source in Finland
stat.fi
Oil; 25 %
Coal; 9 %
Natural gas; 5 %
Peat; 4 %Nuclear energy;
18 %
Hydro power; 4 %
Wind power; 1 %
Biomass; 28 %
Others; 5 %
Oil; 25 %
Coal; 9 %
Natural gas; 5 %
Peat; 4 %Nuclear energy;
18 %
Hydro power; 4 %
Wind power; 1 %
Biomass; 28 %
Others; 5 % Biomass based fuels most
important renewable
source
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0
1
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9
10
Wei
ght
% (
db
)
Rest
P
S
Cl
Na
K
Ca
Si
Biomass Combustion• Large scale combustion of biomass
increases
• Circulating fluidized beds (CFB)
• Bubbling fluidized beds (BFB)
• Low grade biomasses of high interest
• Poor fuel quality gives challenges to design
and operation
Courtesy of Foster Wheeler and ValmetÅbo Akademi Databank 2016
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Low-temperature corrosion
Superheaters
Ash
Pre-heatersC
orro
sio
n Corrosion
and
plugging
• Interest of recovering
maximum heat without
corrosion
• By lowering flue gas temperature 10°C inreases the
boiler efficiency by 0.5%
• Corrosion of pre-heaters and
the flue gas channel
• Cause of corrosion and
operational problems
not clear
• Acid dew point vs hygroscopic
deposits
Fuel
Flemming et al.
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Low-temperature corrosion
Part 1. Dew point corrosion
Sulfuric acid
Hydrogen chloride
Water dew point and sulfurous acid
Part 2. Hygroscopic deposits
Chlorides
Phosphates
Carbonates
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H2S
SO2
SO3
Fuel
Air
SO2
Low-temperature corrosion
– Acid dew point
H2SO4
?
A part of the SO2 that is formed in combustion of sulfur containing fuels is further oxidized to SO3
The final SO3 formation is dependent on many factors, such as:
Sulfur content in the fuel
Temperature
Ash composition (SO3 is a reactive gas and is partly captured in the ash)
Additives
Catalysts (e.g. the use of SCR)
A rule of thumb from fossil fuel combustion is that a few % of SO2 forms SO3
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Homogeneous SO2 to SO3 conversion
SO2(g) + O2(g) ↔ SO3(g)
Example
Inlet gas with1000 ppmv
SO2
3 and 5 vol% O2
Residence time: ~5s
Modified from Fleig et
al. Combustion and
Flame 160 (2013)
Homogeneous SO2 to SO3 conversion
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Catalytic conversion SO2 to SO3
Using selective
catalytic NOx
reduction will lead to
catalytic conversion of
SO2 to SO3
Some ash compounds
may also lead to
catalytic formation of
SO3, e.g. iron oxide
and vanadium
Marier and Dibbs, Thermochimica Acta 8(1-2)
2NH3 + 2NO + 0.5O2 ↔
2N2 + 3H2O
Unwanted reactions:
SO2 + 0.5O2 ↔ SO3
NH3 +SO3 + H2O ↔
NH4HSO4
SCRUrea
injection
Flue
gas
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Equilibrium between SO3 and H2SO4
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150 200 250 300 350 400 450 500 550 600
Co
nv
ersi
on
(%
)
Temperature ( C)
Series1
Series2
SO3
H2SO4
SO3(g) + H2O(g) → H2SO4(g)
SO3 start to form gaseous H2SO4
below 550°C and at 200°C all SO3
converted to H2SO4(g)
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Sulfuric acid dew point
Verhoff and Banchero:
Tdew point = 1000/{2.276 - 0.0294 × ln(pH2O) - 0.0858 × ln(pH2SO4) + 0.0062 × ln(pH2O) × ln(pH2SO4)},
0
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180
10 15 20 25 30
De
w p
oin
t (°C
)
Water vapor in gas (vol%)
Sulfuric acid dew
point above 100°C
Water dew point normally 50-70°C
Tdew point sulfuric acid dew point [K]
pH2O partial pressure of water vapor [mmHg]
pH2SO4(g) or SO3 partial pressures [mmHg]
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Effect of material temperature on
sulfuric acid corrosion
Acid dew point
Water dew point
If water condenses SO2 will absorb in
the water forming sulfurous acid
H2O + SO2 -> H2SO3
Maximum corrosion rate caused by sulfuric
acid is usually 20-30°C below the dew
point temperature
Rela
tive C
orr
osio
nR
ate
Temperature (ºC)
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HCl dew point
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10 15 20 25 30
Tem
per
atu
re (°
C)
H2O (vol%)
H2O100ppm HCl500ppm HCl1000 ppm HCl
Tdew point HCl dew point [°C]
pH2O partial pressure of H2O [mmHg]
pHCl partial pressure of HCl [mmHg] 1 atm = 760 mmHg
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Dew point corrosion
Dew point corrosion can be prevented by
Keeping material temperatures above the dew
point
Adjusting excess oxygen and peak
temperature
Using additives, e.g. limestone, that binds
SO2 and SO3
Co-combustion
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SO3
SO3 capturing potential
of biomass ash
+ash
and
vapors
SO3 is very reactive
Biomass contains
alkaline ash
Can be captured in the
furnace by alkali
vapors (e.g. KCl, KOH)
and ash CaCO3, CaO,
KCl, NaCl, K2CO3,
Na2CO3
K2SO4, Na2SO4,
CaSO4
14
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Measurement techniques to asses
low-temperature corrosion
1. SO3/H2SO4 measurements to determine
dew point
Controlled condensation method
ÅA KCl salt method
2. Air-cooled corrosion probes
3. Electrochemical measurement techniques
4. Dew point meter
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1. SO3/H2SO4(g) measuremnet techniques:
Controlled condensation method
Flue gas cooled between acid
and water dew point
temperature
→ Sulfuric acid condenses
Coil and filter rinsed
Solution analyzed for sulfate
ions with ion chromatography
Not practical to use in the
field
Cooling coil
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1. SO3/H2SO4(g) measuremnet techniques:
ÅA KCl salt method
Selective sulfation of KCl by SO3 or H2SO4 can be utilized in
measurements. 2KCl(s) + H2SO4(g) -> K2SO4(s) + 2HCl(g)
Sulfuric acid is captured in the salt and forms sulfate
SO2 does not react with the salt
Salt is dissolved in water and analyzed for sulfate ions with IC →
H2SO4(g) concentration can be calculated
Vainio et al. Energy & Fuels 2013
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•A fresh carbon steel ring is placed in the probe tip
•Short-term exposure: 2h
•After the exposure corrosion products are washed off
•Annual tube wall thickness loss (mm/year) is
calculated form weight loss, which is a rough
estimation
2. Corrosion probe measurements
Hole for
thermocouple
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4. Dew point meter
Electrodes in the probe
tip
Probe tip temperature
slowly decreased
When condensate is
formed on the sensor a
current reading can be
observed
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Case studies
1. Homogeneous SO3/H2SO4(g) formation in air-
and oxy-combustion
2. Low-temperature corrosion in fluidized bed
combustion of biomass
3. Bark and NCG in a grate fired boiler
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Chalmers Oxy-combustion test unit
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Test casesAir-fired
Oxyfuel 30
• Fuel: propane doped with SO2
• Fuel input 60kWth
• Two cases:
• Air-fired case• SO2 in flue gas: 1000 ppm (on dry basis)
• λ=1.38
• Oxy-fuel case• Dry flue gas recirculation
• SO2 in flue gas: 3000 ppm (on dry basis)
• 30 vol% O2 in oxidizer
• λ=1.25
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Results: air-fired case
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1 2 3 4 5 6 7 8 9
Ave
rage
fu
rnac
e w
all t
em
pe
ratu
re (
°C)
SO3
(pp
mv
in w
et
gas)
Time from start-up (h)
Air case
Controlled cond.
Temperature (°C)
4136 38
34
300
350
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450
500
550
600
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1 2 3 4 5 6 7 8 9
Ave
rage
fu
rnac
e w
all t
em
pe
ratu
re (
°C)
SO3
(pp
mv
in w
et
gas)
Time from start-up (h)
Air case
Controlled cond.
Temperature (°C)
4136 38
3428
34
41
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350
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450
500
550
600
0
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60
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1 2 3 4 5 6 7 8 9
Ave
rage
fu
rnac
e w
all t
em
pe
ratu
re (
°C)
SO3
(pp
mv
in w
et
gas)
Time from start-up (h)
Air case
Controlled cond.
Salt met. (KCl)
Temperature (°C)
4136 38
3428
34
41
25
3335
300
350
400
450
500
550
600
0
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10
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Ave
rage
fu
rnac
e w
all t
em
pe
ratu
re (
°C)
SO3
(pp
mv
in w
et
gas)
Time from start-up (h)
Air case
Controlled cond.
Salt met. (KCl)
Salt met. (NaCl)
Temperature (°C)
SO3/SOX conversion: 2.4-3.4%
Dew point: 148-152°C (calculated)
Vainio et al. Energy & Fuels 2013
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600
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Ave
rage
fu
rnac
e w
all t
em
pe
ratu
re (
°C)
SO3
(pp
mv
in w
et
gas)
Time from start-up (h)
OF30
Temperature (°C)
36 39
54
96
300
350
400
450
500
550
600
0
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20
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Ave
rage
fu
rnac
e w
all t
emp
erat
ure
(°C
)
SO3
(pp
mv
in w
et
gas)
Time from start-up (h)
OF30
Salt met. (NaCl)
Temperature (°C)
36 39
54
9692
65 66
74
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350
400
450
500
550
600
0
10
20
30
40
50
60
70
80
90
100
110
120
130
3 4 5 6 7 8 9 10 11 12 13 14
Ave
rage
fu
rnac
e w
all t
emp
erat
ure
(°C
)
SO3
(pp
mv
in w
et
gas)
Time from start-up (h)
OF30
Salt met. (NaCl)
Salt met. (KCl)
Temperature (°C)
36 39
54
9692
65 66
74
127
300
350
400
450
500
550
600
0
10
20
30
40
50
60
70
80
90
100
110
120
130
3 4 5 6 7 8 9 10 11 12 13 14
Ave
rage
fu
rnac
e w
all t
emp
erat
ure
(°C
)
SO3
(pp
mv
in w
et
gas)
Time from start-up (h)
OF30
Salt met. (NaCl)
Salt met. (KCl)
Salt met. (K2CO3)
Temperature (°C)
Interference from SO2
SO3/SOX conversion: 1.2-3.1%
Dew point: 157-167°C (calculated)
Results: oxy-combustion case
Vainio et al. Energy & Fuels 2013
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2. BFB combustion of biomass
107 MWth, 118 bar, 535 °C
Forest residue, sludge, recycled fuels
Measurements at LUVO area
SO3/H2SO4 measurements
Corrosion probe
Deposit analysis
Objective
Understand the cause of low-temperature
corrosion in biomass combustion
Dew point corrosion (sulfuric acid)
Hygroscopic deposits
Role of ash-forming elements on corrosion
and impact on boiler operation
~40 m
~8 m
Measurement
location
Valmet Technologies OY
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Measurement campaign: BFB boiler
Furnace
H2SO4(g)
Biomass, sludge and demolition wood
Limestone addition on and off
H2SO4(g)
and SO2
40-200 ppmv SO2
<0.1 ppmv H2SO4(g)
40 ppmv HCl
<0.1 ppmv H2SO4(g)
Corrosion
probe
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Low-temperature corrosion in BFB
combustion of biomass
No sulfuric acid detected
Deposits enriched in Ca and Cl, indicating CaCl2
Corrosion when water vapor high ~20 vol%
Corrosion caused by deliquescence
13
14
15
16
17
18
19
20
21
22
23
0.0
0.2
0.4
0.6
0.8
1.0
1.2
Ammonia slip,
limestone off
Limestone off Limestone on
Wa
ter
va
po
r in
flu
e g
as
(vo
l%)
Co
rro
sio
n r
ate
(m
m/y
ear)
Corrosion rate
Water vapor
<0.05
0.00
0.04
0.08
0.12
0.16
0.20
0.24
Al Ca Cl Fe K Na S
Mo
le fra
cti
on
Spot 1 Spot 2 Spot 3 Spot 4 Spot 5
CaCl2
Deposit analysis Corrosion rate at 100°C
Vainio et al Fuel 184 (2016)
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H2S
SO2
SO3
Fuel
Air
SO2
Low-temperature corrosion in BFB combustion of biomass
Low conversion to SO3 due to low furnace temperature and air-staging
SO3 very reactive towards alkaline ash
CaCl2
K2SO4, CaSO4...
Hygroscopic and
deliquescent
salts may cause
low-temperature
corrosion
CaO(s) + 2HCl(g) → CaCl2(s) + H2O(g)
CaCO3(s) + 2HCl(g) → CaCl2(s) + H2O(g) + CO2(g)
Vainio et al Fuel 184 (2016)
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Measurement
location
Grate fired combustor burning
bark and NCG
SO2 1200 ppmv
H2SO4 <0.1 ppmv
NCG = non-condensable
gases from pulping
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Windward side of the carbon steel ring
after washing
No corrosion at 99°C
Ca, Cl, K, S, Fe in deposit
Flue gas temperature during
measurements 180-195°C
More energy could be recovered
Ring temperature
99°C
Ring temperature
86°C
Ring temperature
71°C
0.02
0.3
1.4
0
0.5
1
1.5
2
99 86 71
Ring temperature (°C)
Co
rro
sio
n r
ate
(m
m/y
ear
)
<
Pure water dew point 57 C
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Summary: Part 1. SO3 and dew
point corrosion• A few % of the SO2 may form SO3 in combustion
• Depends on
• Sulfur content in the fuel
• Temperature
• Ash composition
• Additives
• Catalysts (e.g. the use of SCR or catalytic compunds in the ash)
• The presence of sulfuric acid in flue gases may cause severe low
temperature corrosion, dew point depends on H2SO4(g) and H2O
concentrations
• Generally, no acid dew point corrosion in biomass combustion
• Acid dew point corrosion is more a problem in fossil fuel combustion
• In fluidized bed combustion of biomass no H2SO4 due to relatively
low furnace temperature leading to low SO3 formation, heavy air-
staging (no available oxygen in freeboard) and alkaline fly ash
capturing any SO3 formed
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Part 2. Hygroscopic and
deliquescent salts
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Deposit chemistry – formation of
hygroscopic salts in FBC
CaseLimestone
feedLoad
1 Limestone off Full
2 Limestone off Low (~55%)
3 Limestone on Full
Fuel: bitunnous
coal with high S
and Cl
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Case 1 - limestone off, full load
SO2 in the flue gas 900 ppmv
No chlorine in deposit
Vainio et al. 23rd FBC conference
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0
5
10
15
20
25
30
Al Ca Fe K Mg N Na Si Cl S
Mo
l %
T = 70°C, Wind
T = 70°C, Side
T = 99°C, Wind
T = 99°C, Side
Case 2 – limestone off, 55% load
NH3(g) + HCl(g) → NH4Cl(s)
Vainio et al. 23rd FBC conference
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Stability of NH4Cl
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0
2
4
6
8
10
12
14
16
Al Ca Fe K Mg N Na Si Cl S
Ato
m %
T = 50°C, Wind
T = 70°C, Wind
T = 70°C, Side
T = 70°C, Lee
T = 99°C, Wind
T = 99°C, Side
T = 99°C, Lee
Case 3 – limestone on, full load
Formation of CaCl2Vainio et al. 23rd FBC conference
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Stability of CaCl2
CaO(s) + 2HCl(g) ↔ CaCl2(s) + H2O(g) (1)
Ca(OH)2(s) + 2HCl(g) ↔ CaCl2(s) + 2H2O(g) (2)
CaCO3(s) + 2HCl(g) ↔ CaCl2(s) + H2O(g) + CO2(g) (3)
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80
100
120
140
160
180
200
0 10 20 30 40 50 60 70
Tem
pe
ratu
re (
°C)
Time (min)
Deliquescence of CaCl2at 25 vol% H2O
Deliquescence: process by which a salt absorbs
enough water from the flue gas to fully dissolve
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Hygroscopic and deliquescent salts/deposits
Corrosion of
heat exchangers
Plugging
and
corrosion
Deposit
build-up
Corrosion
during down
time
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Process by which a salt absorbs enough water from the flue gas to
fully dissolve
DRH = deliquescence relative humidity, relative humidity at which a
salt takes on water to fully dissolve
For a mixture the DRH is usually lower than for the individual salts
CRH = crystallization relative humidity
DRH ≠ CRH
Deliquescence
DRH CRH
KH2PO4 96.6
Na2CO3 87
KCl 85 62
Na2SO4 84
(NH4)2SO4 80
NH4Cl 77
NaCl 75 47
K2CO3 43
NH4HSO4 40
CaCl2·6H2O 31
DRH at 25°C for some salts
Albayrak et al., Colloid and Interface Science 2014
Deliquescence temperature = temperature at
which deliquescence occurs at a certain
vol% H2O
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Deliquescence and recrystallization
Example:
Measurement of DRH
and CRH of NaCl
aerosol partices
DRH = 75%
CRH = 47%
Pinterich T., Atmos measurement
Technique. 2017
DRH
CRH
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RH and DRH
0
10
20
30
40
50
60
70
80
90
100
35 45 55 65 75 85 95
Re
lati
ve h
um
idit
y (%
)
Temperature (°C)
6 vol% H2O
8 vol% H2O
10 vol% H2O
Above the blue line in the figure
CaCl2 will absorb moisture and
may cause corrosion
Above the red line in the figure
NaCl will absorb moisture and
may cause corrosion
RH = pH2O/p*H2O
pH2O = partial pressure of water vapor
p*H2O = equilibrium vapor pressure of water
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Li et al. Atmospheric
Environment 82 (2014)
Mutual Deliquescence Relative
Humidity (MDRH) for NaCl+KCl
Mixtures of salts can be more
hygrscopic than the individual salts
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Study of hygroscopic properties of
salts at ÅA
Hygroscopic properties of salts and deposits
Deliquescence temperature
Recrystallization
Corrosivity of deliquescent salts
Deliquescence and recrystallization properties of
Chlorides: CaCl2, NH4Cl, PbCl2, ZnCl2, KCl, NaCl..
Phosphates: K3PO4, KH2PO4…
Carbonates: K2CO3, CaCO3
Sulfates: (NH4)2SO4, NH4HSO4, K2SO4, CaSO4..
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Methods
Hygroscopic properties
Visual analysis
Thermogravimetric analysis
Electrochemical methods,
chronoamperometry
Corrosion studies
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TGA of CaCl2 at 25 vol% H2O
50
75
100
125
150
175
200
225
250
-0.50
0.51
1.52
2.53
3.54
4.55
5.56
6.5
0 2 4 6 8 10 12 14 16
Tem
pae
ratu
re (
°C)
Mo
lar
rati
on
of
H2O
/CaC
l 2
Time (h)
Series2
Temperature (°C)H2O/CaCl2
Temperature
120°C
140°C
160°C
At 160°C back to
anhydrous CaCl2
Deliquescence
108°C
17th Nordic Corrosion Congress, 23-25 May 2018
150°C
130°C
CaCl2·0.3H2O
90°C
CaCl2 → CaCl2·0.3H2O → CaCl2·2H2O → CaCl2(aq)
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Chronamperometry
Deliquescence and recrystallization
5-35 vol% H2O, rest nitrogen
Heating and cooling rate: 0.4°C/min
N2
H2O
Salt
T1
T3
H2O
Vent
Gases
(dry)
Condenser
Unit
Tube Furnace
Heated line
Potentio
-stat
T4
Steam
Generator
T2
T5
Vainio E., Hupa E., Engbolm M., Lehmusto J., Lindberg D. 23rd FBC conference: A Novel Method to Detect
Hydrate formation and Deliquescence of Salts and Deposits Related to Low-Temperature Corrosion in FBC
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-0.01
0
0.01
0.02
0.03
0.04
0.05
0.06
80
90
100
110
120
130
140
150
160
170
180
0 0.5 1 1.5 2 2.5
Cu
rre
nt
(µA
)
Te
mp
era
ture
(°C
)
Time (h)
Chronoamperometry
CaCl2 at 35 vol% H2O
Deliquescence
at 119°C
Hydrate
formation
at 150°C
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Hysteresis of CaCl2 – 25 vol% H2O
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
0.1
60
70
80
90
100
110
120
130
140
150
160
0 5 10 15 20 25 30 35
Time (h)
Cu
rren
t (µ
A)
Tem
per
atu
re (
°C)
Temperature (°C)
Current (µA)
118°C
130°C
140°C
150°C
Corrosive
Deliquscence
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Corrosivness of CaCl2 summary
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
5 10 15 20 25 30 35
Tem
per
atu
re (°
C)
Water vapor (vol%)
X Deliquescence of CaCl2 measured with CA
Recrystallization of CaCl2 measured with CA
Deliquescence of CaCl2 measured with TGA
Water dew point
Corrosive
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Example. Material temperature 110°C and fluctuating H2O
due to sootblowing (15→35 vol% H2O)
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
5 10 15 20 25 30 35
Tem
per
atu
re (°
C)
Water vapor (vol%)
X Deliquescence of CaCl2 measured with CA
Recrystallization of CaCl2 measured with CA
Deliquescence of CaCl2 measured with TGA
Water dew point
Deliquescence
Salt will not
recrystallize
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2. Corrosion tests
100 mg of CaCl2 placed
on carbon steel coupons
Various H2O
concentrations:
Temperature
100-160°C
Exposure time: 4h
Corrosion rate (mm/year)
determined from weight
loss
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Vainio et al.
IFQ 2016
0
0.2
0.4
0.6
0.8
1
1.2
80 90 100 110 120 130 140 150 160
0.48
<0.02 <0.02
1.18
<0.02 <0.02 <0.02
1.02
0.36
<0.02 <0.02 <0.02
0.47
Co
rro
sio
n ra
te (m
m/y
ear)
Temperature (°C)
10 vol% H2O 25 vol% H2O 50 vol% H2O 0.5h 50% H2O + 3.5h 25% H2O10 vol% H2O 25 vol% H2O 50 vol% H2O0.5h 50 vol% H2O + 3.5h 25 vol% H2O
1025
5050&25
100°C 110°C 120°C 130°C
After
exposure
25vol%
H2O
Corrosion tests
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Summary: Part 2. Hygroscopic and
deliquescent deposits
Ash composition, additives, boiler load has an effect on the ash
composition in the cold end
Small changes in the combustion process may have a significant
effect on deposit composition
Deposits contain hygroscopic and deliquescent salts. Examples of
highly deliquescent salts are: CaCl2, K2CO3, ZnCl2
Deliquescence is the process by which a salt absorbs enough water
from the gas to fully dissolve. This leads to a highly corrosive
environment
Deliquescent deposit in biomass conversion the main cause of low-
temperature corrosion
May also lead to filter plugging, deposit build-up and down-time
corrosion
Knowledge on ash chemistry and hygroscopic properties of salts leads
to more efficient and reliable power production