Thermal Spray Coatings On Water-Wall Tubes Of Bagasse-Fired Boilers By Ni-Based Alloys For Enhancing Corrosion Prevention Capacit

Abstract

Bagasse-Fired Boilers Heavily Suffer From High Temperature Corrosion Despite The Importance Of Sustainable Boiler Operation In The Sugar Industries. The Failure And Downtime Of Boilers Is A Big Threat To The Effectiveness Of Steam Power Plants, Juice Process Plants, And Distilleries. Corrosion Related Failures Cost A Huge Percentage In The Yearly Maintenance Cost Involved In Ethiopian Sugar Industries. The Coating Of A Compact And Adherent Ni-Based Alloys By Using Powder Flame Thermal Spray Technique Is A Fail-Safe Approach To Extend The Component?�?S Service Time And, Hence, Increase The Thermal, And Electrical Efficiency Of The Boilers. In This Research, Ni Based Coatings Of Ni20cr, Ni50cr, Ni50al, And Cr3c2-30(Ni20cr) ?�? Sprayed By Using Powder Flame Thermal Spray Coating Has Been Investigated Through Detailed Laboratory Studies In 3.5wt% Nacl And 0.5n H3po4-Naoh Environments. The Pristine And Corroded Carbon Steel Substrate (Sa210-A1) Was Characterized By Om, Sem, Tga, Dta, And While The Coated Samples Were Characterized By Xrd, Eis, And Weight Loss And The Results Were Consistent. The Physical Properties Of The Sample Has Also Been Studied Using Weight Loss, Thickness Loss, Particle Density, And Hardness. The Exposures Were Conducted In A Simulated Boiler Environment At 600 ??C For Up To 120h With And Without Nacl Salt. The Applied Coatings Were Highly Protective In All Environments Due To Formation Of Corresponding Protective Layers Of Cr2o3 And Al2o3 On The Substrate Surface. The Oxide Scale Formed By Powder Flame Thermal Spray Techniques With Ni Based Alloys Coatings Has Lowered The Corrosion Rate Because The Created Oxide Was Continuous, Adh