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Title: Duct injection technology prototype development

Abstract

This report describes a test program conducted to determine the corrosion rate of materials in the dry scrubber or duct injection systems. Four materials were evaluated: 1010 carbon steel, Corten, 317SS and Hastelloy C-276. The results show that acidic conditions result in higher corrosion rates than alkaline conditions for all the materials. The carbon steel, Corten and stainless steel show moderate to heavy pitting attack in the acidic environment. For the alkaline conditions, the corrosion rates of carbon steel and Corten were higher than the stainless steel or Hastelloy C-276. Also, the corrosion rate of abraded specimens were four time those of unabraded specimens in the flue gas. It is probable that areas of wall-wetting and plugging in the duct injection process will exhibit high rates of corrosion for the carbon steel, Corten, and stainless steel materials. General corrosion and pitting corrosion will predominate. Additionally, abraded duct areas will corrode at a significantly higher rate than unabraded duct materials. 6 refs., 11 figs., 7 tabs.

Authors:
 [1]
  1. (Babcock and Wilcox Co., Alliance, OH (United States). Research and Development Div.)
Publication Date:
Research Org.:
United Engineers and Constructors, Inc., Denver, CO (United States). Stearns-Roger Div.; Babcock and Wilcox Co., Alliance, OH (United States). Contract Research Div.
Sponsoring Org.:
USDOE; USDOE, Washington, DC (United States)
OSTI Identifier:
6019612
Report Number(s):
DOE/PC/88852-T3-Rev.1
ON: DE92001791
DOE Contract Number:
AC22-88PC88852
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
20 FOSSIL-FUELED POWER PLANTS; 36 MATERIALS SCIENCE; CALCIUM HYDROXIDES; CORROSIVE EFFECTS; CARBON STEELS; CORROSION; CHLORINE COMPOUNDS; HASTELLOYS; STAINLESS STEEL-317; SULFURIC ACID; ABRASION; DUCTS; EROSION; FLUE GAS; FLY ASH; PH VALUE; PITTING CORROSION; SLURRIES; SORBENT INJECTION PROCESSES; SULFUR DIOXIDE; TEMPERATURE EFFECTS; AEROSOL WASTES; ALKALINE EARTH METAL COMPOUNDS; ALLOYS; ASHES; CALCIUM COMPOUNDS; CHALCOGENIDES; CHEMICAL REACTIONS; COMBUSTION PRODUCTS; DISPERSIONS; GASEOUS WASTES; HALOGEN COMPOUNDS; HIGH ALLOY STEELS; HYDROGEN COMPOUNDS; HYDROXIDES; INORGANIC ACIDS; IRON ALLOYS; IRON BASE ALLOYS; MIXTURES; NICKEL ALLOYS; NICKEL BASE ALLOYS; OXIDES; OXYGEN COMPOUNDS; RESIDUES; STAINLESS STEELS; STEELS; SULFUR COMPOUNDS; SULFUR OXIDES; SUSPENSIONS; WASTES; 200202* - Fossil-Fueled Power Plants- Waste Management- Noxious Gas & Particulate Emissions; 360105 - Metals & Alloys- Corrosion & Erosion

Citation Formats

Harper, S.L.. Duct injection technology prototype development. United States: N. p., 1991. Web. doi:10.2172/6019612.
Harper, S.L.. Duct injection technology prototype development. United States. doi:10.2172/6019612.
Harper, S.L.. 1991. "Duct injection technology prototype development". United States. doi:10.2172/6019612. https://www.osti.gov/servlets/purl/6019612.
@article{osti_6019612,
title = {Duct injection technology prototype development},
author = {Harper, S.L.},
abstractNote = {This report describes a test program conducted to determine the corrosion rate of materials in the dry scrubber or duct injection systems. Four materials were evaluated: 1010 carbon steel, Corten, 317SS and Hastelloy C-276. The results show that acidic conditions result in higher corrosion rates than alkaline conditions for all the materials. The carbon steel, Corten and stainless steel show moderate to heavy pitting attack in the acidic environment. For the alkaline conditions, the corrosion rates of carbon steel and Corten were higher than the stainless steel or Hastelloy C-276. Also, the corrosion rate of abraded specimens were four time those of unabraded specimens in the flue gas. It is probable that areas of wall-wetting and plugging in the duct injection process will exhibit high rates of corrosion for the carbon steel, Corten, and stainless steel materials. General corrosion and pitting corrosion will predominate. Additionally, abraded duct areas will corrode at a significantly higher rate than unabraded duct materials. 6 refs., 11 figs., 7 tabs.},
doi = {10.2172/6019612},
journal = {},
number = ,
volume = ,
place = {United States},
year = 1991,
month = 8
}

Technical Report:

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  • Babcock Wilcox has conducted a program to identify atomizers appropriate for successful in-duct injection of humidification water and lime slurries. The purpose of this program was to identify and quantify atomizer spray and performance criteria that affect the operations and reliability of the in-duct SO{sub 2} removal process, and compare commercially available atomizers to these criteria.
  • Babcock & Wilcox has conducted a program to identify atomizers appropriate for successful in-duct injection of humidification water and lime slurries. The purpose of this program was to identify and quantify atomizer spray and performance criteria that affect the operations and reliability of the in-duct SO{sub 2} removal process, and compare commercially available atomizers to these criteria.
  • The objective of the Duct Injection Technology Prototype Development project is to develop a sound design basis for applying duct injection technology as a post-combustion SO{sub 2} emissions control method to existing, pre-NSPS, coal-fired power plants. This report is divided into five major topics: (1) design criteria; (2) engineering drawings; (3) equipment sizing and design; (4) plant and equipment arrangement considerations; and (5) equipment bid specification guidelines.
  • Duct Injection systems remove the sulfur dioxide from flue gas streams by injecting a wet or dry sorbent in the flue gas. Calcium hydroxide is injected as a sorbent which reacts with sulfur dioxide in the flue gas to form a calcium sulfite compound. The major material concerns are: Corrosion from condensing flue gas (wall wetting) and underdeposit damage from deposited fly ash and calcium sulfite. Weld corrosion is also a concern; erosion from slurry injection of the chemical sorbent; and cracking of ceramic components from thermal cycling. Some components have a ceramic coating, such as aluminum oxide to providemore » protection from the highly erosive environment at the slurry injection sites. These components crack and fail prematurely because of thermal cycling. This test program was designed to determine the corrosion rates of the duct injection construction materials in a range of environments. Carbon steel and Corten A are alloys presently used as the ductwork material. Because the majority of installations of duct injection systems will be retrofits, it is appropriate to evaluate carbon steel and Corten corrosion behavior in this test program. Stainless steel (300 series) is a bolt and hanger material in existing duct structures and also a possible duct material. Hastelloy C-276, a nickel-based alloy, is being used in highly corrosive areas of wet scrubbers. A two-part test program was designed to meet the goals of this test program. First, retort tests were used to evaluate the corrosion behavior of materials under conditions closely simulating expected service environments. Second, electrochemical corrosion tests were performed to evaluate the effect of chlorides, oxygen, and pH upon corrosion rates. 6 refs., 11 figs., 7 tabs.« less
  • The objective of the Duct Injection Technology Prototype Development Project is to develop a sound design basis for applying duct injection technology as a post-combustion SO{sub 2}emissions control method to existing coal-fired power plants. The necessary engineering design and scale-up criteria will be developed for the commercialization of duct injection technology for the control of SO{sub 2} emissions from coal-fired boilers in the utility industry. The primary focus of the analyses summarized in this Topical Report is the review of the known technical and economic information associated with duct injection technology. (VC)