Materials Route Map and Summary. Wet Calcium FGD Decision Guide A tool for access to Power Plant Air Quality Decisions

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1 Materials Route Map and Summary Wet Calcium FGD Decision Guide A tool for access to Power Plant Air Quality Decisions

2 Areas of corrosion in scrubber systems

3 Considerations for scrubber materials Scrubber inlet Scrubber shell Spray piping Baffles, trays Mist eliminators Recirculating tank Agitator Recycle pump Nozzles Plastic lining is used in china for scrubber shell Ceramic block, FRP, rubber, 276, and 2205 used in Europe and U.S. 276 often used in scrubber inlet due to heat and corrosion Lots of recent crevice corrosion problems

4 Wet limestone scrubber conditions

5 Marsulex materials selections

6 Special Metals solution to 2205 crevice corrosion Crevice corrosion was found in 86 scrubbers in the U.S. with 2205 shells. Special Metals investigated the problem and offered solutions

7 Variety of nickel alloys and stainless for FGD- ATI uct Line Description Products/ATI Company Nickel Alloys Stainless Steel The Flue Gas Desulphurization (FGD) environment often requires resistance to both chlorides and sulfuric acid. flues, damper seals, etc. Nickel alloys are often required. The most commonly used alloys are listed on the right. Resistance to chlorides is a requisite property of alloys used in FGD applications. The level of chlorides will be dependent on many ATI 625 ATI 22 ATI 276 ATI 59 ATI 304L ATI 316L ATI 317L ATI 317LMN ATI 904L AL-6XN

8 S31266 can be an option for scrubber shell- Industeel Many recently-constructed wet FGD systems that used the duplex alloy UNS S32205 or the austenitic grade S31726 and even more alloyed grades have experienced severe corrosion attack over the last few years. These issues were most often related to under-deposit/crevice corrosion. It is recognized that the primary cause of this crevice corrosion was the shift from natural oxidation to the forced air oxidation (FAO) system, which creates a highly-oxidizing environment inside the scrubber. Other parameters such as the presence of manganese oxide are also reported to have a detrimental impact on the crevice corrosion resistance of these stainless steels. The effect of calcium bromide on localized corrosion is arousing considerable interest since this compound is commonly being considered or being added to achieve mercury emission limits set by local regulations in North America. Industeel has conducted an extensive experimental program in order to highlight the influence of all these parameters on the localized corrosion resistance of several stainless steel materials. The results obtained confirm the detrimental impact of FAO. However, no significant influence of manganese oxide has been determined. The super-austenitic materials UNS S31266 is an interesting candidate material for FAO wet FGD systems showing excellent pitting and crevice corrosion resistance even when bromide irons are added. It s crevice corrosion resistance is higher than that of the nickel base material UNS N06625

9 Mill Creek upgrades with Alloys A new generation of Ni-Cr-Mo alloys has recently been introduced. Field performance, laboratory data and cost analysis support the use of these new generation Ni-Cr-Mo alloys in FGD systems. Hastelloy C-2000 alloy, the most recent of these new Ni-Cr-Mo alloys, has been used in various portions of the FGD systems at Louisville Gas & Electric. Hastelloy C-2000 alloy is used as an upgrade for organic coatings, stainless steel, Hastelloy C-276, and titanium grade 7 materials in these FGD systems. Larry VanGansbeke of Louisville Gas & Electric and Larry Paul and Dale Kingseed of Haynes International report that Hastelloy C-2000 alloy is particularly suitable for handling the wide variety of environments that are encountered in FGD systems. The corrosive conditions in FGD systems are a material selection challenge. The corrosivity of each system is a function of coal chemistry, design and operation practices. Each of these factors influences material selection. In all cases, sulfuric acid is the most abundant corrosive agent formed in FGD systems. Chlorides, fluorides and other contaminants can also be present and aggravate corrosion further, especially if these species are allowed to concentrate to high levels in the reaction tank. These corrosive conditions will vary with location within the FGD system and may change with time as well. Other issues that need to be considered when assessing the corrosive conditions are areas where solid deposits might collect on the walls of ductwork, puddling of liquids on the floor of ducts, and hot and cold spots in the scrubber system. Areas that are exposed to repeated wetting and drying are especially vulnerable to corrosion because each cycle tends to concentrate the corrosive materials. The next power point lists these spots and summarizes the corrosive conditions and alloys which have been used

10 LGE upgrade options Component Conditions Materials Inlet Duct Temperatures of F Carbon steel Inlet Duct Wet/Dry Area at the Absorber Inlet Absorber Vessel Spray Nozzles and Piping Mist Eliminators Reheater Tubes Outlet Duct Dampers & Expansion Joint Frames Temperatures of F Alternate wet/dry areas Deposits typical Temperatures of F Controlled ph Chlorides to 100,000 ppm Fluorides to 10,000 ppm Temperatures of F Controlled ph Slurry abrasion on nozzles Droplet impingement Low ph with Cl, F, etc. Temperatures of F Low ph with Cl, F, etc. Temperatures of F Low ph with Cl, F, etc. Temperatures of F Low ph with Cl, F, etc. Condensing acids at cold spots Nickel alloys Titanium alloys Sealed acid brick Stainless steels Nickel alloys Rubber linings Coating systems Ceramics (SiC) Nickel alloys Cobalt alloys Stainless steels Nickel alloys Polymers Carbon steels Stainless steels Nickel alloys Stainless steels Nickel alloys Coating systems Nickel alloys

11 LGE example for China on alloy selection The new generation of Ni-Cr-Mo alloys (C-2000, 59 and 686 alloys) all have improved resistance to sulfuric acid compared to the Ni-Cr-Mo alloys that have been traditionally used in FGD systems (Hastelloy C-276 and C-22 alloys). Higher chromium and molybdenum levels in the alloys also appear to correspond to increasing corrosion resistance to test solutions containing high chloride or high fluoride levels. Other areas that receive particular attention in FGD systems are the welds. Because welds are solidified from a liquid, micro-segregation occurs and the grain size is not well controlled. This causes the welds to be in a non-optimum state for corrosion resistance. For the Ni-Cr-Mo alloys, it is common to weld with matching filler metal, since these alloys are the most corrosion-resistant class of materials in FGD systems. Louisville Gas and Electric has found that oftentimes, when one considers the cost of installation, the life cycle, and the consequences of failure, the highest priced material may yield the lowest product life cycle cost. This is the particular case when considering scrubber wallpaper lining systems where the actual cost of 1/16 in. thick alloy cladding may be only one-third the total system cost for a carbon steel alloy clad duct system (one quarter the cost of an insulated and carbon steel alloy clad duct system). Therefore, if an advanced material such as C-20000, 686 or 59 alloy can yield substantial benefits over lesser alloys, their slight up-front cost premiums are more than offset by their improved service and their lower life cycle cost. Indeed, if the field conditions are so severe that they require an alloy such as Hastelloy C-276, they probably are severe enough to justify a more advanced alloy. The life cycle cost improvements that are possible when using advanced alloys for damper seals can be astronomical. When considering the cost of fabrication and installation, it is conceivable that an extra investment of a fraction of a percent in the overall project cost to purchase the best alloy available could extend the life from 25 percent to 400 percent. Louisville Gas and Electric is in the process of procuring new Hastelloy C-2000 alloy steam reheaters to replace the existing corroded stainless steel elements on the FGD system at Mill Creek 4. The company has also replaced portions of the original titanium and Hastelloy C-276 alloy absorber inlet ducts with Hastelloy C-2000 alloy. Three years ago, the outlet ducts were lined with Hastelloy C-276. Testing continues, using samples of C-2000, 686 and 59 alloys in the scrubber outlet duct to gain additional field experience, should additional lining in the outlet ducts or the stacks be needed.

12 Bromine Corrosion is new problem due to mercury regulations-analysis of LCRA

13 Certainty of Outcome for Calcium WFGD 130+ year Company and empirical data collection 40,000 MW WFGD SEMPLATE experience over 30+ years New or retrofit SEMPLATE experience Scrubbers low-grade alloy life extension retrofit Zero discharge/high chloride tanks/thickeners/silos Process upgrade vessel modifications Results through highly experienced corporate resources Corrosion engineering Civil design and FEA Installation

14 Advantages of SEMPLATE for Calcium WFGD Fire retardant, 1.25 (32mm) thick ceramic barrier Resist chlorides in excess of 75,000ppm Resist wide range of temperature and ph upsets Non-metallic, no pitting corrosion Non-bond dependent, no disbondment Withstands tremendous physical and mechanical abuse

15 Sauereisen is a leading manufacturer of proven, engineered solutions for asset preservation through the use of corrosion resistant materials. By selecting this 3 rd generation manufacturer, you receive an experienced, trustworthy team providing service, application support and peace of mind for the best overall value. World Headquarters: Pittsburgh, PA Fiber-reinforced polymer linings offering chemical protection, abrasion resistance, and low permeability for scrubber ducts and associated tankage.

16 Organic Membrane / Inorganic K 2 SiO 3 Concrete provides dual protection against corrosive, abrasive & temperature environments common to flue gas ducts and stacks. Please contact us regarding your application and specific requirements. (412)

17 Derakane and Hetron epoxy vinyl ester resins, Hetron chlorendic polyester resin, and Aropol isophthalic polyester are used in many pollution control applications Cooling Towers -Aropol isophthalic polyester resins are used in structural profiles and perform better than traditional materials -Hetron FR620T-20M is used in fan shrouds and exterior components where fire retardance is required -FRP is low or no maintenance and not subject to internal deterioration or biological attack like wood Stack Liners When made from Derakane 510C-350 resin or Hetron FR992 resin have superior corrosion resistance and are considerably less expensive than C-276 clad steel Demister Blades When made from Derakane 510C-350 resin, Derakane resin, Hetron FR992 resin and Hetron 197 resin have superior corrosion resistance -FRP blades are lightweight, easy to install, and will not become embrittled like thermoplastic materials Ductwork When made from Derakane 510C-350 resin or Hetron FR992 resin offers superior corrosion resistance -Ducts made from these resinswwithstand temperature excursions up to 315 C (600 F) -FRP ducts lightweight and do not require insulation Scrubbers -Shells and internals made from Derakane resin, Derakane 510C-350 resin, Hetron 922 resin and Hetron FR992 resin have superior corrosion resistance and excellent abrasion resistance. -Scrubbing equipment made from these resins requires less maintenance than acid brick or rubber lining and are much less expensive than C-276 clad steel Slurry tanks and Piping When made from Derakane resin, Derakane 510A-40 resin and Hetron 922 resin offer excellent abrasion resistance -FRP slurry tanks are much lighter than metal, and less expensive than rubber-lined steel Process Water Tanks and Piping -When made from Aropol 7334 polyester resin and Aropol 7241 resin, process water tanks and piping are very economical and can handle process water up to 150 F -Equipment made from Derakane resin and Hetron 922 resin can handle process water up to 180 F

18 Since 2004 Fiber Reinforced Plastic (FRP) has been used in 70+ FRP stack liners, 24+ FRP jet bubbling reactors, and 75+ limestone slurry systems Ashland thermoset resins are use to fabricate industrial FRP equipment and FRP liners Ashland Performance Materials is the largest global producer of Epoxy Vinyl Ester Resins (EVER) and Unsaturated Polyester Resin (UPR) Ashland works with end users, designers, engineers and fabricators to ensure the correct resin is used (based on case histories and ASTM C-581 corrosion data) Ashland provides resin recommendations and suggested corrosion barrier construction in writing upon request Industry papers, case histories and performance data can be supplied upon request FRP equipment can be manufactured in the field at lower cost vs. alloys (right two pictures) FRP composite based on Ashland EVER has the same chemical resistance to acid and better resistance to acid chloride salts than C-276 and is superior to 2205 duplex stainless steel in both cases Ashland resins have been used to repair failed 2205 based scrubbers (bottom pictures) Ashland provides education modules on material selection for pollution control and other industrial applications (request a Lunch & Learn at Contact Kevin Lambrych at or krlambrych@ashland.com for more information

19 Plastic lining for Chinese scrubbers is $ several million per 500 MW unit Lining cost for GGH is $.2/kw Scrubber lining $ 1.2/kw Ductwork lining is $ 0.4/kw, stack is $0.6/kw 19

20 Duromar has new coating systems

21 FGD Coatings Analysis in Chinese Revision Date: 7/21/2014 Tags: FGD, Coating, Regulation, China 烟囱防腐材料公司 一 重庆大众防腐股份有限公司 公司于 1993 年成立以来, 一直定位于工业腐蚀控制, 从 2004 年前的钢结构 地坪防腐施工等普通防腐业务, 逐渐过渡为目前以烟囱防腐为主的工业特殊防腐及石化 钢铁 化工 航天航空等高热 低温 强腐蚀等特殊防腐控制相结合大型特种防腐公司 公司主要资质 国家级高新技术企业 建设部一级防腐保温专业施工资质 ISO18000 职业健康安全管理体系的认证 ISO9001 质量管理体系 ISO14000 环境管理体系 中国工业防腐蚀施工专业委员会副主任委员单位 自有知识产权特殊腐蚀控制国家专利 14 项 专家团队 专家顾问团队涵盖宏观经济 化工工艺 科研战略 新技术 新材料 资本市场 防腐院士 高分子材料理论 环保 企业行为学 电力 化工装置设计等行业共计 20 余人 技术优势 公司拥有工业特殊腐蚀控制材料研发一流团队, 秉承 国际一流工业特殊腐蚀控制资源的探寻者 的行为理念 设计先进 工艺可靠 性能优化 培训到位 监造执法 的工作理念致力于特殊腐蚀材料及工艺的研发 创新性的使用 VP3-2( 厚浆型液体氟橡胶 ) 材料替代聚四氟乙烯薄膜及板材 弹性氟橡胶板材应用于大温度波动的强腐蚀环境

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