Erosion-corrosion modelling of gas turbine materials for coal-fired combined cycle power generation

Abstract

The development of coal-fired combined cycle power generation systems is receiving considerable worldwide interest. The successful development and commercialisation of these new systems require that all the component parts are manufactured from appropriate materials and that these materials give predictable in-service performance. Corrosion and erosion-corrosion, resulting from coal derived particulates, deposition and gaseous species, have been identified as potential life limiting factors for these systems. Models to predict these modes of materials degradation are under active development. This paper outlines the development and testing of models suitable for use in gas turbine environments. The complexity of the corrosion processes means that an empirical approach to model development is required whereas a more mechanistic approach can be applied to erosion processes. For hot corrosion conditions, statistically based corrosion models have been produced using laboratory tests for two coatings and a base alloy at typical type I and type II hot corrosion temperatures (900 and 700°C). These models use the parameters of alkali sulphate deposition flux and SO x partial pressure (at each temperature and for set HCl partial pressures), to predict the rate of the most likely localised damage associated with hot corrosion reactions. For erosion-corrosion modelling, a series of laboratory tests have been carried out to investigate erosion behaviour in corrosive conditions appropriate to coal-fired gas turbines. Materials performance data have been obtained from samples located in the hot gas path of the Grimethorpe PFBC pilot plant, under well characterised conditions, for testing the corrosion and erosion-corrosion models. The models successfully predict the materials damage observed in the pilot plant environments.