Numerical Study on the Homogeneous Reactions of Mercury in a 600 MW Coal-Fired Utility Boiler

The homogeneous oxidation of elemental mercury (Hg0) can promote Hg pollution control in coal-fired power plants, while the mechanisms and quantitative contributions of homogeneous reactions in Hg0 oxidation, especially the reactions between Hg and chlorine (Cl), are still unclear. Here, a numerical study on the homogeneous reactions of Hg was conducted within a 600 MW tangentially fired boiler for the first time. A novel Hg sub-model was established by coupling the thermodynamics, reaction kinetics and fluid dynamics. The results showed that the higher Cl content in coal was beneficial to the oxidation of Hg0. The homogeneous reactions of Hg mainly occurred in the vertical flue pass at low temperature. Hg0 was still the dominant Hg-containing species at the boiler exit, and the concentration of mercury chloride (HgCl2) was the highest among the oxidized mercury. When low-Cl coal was fired, the addition of a small amount of chlorine species into the boiler at the burnout area increased the ratio of HgCl2 by over 16 times without causing serious chlorine corrosion problems.

Chlorine Corrosion in a Low-Power Boiler Fired with Agricultural Biomass

The selection of appropriate heat-resistant materials which are at the same time resistant to atmospheres rich in chlorine and its compounds is one of the most important current construction problems in steel boiler elements when using biomass fuels of agricultural origin. In the research presented here, an area was identified in the furnace of a 10 kW boiler where there was a potential risk of chlorine corrosion. This zone was determined based on numerical analysis of the combustion process; it is the zone with the highest temperatures and where the gas atmosphere conducive to the formation of chlorine corrosion centers. Subsequently, tests were carried out in the process environment of the combustion chamber of a 10 kW boiler (the fuel was barley straw) by placing samples of eight construction materials in a numerically-designated zone. These included samples of steel (coal boiler St41K, heat-resistant H25T and H24JS, and heat-resistant valve 50H21G9N4) as well as intermetallic materials based on phases (FeAl, Fe3Al, NiAl, and Ni3Al). The samples remained in the atmosphere of the boiler furnace for 1152 h at a temperature of 750–900 °C. After this time, the surfaces of the samples were subjected to SEM microscopy and scanning analysis. The results showed that the St41K boiler steel was not suitable for operation under the assumed conditions, and that a thick layer of complex corrosion products was visible on its surface. The least amount of corrosion damage was observed for the samples of 50H21G9N4 steel and intermetallic materials.

Reaction Kinetics of Chlorine Corrosion to Heating Surfaces during Coal and Biomass Cofiring

The high content of chlorine in biomass will cause serious ash deposition and corrosion problems on the heating surface in boiler, reduce heat transfer efficiency, and endanger the boiler operation safety. On the basis of discussing the mechanism of chlorine corrosion to heating surface in the boiler, the temperature, atmosphere, and fouling in the boiler are simulated by high-temperature reaction device. Reaction kinetics of chlorine corrosion to heating surfaces during coal and biomass cofiring was studied by the weight gain method, which provides a theoretical basis for solving the problem of corrosion and improving the safety of boiler operation. The results show that the weight gain caused by corrosion increases with time, and its curve is in accordance with the parabola. In the early stage, the corrosion rate is very fast, and the corrosion gradually slows down after the protective layer is formed. The mixing ratio of straw biomass increases, and the corrosion rate increases proportionally. With the increase in temperature, the rate of corrosion reaction increases continuously. When the temperature exceeds 600°C, the corrosion reaction rate increases greatly. The concentration of HCl in the gas phase increases and the rate of corrosion reaction increases rapidly. Under the constant temperature, the reaction kinetics characteristics of chlorine corrosion were analyzed by model function matching. The best kinetic model function for calculating the kinetic parameters was determined, and the kinetic equation of corrosion reaction was established to quantitatively characterize the corrosion reaction.

Characteristics of Corrosion Related to Ash Deposition on Boiler Heating Surface during Cofiring of Coal and Biomass

In order to investigate the regularity and mechanism of corrosion related to ash deposition on the boiler heating surface during cofiring of coal and biomass, the influence of fuel property, type of metal tubes (heating surface), proportion of blended biomass, and atmosphere in the furnace was studied by using the static corrosion mass gain method with the high-temperature tube furnace system. The results indicated that the effect of biomass property on ash corrosion is greater than that of coal, which was mainly due to high content of alkali metals and chlorine in biomass fuels. The corrosion resistance of metal pipes is T91 > 12CrMoVG > 20G. T91 is the most appropriate one, and it can effectively inhibit chlorine corrosion and can be used as the ideal material for the biomass-fired boiler and the biomass and coal cofired boiler. In addition, ash deposition can significantly aggravate the corrosion of metal tubes, and the degree of corrosion tends to become significant with increasing proportion of blended biomass fuels. HCl can aggravate metal corrosion, which can be inhibited by SO2.

Potassium and chlorine distributions in high temperature halloysite formed deposits

The paper presents results of investigations on KCl interaction with halloysite under high temperature conditions. Halloysite is an aluminosilicate that can be used as a fuel additive to prevent chlorine corrosion and formation of low melting corrosive deposits during combustion of biomass. It is claimed that an increase of the emission of gaseous chlorine as HCl(g) and decrease of chlorine share in the ash as result of KCl and halloysite interaction should be expected. During presented tests the mixtures of KCl and halloysite with different ratios were thermally decomposed in a muffle furnace at high temperatures of 900°C and 1100°C. Then, the analyses of potassium and chlorine contents in the formed solid residues were determined. Besides, it has been proved that halloysite addition changes the ash deposit structure as well as increases the ash fusion temperatures. This was supported by performing phase equilibrium calculations for the investigated different halloysite/KCl mixtures. The positive effects of halloysite on potassium capture while reducing chlorine content in solid residue to prevent formation of corrosive deposits have been confirmed.

Chlorine corrosion of blast furnace gas pipelines: Analysis from thermal perspective

With the broad application of dry dedusting of blast furnace gas (BFG), the issue of BFG pipeline corrosion comes up because of chlorine in the BFG. Existing methods in preventing the corrosion, such as spraying alkali or installing corrosion-resistant materials, require a significant amount of investment. This paper conducted a novel thermal analysis of the corrosion mechanism to support the study on corrosion prevention without using additional materials. Firstly, thermal models were established to reflect the relationships among the amount of condensation water, the mass transfer rate, the concentration of chloride ion and the ambient temperature. Secondly, the relationship between BFG temperature and the corrosion rate was obtained via a cyclic exposure experiment. Key factors that affect the pipeline corrosion under various BFG temperatures were identified. Finally, a control scheme of the BFG temperature was proposed to avoid the chlorine corrosion.