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00574 RELIABILITY / CORROSION PROBLEMS OF FGD INDUSTRY COST EFFECTIVE SOLUTIONS BY NI - CR - MO ALLOYS & AN ADVANCED 6 MO ALLOY 31

Product Number: 51300-00574-SG
ISBN: 00574 2000 CP
Author: D.C.Agarwal, W.R.Herda, Robert W. Berry
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Reviews of materials of construction (MOC) to adequately solve and control complex corrosion problems in flue gas desulfurization systems (FGD) of coal fired power plants have been fairly well documented. The utilities, which were forced to abide by the revised clean air act of 1970, suddenly found themselves in the position of being "chemical plant operators"; a role for which they were ill prepared. Their expertise in mechanical engineering, electrical engineering, water chemistry and coal management was of little or no use, thus leading to an onslaught of monumenlal corrosion problems, unscheduled shut downs, soaring maintenance costs, lost revenues and the penalties imposed form buying power from the grid, while quick fixes were being developed. This was a nightmare for the power plant operators during the 1970's and 80's and the problems were often traced to corrosion of material components and unreliability of non-metallic coatings. A concerted effort by the FGD industry (A/E firms, EPRI, alloy producers, lining suppliers, various research institutions, universities et al) was mounted to define the problems and provide cost effective solutions. The industry today has a much better (if not total) understanding of the complexity of the corrosive environments of wet scrubber systems and this knowledge was gained only after years of investment in research and development programs. The results of these programs have led to improved alloy metallurgy, non-metallic coatings, process design improvements and better fabrication/inspection techniques. The benefits of this effort are that today the industry is fully enjoying the "reliability in performance" in FGD systems with minimal interruption, a phenomenon which was almost non existent about 20 years ago. This paper describes the chronology of the improvements over the past 30 years and the various evolutionary material solutions with emphasis on case histories of Ni-Cr-Mo alloys, especially alloy 59 for the most severe and critical areas and 6Mo alloys for less critical areas and dampers. Keywords: Flue gas desulfurization, FGD, Nickel alloys, Ni-CroMo alloys, 6Mo alloys, wallpapering, alloy 59, UNS N06059, alloy C-276, UNS N10276, alloy 31, UNS N08031, localized corrosion, acid dew point corrosion, scrubbers
Reviews of materials of construction (MOC) to adequately solve and control complex corrosion problems in flue gas desulfurization systems (FGD) of coal fired power plants have been fairly well documented. The utilities, which were forced to abide by the revised clean air act of 1970, suddenly found themselves in the position of being "chemical plant operators"; a role for which they were ill prepared. Their expertise in mechanical engineering, electrical engineering, water chemistry and coal management was of little or no use, thus leading to an onslaught of monumenlal corrosion problems, unscheduled shut downs, soaring maintenance costs, lost revenues and the penalties imposed form buying power from the grid, while quick fixes were being developed. This was a nightmare for the power plant operators during the 1970's and 80's and the problems were often traced to corrosion of material components and unreliability of non-metallic coatings. A concerted effort by the FGD industry (A/E firms, EPRI, alloy producers, lining suppliers, various research institutions, universities et al) was mounted to define the problems and provide cost effective solutions. The industry today has a much better (if not total) understanding of the complexity of the corrosive environments of wet scrubber systems and this knowledge was gained only after years of investment in research and development programs. The results of these programs have led to improved alloy metallurgy, non-metallic coatings, process design improvements and better fabrication/inspection techniques. The benefits of this effort are that today the industry is fully enjoying the "reliability in performance" in FGD systems with minimal interruption, a phenomenon which was almost non existent about 20 years ago. This paper describes the chronology of the improvements over the past 30 years and the various evolutionary material solutions with emphasis on case histories of Ni-Cr-Mo alloys, especially alloy 59 for the most severe and critical areas and 6Mo alloys for less critical areas and dampers. Keywords: Flue gas desulfurization, FGD, Nickel alloys, Ni-CroMo alloys, 6Mo alloys, wallpapering, alloy 59, UNS N06059, alloy C-276, UNS N10276, alloy 31, UNS N08031, localized corrosion, acid dew point corrosion, scrubbers
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