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Eingeladener Vortrag
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Corrosive geothermal brines are a major challenge to geothermal power-plants. For cost reasons, plant designers favorize low alloyed steels, e.g., carbon steel, which are susceptible to uniform and localized corrosion when exposed to geothermal brines having acidic and saline properties. To solve such problem, coatings or inhibitors would be a protective solution as an alternative to the use of high alloyed materials.
This study investigated a coating system consisting of polyaniline/silicon dioxide basing on locally available resources. Protection against corrosion of carbon steel is shown by long-term exposure and electrochemical tests of coated carbon steels, performed in an artificial acidic and saline geothermal brine, comparable to real conditions at a site in Indonesia.
Therefore, an integrated coating system is presented for corrosion protection, combining the electro-chemical functionality of polyaniline and the physical advantages of silica.
The screening of coatings shows that the modification by adding individual pigment was not sufficient to protect carbon steel even during a short-term exposure, indicated by the discoloration after only seven days of exposure.
Electrochemical tests indicated that the coating cathodically protects carbon steel or slows down the corrosion reaction.
A long-term exposure test confirmed that the PANI/SiO2 modified coating successfully protects the carbon steel in the Sibayak artificial geothermal water at 150 °C for 6 months.
Colours, nano and surface
(2022)
The basic ideas of colours and pigments are presented. The correlation between nanomaterials and colours are explained. Different methods are presented for investigating nanoparticles and their surface. At the end a case study is presented explaining the importance of coating for the properties of nanoparticles.
Study of Polyaniline/Silicon Dioxide based Coating on Carbon Steel in Artificial Geothermal Brine
(2021)
Geothermal brines are corrosive in nature because of their salt contents and high temperatures. Therefore, they pose a major challenge to geothermal power-plants, which are mostly built of low alloyed steels, e.g., carbon steel. Carbon steel is susceptible to uniform and localized corrosion when exposed to geothermal brines having acidic-saline properties. To overcome this limitation, geothermal power plants should be built by either high alloyed materials or by integrating protection systems on carbon steel, such as coatings and inhibitors. We studied a coating system containing polyaniline/silicon dioxide basing on locally available resources that provides protection against corrosion of carbon steel and enhance the thermal resistance in geothermal environments. Here, exposure and electrochemical tests of coated carbon steels were performed in an artificial geothermal brine. The solution had a pH of 4, with the composition of 1,500 mg/L of chlorides, which is based on the chemical analysis of geothermal brine found in Sibayak, Indonesia. All exposure tests were conducted using autoclaves at 150 °C with a total pressure of 1 MPa, which was performed for up to six months to evaluate the durability of the coating system. Post-experimental analyses were performed by assessing the surface of specimens using optical and electron microscopes. On the other hand, electrochemical tests were performed for seven days at 25 °C and 150 °C to investigate the kinetics of electrochemical reactions by measuring open circuit potential and electrochemical impedance spectra. Experimental results showed the corrosion resistance of PANI/SiO2 composite coatings, where polyaniline and SiO2 play their roles as stabilizers.
Study of Polyaniline/Silicon Dioxide based Coating on Carbon Steel in Artificial Geothermal Brine
(2021)
By using the available resources in Indonesia, such as silicon dioxide and marine coating base, the PANI/SiO2 modified alkyd coating was able to protect carbon steel in a deaerated artificial geothermal water. The screening of coatings shows that the modification by adding individual pigment was not sufficient to protect carbon steel even during a short-term exposure, indicated by the discoloration after only seven days of exposure. Electrochemical tests indicated that there was no significant change in the Ecorr between the coated and uncoated carbon steel at room temperature. At 150 °C, the coated carbon steel has a lower potential than that of carbon steel, indicating that the coating is protecting carbon steel cathodically or slowing down the corrosion reaction. Finally, a long-term exposure test confirmed that the PANI/SiO2 modified coating successfully protects the carbon steel in the Sibayak artificial geothermal water up to 150 °C for 6 months.
The aim of this study is to develop nanometer-thin epoxy-based films on aluminium alloy AA2024-T3 as a model coating system for high resolution corrosion studies. Spin coating was used for the layer-by-layer (LbL) deposition of poly-(ethylenimine) (PEI) and poly([o-cresyl glycidyl ether]-co-formaldehyde) (CNER) bilayers. The film chemistry and the cross-linking process were characterized by means of Fourier-transform infrared spectroscopy (FTIR).
Ellipsometric data confirmed the linear increase of film thickness. The potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) results indicate the improvement of the film barrier properties with increasing film thickness. Mapping of the topography and the volta potential was performed by means of scanning Kelvin probe force microscopy (SKPFM).
The results indicate the presence of a homogeneous film structure, while the intermetallic phases can still be identified below the coating. The SKPFM Analysis confirmed that the model films are suitable for investigation of corrosion processes at the coating/metal interface.
The passive fire protection of steel structures and other load-bearing components will continue to gain importance in future years. In the present contribution, novel intumescent aluminosilicate (geopolymer-bound) composites are proposed as fire-protective coatings on steel. Steel plates coated with these materials were exposed to the standard temperature-time curve as defined in ISO 834 – 1:1999. The coatings partially foamed during curing and expanded further during thermal exposure, demonstrating their intumescent characteristic.Thermogravimetryandoscillatory rheometry determined that the intumescent behavior is attributed to a transition to a viscous state (loss factor > 1) in the temperature range of major water release, differing from conventional geopolymers. XRD and SEM images showed that the coatings had characteristics of ceramic or glass-ceramic foams after fire resistance testing, suggesting superior performance under challenging conditions. The thickness of the coatings influenced their foaming and intumescent behavior and thus the time for the coated steel plates to reach 500 °C. A number of additives were also studied with the best performance obtained from samples containing sodium tetraborate.Acoating of just 6mmwas able to delay the time it takes for a steel substrate to reach 500 °C to more than 30 minutes.
Iron-doped SnO2 coatings were deposited in a 50 kHz DC-pulsed magnetron sputtering discharge. The pulses had a duration of 4 µs in selected gas mixtures from pure argon up to
60% of oxygen at a constant total pressure of 0.2 Pa. A single target of SnO2 with Fe inset was used. The mass spectrometry study detected the gas-related ions Ar+, O2+ and O+, where the last one becomes the dominant positive ion at higher oxygen contents. Atomic oxygen ions had a higher energy as it resulted from the collision-caused dissociation on the target surface. The tin-related species were detected as Sn+ and SnO+. SnO2+ species were not detected. The deposition rate decreased by using gas mixtures with oxygen as well as the corresponding amount of Sn-related species in the plasma. The increase of oxygen also increased significantly the sheet resistance of the films. The XPS study showed that the iron concentration decreased by using additional oxygen. But the O/Sn ratio in the coatings was constant, contrary to the increased FeO/Fe ratio in the films. An additional analysis of the coatings by spectroscopic ellipsometry has shown a dependence of the polarizability and the permittivity on the amount of oxygen used during the deposition. In contrast, the study has found no such dependence for the absorption of the layers.
The environmental concerns about availability of fossil fuels and greenhouse gas effect increase and alternative renewable fuels for power plants are gaining significantly of importance. One of the alternative renewable fuels is biomass but it is a difficult fuel because of its diversity and complexity. It can contain high percentages of K and Cl responsible for corrosion together with sand that have additionally an abrasive effect during combustion. Because of permanently extending the surface reaction due to abrasion the corrosion of the materials increases. In particular in power plants, the superheater tubes are exposed to a corrosive abrasive attack that is one of the main sources of concern. The development of new alloys for multilayer surface, which combines corrosive and abrasive resistance is therefore of high importance. Those new technical approaches must be at the same time cost-effective to be an alternative to conventional materials. This paper presents the principle of experimental methods developed for the investigations of high temperature corrosion combined with abrasion in thermochemical processes with high hydrochloric acid concentrations like during biomass combustion. The aim of the presented investigation methods it to test and develop suitable alloys for coatings for the super heater tubes of biomass power plants. First results of abrasion investigations show improved abrasion resistance compared to the multi-component reference material Alloy 625.
A way to increase the application range and the lifetime of metallic substrates is their protection by coatings. Here the effect of alumina coatings on common steel substrates having different Chromium content is examined. The background of the investigations is to expand the application possibilities of mechanically good steels to higher temperatures and corrosive atmospheres in the framework of the European project POEMA (“Production of Coatings for New Efficient and Clean Coal Power Plant Materials”) which was introduced to identify materials that can withstand the aggressive conditions arising during the oxyfuel process in modern coal power plants. This process is one possibility to reduce the CO2 emission by firing the coal in oxygen and recirculated flue gas.
Substrate materials were P92 (9% Cr), K44X (19% Cr), and HR3C (25% Cr). The alumina coatings were deposited by a sol-gel-process using boehmite, this is relatively simple and offers application possibilities for a wide technical range without special surface preparations. All samples were dried for 30 minutes at 650° C to remove the organic components and to start the crystallization process of the alumina. For P92 and HR3C the following conditions simulated the oxyfuel process: 650°C in wet flue gas for 300h for the steel P92, the same conditions for 2000 hours for the steel HR3C. K44X was tested at 900°C in laboratory air for 500 hours. As well after drying as after testing TEM characterizations were performed, where the interfaces between steel and coating are of special interest to characterize the microstructure, detect failure mechanisms, and identify diffusion and crystallization processes and so to understand the mode of action of the alumina coating.
The TEM samples were prepared by the lift-out-technique using a FIB Quanta 3D and were investigated in a STEM JEM2200FS at 200kV.
After the coating and drying process all steels show chromium oxide layers directly at the steel surface, they vary in thickness and are island shaped in the case of the steel K44X. Chromium depletion arose more or less in the superficial zones of all samples. After the long term tests K44X showed breakaway oxidation while P92 and HR3C presented intact interfaces. This reveals: Beside the positive impact of the coating not only the Chromium content of a substrate is essential for the formation and self-healing of protective chromium oxide layers during the service time of steels. One has to consider the possibility of the steel to allow a continuously Cr diffusion to the interface and so e renewal of the Cr-oxide layer.