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Fireside corrosion in coal-fired utility boilers (CORROSION)

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Early fireside corrosion detection

A new sensor that measures fireside corrosion rates has been developed and demonstrated in power plant boilers.

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Corrosion in critical parts of power plants and municipal waste incinerators is an ongoing cause for concern. Maintenance engineers often need to perform major processes to determine whether corrosion will impact maintenance performance. KEMA has developed a simple but effective method for detection of early corrosion. The effects of corrosion on a variety of coated materials were tested, as were the effects of fireside additives for reducing corrosives. The results gave an indication of how the materials tested would perform in coal-firing situations. In order to detect the rate of corrosion, an on-line electrochemical fireside corrosion monitor was developed and demonstrated. The on-line sensor measures the thickness of a metal foil that has been corroded over time by determining the conveyance of heat in the foil. Heat pulses are applied optically and the dispersion of the pulse is measured by pyrometry. The foil is located on top of the KEMCOP (KEMa COrrosion Probe), is made of the same material and can be mounted in power and waste incineration plants. The pyrometry signals can be interpreted using a mathematical model of the heat transfer to the foil. The results show that the thickness of the foil is crucial for determining both accuracy and the lifetime of the sensor. A discrepancy exists in that thinner foil is equal to higher degrees of accuracy but also a shorter lifetime. The advantages of the sensor is that it is easily accessible, can be mounted and dismounted during operation and can also be used as a thermometer. Furthermore, it can give information about corrosion rates and the quality and composition of corrosion products as a result of the firing conditions. All data are stored confidentially in a unique database. The on-line corrosion monitor has already been installed and demonstrated in coal fired power plants. KEMA is looking for partnerships with universities, research organisations and companies involved in fireside corrosion issues.

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