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Title: Hot Section material Systems Testing and Development for Advanced Power Systems

Authors:
; ;
Publication Date:
Research Org.:
Florida Turbine Technologies, Inc.
Sponsoring Org.:
USDOE - Office of Fossil Energy (FE)
OSTI Identifier:
901619
Report Number(s):
DOE/ER/83660-Final Report
DOE Contract Number:
FG02-03ER83660
Type / Phase:
SBIR
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
01 COAL, LIGNITE, AND PEAT; 20 FOSSIL-FUELED POWER PLANTS; 36 MATERIALS SCIENCE; Materials; Thermal Barrier Coatings; TBC; Syngas; Turbine; Airfoil; Test Rig

Citation Formats

Davies, Daniel, Hebert, Ryan, and Mills, Jake. Hot Section material Systems Testing and Development for Advanced Power Systems. United States: N. p., 2006. Web.
Davies, Daniel, Hebert, Ryan, & Mills, Jake. Hot Section material Systems Testing and Development for Advanced Power Systems. United States.
Davies, Daniel, Hebert, Ryan, and Mills, Jake. Sun . "Hot Section material Systems Testing and Development for Advanced Power Systems". United States. doi:.
@article{osti_901619,
title = {Hot Section material Systems Testing and Development for Advanced Power Systems},
author = {Davies, Daniel and Hebert, Ryan and Mills, Jake},
abstractNote = {},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Sun Dec 31 00:00:00 EST 2006},
month = {Sun Dec 31 00:00:00 EST 2006}
}

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  • This report summarizes the results of the General Electric Fireside Corrosion Task II Program. This program was designed to evaluate the erosion/corrosion behavior of gas turbine nozzle guide vane and rotor blade materials in both simulated and actual pressurized fluidized bed combustor (PFBC) environments. Simulation testing included exposing disc-shaped specimens in atmospheric pressure small burner rig test stands operated at 1600/sup 0/F (871/sup 0/C) for periods up to 1300 hours. PFBC evaluation testing consisted of exposing airfoil shaped specimens to the efflux from a PFBC in a turbine test section installed in the Exxon PFBC Miniplant facility at Linden, N.J.more » Candidate gas turbine materials included three cast vane and blade base alloys, FSX-414, IN-738, and U-700, and one protective coating system, platinum-chromium-aluminide (RT-22). Small burner rig testing consistently showed the nickel-base alloys U-700 and IN-738 most susceptible to corrosion/sulfidation, followed by the cobalt-base alloy FSX-414; the RT-22 coating on IN-738 was most resistant to hot corrosion attack. Parts life estimates have been made for the nickel and cobalt-base alloys based on corrosion rates determined from the PFBC testing.« less
  • Activities are reported in a program to provide 1000-hour engineering data on the corrosion/erosion deterioration of gas turbine materials U 700 and IN-738 exposed to the exhaust gas from a pressurized fluidized bed combustor. The results show that on the leading edges of the specimens there was deposition, corrosion, and erosion all occurring in the same area. It is reasonable to expect that corrosion and erosion might occur simultaneously. But the occurrence of erosion and deposition in the same area is unlikely except if there was a significant change in the gas velocity during the test. This was the casemore » for the 100 hour shakedown test since the mass flow through the turbine test section decreased significantly after the first 50 hours due to plugging of the inlet orifice of the turbine test section upstream of the cascades.« less
  • The objective of this program was to provide an experimental basis for specifying materials for heat exchangers and gas turbines exposed to a pressurized fluidized bed combustor environment. A 1000 hour test was completed which: (1) exposed heat exchanger materials both within the fluidized bed and in the freeboard of a pressurized fluidized bed combustor at temperatures ranging from 1050 to 1600/sup 0/F for up to 1117 hours; and (2) provided the first successful long term exposure of turbine blade materials subjected to PFBC flue gas where the particulates were removed solely by cyclones. This report describes the operating conditionsmore » and major observations during this test period. Operating conditions varied sufficiently to significantly alter the particulate loading and mean particle diameter of the particulate entering the turbine section. This permitted several observations to be made: most of the turbine blade specimens appeared to be in satisfactory condition showing little, if any, erosion; particulate loading and/or particle size had a profound effect on the degree of deposition and erosion on the turbine blades; and in general, erosion was not visually apparent when 3 stages of conventional cyclones were used to clean the PFBC flue gas (however, upsets could cause marked erosion if the grain loading and particulate size increased only by small amounts). The heat exchanger specimens appeared to be in satisfactory condition both in bed and above the fluidized bed. These tests indicated the possibility that conventional cyclones alone may be sufficient to protect gas turbine blade materials exposed to PFBC flue gas. Also, there seems to be satisfactory heat exchanger materials for above-bed use and probably in-bed use.« less
  • The second and third segments of a 1000 hour exposure test of potential gas turbine and boiler tube materials for use in Pressurized Fluidized Bed Coal Combustion were successfully completed. This brought the total exposure time to 565 hours on the gas turbine specimens and 682 hours on the heat exchanger specimens. The 100 hour test (Run 79) had to be terminated prematurely because of a plug in the solids discharge line from the first (recycle) cyclone. The 215 hour test (Run 80) was interrupted at the 82 hour mark to replace a leaking valve. After the interruption, the turbinemore » flow rate dropped 12% as a result of a blockage at the turbine inlet. The lower level flow, still within specifications, was maintained for the duration of the run. Measurements of the particulate loading entering the gas turbine during Run 79 indicated a rise in loading from a level of 0.01 gr/SCF at the beginning to 0.03 gr/SCF near the end of the test. This increase was presumably a consequence of the first cyclone dipleg plugging. The particulate had a mass median size of 1.5 microns with little variation from the beginning to the end of the test. During Run 80 particulate measurements taken before and after the turbine were low and consistent, averaging about 0.02 gr/SCF. The particulates had a mass median size of 1.2 microns. The gas turbine specimens showed no visible signs of attack after 565 hours. There was, however, substantial flyash deposition, similar to the deposits found after the first 250 hour test. All the heat exchanger probe specimens looked satisfactory except for an Inconel 800/Hastelloy X probe controlled at 1400/sup 0/F. There was considerable wastage and a small rupture near the capped end. A piece was removed for analysis and the probe repaired for future tests.« less
  • The first portion of a 1000 hour exposure test of potential gas turbine and boiler tube materials suitable for use in Pressurized Fluidized Bed Coal Combustion (PFBC) was successfully completed. A 250 hour test was carried out in the Exxon PFBC Miniplant under realistic test conditions. The run was interrupted for one six hour period. Flue gas temperatures downstream of the combustor were maintained at 1550/sup 0/F or higher. Gas turbine and boiler tube specimens showed no obvious signs of damage after the 250 hour test. The gas turbine specimens showed some signs of deposition, but the deposits were easilymore » removed by brushing.« less