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Organisationseinheit der BAM
Eingeladener Vortrag
- nein (10)
Technically relevant P92 steel (9% Cr) was coated with a micron-thick porous alumina layer prepared by sol-gel technique and treated with flue gas (60 CO2-30 H2O-2 O2-1 SO2-7 N2 (mole fraction in %)) at 650 ° to mimic an oxyfuelcombustion process. Local defects in the coating were marked using focused ion beam (FIB) technique and were inspected after exposition to hot flue gas atmosphere at 300, 800, and 1300 h, respectively. Local defects like agglomerated alumina sol particles tend to spall off from the coating uncovering the underlying dense chromia scale. Re-coating was found to restore the protection ability from oxidation when repeatedly treated with hot flue gas. Cracks and voids did not promote the local oxidation due to the formation of crystalline Mn/S/O species within and on top of the coating. The protective character of the steel-coating system is a result of (i) the fast formation of a dense chromia scale at the surface of sol-gel alumina-coated P92 steel bars in combination with (ii) the porous alumina coating acting as diffusion barrier, but also as diffusion partner in addition with (iii) fast Mn outward diffusion capturing the S species from flue gas.
The role of Fe3+ ions in the transformations from boehmites and pseudoboehmite xerogels via transition aluminas to corundum was studied here. Especially, the active iron species responsible for the decrease of the temperature of transformation to corundum were looked for. To enable the formation of various Fe3+
and Fe2+ species, samples were subjected to thermal treatments in different atmospheres as well as mechanically activated. Thermal analysis and ESR spectroscopy served to follow the processes and to characterise the resulting products. It was found that (i) isolated Fe3+ ions can indicate local structural changes but have (almost) no influence on the temperature of corundum formation, (ii) the temperature of corundum formation decreases in the result of action of small
α-Fe2O3 particles and (iii) during thermal treatments Fe3+ ions are distributed between different phases or precursors thereof: transition aluminas, corundum, Fe2O3, and a Fe3+ pool.
The investigation of iron-doped AlO(OH)/Al2O3 systems revealed that the combined employment of Mössbauer and ESR spectroscopies together with thermal analysis yields meaningful data with complementary information. This mutual complementarity is based on the coexistence of Fe point defects with the corresponding aggregated FeOx species which has been observed even for very low Fe concentrations. Competing redox processes between the dopant, the AlOx matrix, and the gas atmosphere during the thermal treatment enable the generation of solid phases exhibiting specific chemical properties. The entire reaction process is influenced by a specific mechanical and thermal pre-treatment that affects predominantly oxydative processes in the matrix. A protecting influence of the matrix preventing further reductive attack of the Fe3+ Fe2+ ions by hydrogen has been established.
The fate of doped iron species during various mechanically and thermally initiated redox reactions and aggregation processes in crystalline and amorphous AlO(OH) or Al2O3 matrices was investigated. The amorphization of the matrix was performed by chemical (i.e., via sol-gel processes) or mechanochemical treatment (high-energy ball milling). Thermal analysis, coupled with mass spectrometry (TA-MS), Mössbauer spectroscopy, and electron spin resonance (ESR), was used. The TA under various gas atmospheres allowed preparing samples under a controlled temperature regime, together with a controlled gas influence. Both the effect of mechanical activation and the influence of the iron doping could be followed macroscopically via the down-shift of the peak temperature of the corundum formation. The ESR data characterize the Fe3+ ions and their interaction with the magnetic surrounding based on the fine structure parameters. The Mössbauer data allowed the characterization of the Fe(0), Fe2+, and Fe3+ species, together with providing information about their coordinative surrounding. Both methods provided general complementary spectroscopical information.
Unexpectedly, (FeOx)n and (FexAl1-x)2O3 aggregates could also be detected in the range of low Fe concentrations. It was demonstrated that even in the low-level doped systems [(FexAl1-x)2O3 with x ≥ 0.01], all the essential spectroscopic phenomena occur. At higher Fe concentrations, they were discovered to be caused by magnetic and spin exchange interactions as well as by solid-state reactions during and after the mechanical activation.
In order to reduce CO2 emissions fossil fuelled power stations with high combustion efficiency are being developed. The increase of the operating temperature, a common way to improve combustion efficiency, leads to enhanced corrosion of heat exchange steel tubes in the power plants. Within the framework of the European project “Production of Coatings for New Efficient and Clean Coal Power Plant Materials” (POEMA)", high temperature corrosion protection coatings are now under investigation.
Thin porous sol-gel alumina films are promising candidate coating materials. Coatings were prepared by applying boehmite sols on grinded steel P92 and subsequent heat treatments at temperatures up to 650 °C. Thus a porous layer of worm-like particles was formed consisting of nano-crystallites and amorphous alumina. A dense interface with satisfying adhesion resulted from diffusion of chromium and iron ions out of the steel into the porous coating. However, the film locally exhibited some cracks caused by steep edges in the grinded steel surface. An appropriate substrate pretreatment should avoid this problem.
The protection of the steel relies on the barrier function of the alumina coating and the formation of a dense chromia layer at the steel surface.
Future coal power plants will in case of oxyfuel combustion be operated with altered atmospheres. Hence, corrosion attack might become more severe and steels have to be protected. An alumina-sol was used to coat X20CrMoV12-1 (X20) with alumina to test the protection. Testing was performed at 600 °C in flowing H2O–CO2–O2 and static laboratory air for 1000 h. Oxidation under air is minor compared to exposure in oxyfuel atmosphere. In both cases a multilayered oxide (hematite, magnetite, spinel) was formed on uncoated steels. Carburization appeared on uncoated X20 in H2O–CO2–O2. The coating demonstrates a high protection.
In Kohlekraftwerken mit Oxyfuel-Technologie erfolgt die Verbrennung unter Zufuhr von reinem Sauerstoff. Damit steht für die Abscheidung und Speicherung von CO2 ein Rauchgas mit hohem CO2-Anteil zur Verfügung (CCS-Technologie). Aufgrund dieses Verbrennungsprozesses ändert sich im Wesentlichen die Rauchgaszusammensetzung hin zu hohem H2O- und SO2 -Anteil. Deshalb wurden in verschiedenen Laboratorien kommerzielle Kraftwerksstähle unter den entsprechenden korrosiven Bedingungen getestet. Im Vergleich zur herkömmlichen Verbrennungsmethode zeigten die ferritisch-martensitischen Stähle schon nach 1000 h Auslagerungszeit unter Oxyfuel-Bedingungen eine durch einen deutlich erhöhten Materialverlust gekennzeichnete Korrosion. Eine Möglichkeit um dennoch die Lebensdauer dieser Stähle zu gewährleisten, besteht im Aufbringen geeigneter Schutzschichten auf die Stahloberfläche. Die vorliegende Arbeit befasst sich mit der Herstellung und Bewertung von Sol-Gel-Aluminiumoxidschichten als Schutz vor Korrosion in Oxyfuel-Rauchgas-Atmosphäre. Diese wurden auf den warmfesten Stahl X20CrMoV12-1 (X20) mittels der Tauchmethode aufgebracht. Anschließend erfolgte eine Auslagerung der beschichteten Proben für 1000 h bei 600 °C in einer H2O-CO2-O2-SO2 -Atmosphäre.
Im Vergleich zum unbeschichteten Stahl X20 war der Materialverlust des beschichteten Stahls deutlich geringer. Insbesondere konnte durch die Aluminiumoxidschicht der Transport von CO2 und SO2 zur Stahloberfläche verhindert werden.
In Kohlekraftwerken mit Oxyfuel-Technologie erfolgt die Verbrennung unter Zufuhr von reinem Sauerstoff. Damit steht für die Abscheidung und Speicherung von CO2 ein Rauchgas mit hohem CO2-Anteil zur Verfügung (CCS-Technologie). Aufgrund dieses Verbrennungsprozesses ändert sich im Wesentlichen die Rauchgaszusammensetzung hin zu hohem H2O- und SO2 -Anteil. Deshalb wurden in verschiedenen Laboratorien kommerzielle Kraftwerksstähle unter den entsprechenden korrosiven Bedingungen getestet. Im Vergleich zur herkömmlichen Verbrennungsmethode zeigten die ferritisch-martensitischen Stähle schon nach 1000 h Auslagerungszeit unter Oxyfuel-Bedingungen eine durch einen deutlich erhöhten Materialverlust gekennzeichnete Korrosion. Eine Möglichkeit um dennoch die Lebensdauer dieser Stähle zu gewährleisten, besteht im Aufbringen geeigneter Schutzschichten auf die Stahloberfläche. Die vorliegende Arbeit befasst sich mit der Herstellung und Bewertung von Sol-Gel-Aluminiumoxidschichten als Schutz vor Korrosion in Oxyfuel-Rauchgas-Atmosphäre. Diese wurden auf den warmfesten Stahl X20CrMoV12-1 (X20) mittels der Tauchmethode aufgebracht. Anschließend erfolgte eine Auslagerung der beschichteten Proben für 1000 h bei 600 °C in einer H2O-CO2-O2-SO2 -Atmosphäre.
Im Vergleich zum unbeschichteten Stahl X20 war der Materialverlust des beschichteten Stahls deutlich geringer. Insbesondere konnte durch die Aluminiumoxidschicht der Transport von CO2 und SO2 zur Stahloberfläche verhindert werden.