Development of nondestructive evaluation methods for hot gas filters

Abstract

Rigid ceramic hot gas candle filters are currently under development for high-temperature hot gas particulate cleanup in advanced coal-based power systems. The ceramic materials for these filters include monolithics (usually non-oxides), oxide and non-oxide fiber-reinforced composites, and recrystallized silicon carbide. A concern of end users in using these types of filters, where over 3000 may be used in a single installation, is the lack of a data base on which to base decisions for reusing, replacing or predicting remaining life during plant shutdowns. One method to improve confidence of usage is to develop nondestructive evaluation (NDE) technology to provide surveillance methods for determination of the extent of damage or of life-limiting characteristics such as thermal fatigue, oxidation, damage from ash bridging such as localized cracking, damage from local burning, and elongation at elevated temperatures. Although in situ NDE methods would be desirable in order to avoid disassembly of the candle filter vessels, the possible presence of filter cakes and/or ash bridging, and the state of current NDE technology prevent this. Thus, off-line NDE methods, if demonstrated to be reliable, fast and cost effective, could be a significant step forward in developing confidence in utilization of rigid ceramic hot gas filters. Recently, NDE methods have been developed which show promise of providing information to build this confidence. Acousto-ultrasound, a totally nondestructive method, together with advanced digital signal processing, has been demonstrated to provide excellent correlation with remaining strength on new, as-produced filters, and for detecting damage in some monolithic filters when removed from service. Thermal imaging, with digital signal processing for determining through-wall thermal diffusivity, has also been demonstrated to correlate with remaining strength in both new (as-received) and in-service filters. Impact acoustic resonance using a scanning laser vibrometer has been demonstrated to allow detection of changes in frequency which may be correlated to remaining strength. These methods have been shown to be applicable to clay-bonded SiC filters, recrystallized SiC filters, CVI–SiC composite filters and oxide composite filters. Other NDE methods under development include: (a) fast, high spatial-resolution X-ray imaging for detecting density variations and dimensional changes; (b) air-coupled ultrasonic methods for determining through-thickness compositional variations; and (c) acoustic emission technology with mechanical loading for detecting localized bulk damage.