Corrosion behavior of Haynes® 230® nickel-based super-alloys 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 Yongin

doi:10.3139/120.110742

Article

Corrosion behavior of Haynes^® 230^® nickel-based super-alloys 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 Yongin

Published/Copyright: May 15, 2015

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From the journal Materials Testing Volume 57 Issue 6

Abstract

The corrosion behavior of commercially available Haynes^® 230^® nickel-based alloy samples was investigated by exposure to coal-gasifying integrated coal gasification combined cycle pilot plant facilities affiliated with the Institute for Advanced Engineering (2.005 MPa and 160-300 °C). The morphological and microstructural analyses of the exposed samples were conducted using scanning electron microscopy and energy-dispersive X-ray spectroscopy analysis on the external surface of the recovered corrosion test samples to obtain information of the corrosion scale. These analyses based on the pre- and post-exposure corrosion test samples combined with thermodynamic Ellingham-Pourbaix stability diagrams provided preliminary insight into the mechanism of the observed corrosion behavior prevailing in the piping materials that connected the particulate removal unit and water scrubber of the integrated coal gasification combined cycle pilot plant. Uniform material wastage was observed after 46 hours of operation, and a preliminary corrosion mechanism was suggested: the observed material waste and corrosion behavior of the Haynes^® 230^® nickel-based alloy samples cut off from the coal syngas integrated coal gasification combined cycle plant were explained by the formation of discontinuous (complex) oxide phases and subsequent chlorine-induced active oxidation under the predominantly reducing environment encountered. This contribution continues the already published studies of the Fe-Ni-Cr-Co alloy Haynes^® 556^®.

Kurzfassung

Das Korrosionsverhalten einer kommerziell erwerblichen Nickellegierung Haynes^® 230^® wurde in der diesem Beitrag zugrunde liegenden Studie untersucht, indem sie einer Kohlevergasungsanlage in der Pilotanlage eines Synthesegas-Kombikraftwerks am Institute for Advanced Engineering (Korea) ausgesetzt wurde (2,005 MPa und 160-300 °C). Es wurde eine morphologische und mikrostrukturelle Analyse der äußeren Oberfläche der ausgesetzten Proben mittels REM- und EDS-Analyse durchgeführt, um Informationen über die Korrosionsschichten zu erhalten. Diese Analysen mit den Proben vor und nach dem Korrosionsversuch ergaben zusammen mit thermodynamischen Ellingham-Pourbaix-Stabilitätsdiagrammen einen ersten Einblick in das Korrosionsverhalten von Rohrwerkstoffen, die zur Verbindung der speziellen Entnahmeeinrichtungen und dem Wasserreiniger in integrierten Kohlevergasungs-Kombikraftwerken verwendet werden. Es wurde ein gleichförmiger Materialabtrag nach 46 Betriebsstunden beobachtet und hierfür ein erster Korrosionsmechanismus vorgeschlagen. Der beobachtete Materialverlust und das Korrosionsverhalten der Nickellegierung Haynes^® 230^®, 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. Der Beitrag schließt an eine bereits veröffentlichte Untersuchung mit der Nickellegierung Fe-Ni-Cr-Co Legierung Haynes^® 556^® an.

§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 BSc from the Hanyang University of Seoul, Korea, in 1982. He graduated with an MSc 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 BSc in Materials Science and Engineering from the Incheon National University, Incheon, Korea, in 2007. Her MSc 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 BSc and MSc 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 BSc in Chemical & Biological Engineering & Chemical Engineering from the Hanbat National University in 1994. His MSc and PhD 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 BSc and MSc 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 BSc in Chemical Engineering from the Yonsei University, Seoul, Korea, in 1979. His MSc and PhD degrees were conferred in the field of Chemical Engineering at Korea Advanced Institute of Science and Technology, Daejeon, Korea and the University of Utah, Salt Lake City, USA, in 1981 and 1990, respectively. He is currently working as Executive Research Director of the Plant Engineering Center, Institute for Advanced Engineering, Yongin-si, Gyeonggi-do, Korea.

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Published Online: 2015-05-15

Published in Print: 2015-06-01

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https://doi.org/10.3139/120.110742