Boiler materials for ultra-supercritical coal power plants-stearnside oxidation

The corrosion behavior of tubing materials carrying steam at high temperature is of great concern to fossil power plant operators. This is due to the fact that the oxide films formed on the steam side can lead to major failures and consequently to reduced plant availability. The wall loss of the pressure boundary caused by oxidation can increase the hoop stresses and cause premature creep failures; second, the increased insulation of the tubes due to the low thermal conductivity of the oxide film can lead to increased metal temperature, thereby exacerbating the fireside corrosion as well as creep problems. The third concern is that thicker oxides may spall more easily when the plant is cooled down. On restart, the spalled material mail lodge somewhere in the system with the potential for causing tube blockages, or it may be swept out with the working fluid and enter the steam turbine causing erosion damage to the turbine nozzles and blades. Failures of tubing and turbine components by these mechanisms have been widely reported in the United States. In view of the importance of the steamside oxidation, a major study of the phenomenon is being carried out as part of a major national program sponsored by the U.S. Department of Energy and the Ohio Coal Development Office. As a prelude to the experimental work, a literature survey was performed to document the state of the art. Results of the review are reported here.