Corrosion behavior of Haynes® 556® Fe-Ni-Cr-Co alloy for integrated coal gasification combined cycle syngas plants: A plant exposure study*

Sungkyu Lee; Min Jung Kim; Jieun Lee; Suk-Hwan Kang; Seung-Jong Lee; Yongseung Yun

doi:10.3139/120.110728

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Corrosion behavior of Haynes® 556® Fe-Ni-Cr-Co alloy for integrated coal gasification combined cycle syngas plants: A plant exposure study*

Sungkyu Lee , Min Jung Kim , Jieun Lee , Suk-Hwan Kang , Seung-Jong Lee and Yongseung Yun

Published/Copyright: April 21, 2015

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From the journal Materials Testing Volume 57 Issue 5

Abstract

A corrosion exposure test was performed on a commercially available Haynes® 556® Fe-Ni-Cr-Co alloy sample to investigate its solid/gas reaction behavior in integrated coal gasification combined cycle pilot plant facilities affiliated with the Institute for Advanced Engineering (2.005 MPa and 160–300 °C). Thermodynamic Ellingham-Pourbaix stability diagrams were constructed and the post-exposure samples were examined ex-situ by morphological and microstructural SEM and EDS analyses on the external surfaces to obtain information on the corrosion scale and provide insight into the mechanism of the observed corrosion behavior in the piping materials connecting the particulate removal unit and water scrubber of the integrated coal gasification combined cycle pilot plant. Uniform material thinning was observed after 46 hours of operation, and a preliminary corrosion mechanism was suggested. The observed material wastage and corrosion behavior of the Haynes® 556® Fe-Ni-Cr-Co alloy sample cut off from the coal syngas IGCC plant were explained by the formation of discontinuous (complex) oxide phases and subsequent chlorine-induced active oxidation under the predominantly reducing environment encountered.

Kurzfassung

Für den vorliegenden Beitrag wurde ein Korrosions-Auslagerungsversuch mit der kommerziell erwerblichen Fe-Ni-Cr-Co Legierung Haynes® 556® durchgeführt, um ihre Gas-Metall-Reaktion in einer Pilot-Kraftwerkskombianlage mit integrierter Kohlevergasung (Integrated Coal Gasification Combined Cycle (IGCC) Plant), die zum Institute for Advanced Engineering gehört und bei 2.005 MPa sowie zwischen 160 und 300 °C betrieben wird, zu untersuchen. Es wurden thermodynamische Ellingham-Pourbaix-Stabilitätsdiagramme aufgestellt und die Proben nach den Korrosions-Auslagerungsversuchen ex-situ morphologisch und mikrostrukturell mittels REM- und EDS-Analyse auf der äußeren Oberfläche untersucht, um Informationen über die Korrosionsschichten zu erhalten und um Erkenntnisse über das beobachtete Korrosionsverhalten der Rohrwerkstoffen zu gewinnen, die die speziellen Entnahmeeinrichtungen und den Wasserreiniger in integrierten Kohlevergasungs-Kombikraftwerken verbinden. Es wurde ein gleichförmiger Materialabtrag nach 46 Betriebsstunden beobachtet und hierfür ein erster Korrosionsmechanismus vorgeschlagen. Der beobachtete Materialverlust und das Korrosionsverhalten der Probe aus Fe-Ni-Cr-Co Legierung Haynes® 556®, die der IGCC-Anlage entnommen wurde, wurden mit der Bildung von diskontinuierlichen komplexen Oxid-Phasen und nachfolgender Chlorgas-induzierter aktiver Oxidation unter überwiegend reduzierenden Umgebungsbedingungen erklärt.

§Correspondence Address, Dr. Sungkyu Lee, Principal Engineer, Plant Engineering Center, Institute for Advanced Engineering (IAE), 633-2 Goan-ri, Baegam-myeon, Cheoin-gu, Yongin-si, Gyeonggi-do, 449-863, Korea, E-mail: sklee@ajou.ac.kr

Sungkyu Lee, born 1959, received his BS from the Hanyang University of Seoul, Korea, in 1982. He graduated with an MS and PhD in Materials Science and Engineering from the University of Minnesota at Twin Cities, USA, in 1991 and 1994, respectively. Now, he is working as Principal Engineer at the Plant Engineering Center, Institute for Advanced Engineering, Yongin-si, Gyeonggi-do, Korea.

Min Jung Kim, born 1983, received her BS in Materials Science and Engineering from the Incheon National University, Incheon, Korea in 2007. Her MS and PhD degrees were conferred in Materials Science and Engineering at the Hongik University, Seoul, Korea and Sungkyunkwan University, Suwon, Korea in 2009 and 2013, respectively. She is currently working as Research Fellow at the Advanced Materials Technology Research Center, Sungkyunkwan University, Suwon-si, Gyeonggi-do, Korea.

Jieun Lee, born 1984, received her B. S. and M. S. in Chemical Engineering and Chemical & Biological Engineering from the Seoul National University of Technology, Korea, and Korea University, Seoul, Korea, in 2008 and 2011, respectively. Now, she is working as Researcher at the Plant Engineering Center, Institute for Advanced Engineering, Yongin-si, Gyeonggi-do, Korea.

Suk-Hwan Kang, born 1971, received his B. S. in Chemical & Biological Engineering & Chemical Engineering from the Hanbat National University, Daejeon, Korea in 1994. His M. S. and Ph.D. degrees were conferred in the field of Chemical Engineering at Chungnam National University, Daejeon, Korea, in 1997 and 2003, respectively. Now, he is working as Principal Engineer at the Plant Engineering Center, Institute for Advanced Engineering, Yongin-si, Gyeonggi-do, Korea.

Seung-Jong Lee, born 1966, received his B. S. and M. S. in Chemistry and Organic Chemistry from the Yonsei University, Seoul, Korea in 1988 and 1990, respectively. His PhD was conferred in Systems Engineering at Ajou University, Suwon, Korea, in 2002. Now, he is working as Principal Engineer at the Plant Engineering Center, Institute for Advanced Engineering, Yongin-si, Gyeonggi-do, Korea.

Yongseung Yun, born 1957, received his B. S. in Chemical Engineering from the Yonsei University, Seoul, Korea in 1979. His M. S. and Ph.D. degrees were conferred in the field of Chemical Engineering at Korea Advanced Institute of Science and Technology, Daejeon, Korea and the University of Utah, USA, in 1981 and 1990, respectively. He is currently working as an executive research director of the Plant Engineering Center, Institute for Advanced Engineering, Yongin-si, Gyeonggi-do, Korea.

Work leading to this manuscript was conducted at the Institute for Advanced Engineering, Korea (IAE) and all of the legal claims for the research belong to the IAE

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Published Online: 2015-04-21

Published in Print: 2015-04-30

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https://doi.org/10.3139/120.110728