www.azz.

com/wsi-europe 1
Weld Overlay
High Temperature Corrosion in Biomass Combustion
World Bioenergy Conference
Hans Bengtsson
2014-06-05
www.azz.com/wsi-europe 2
AZZ at a Glance
AZZ incorporated
HQ: Fort Worth Texas, USA
Employees: 3,400
Locations: 49
Market cap: $ 1,05bn
AZZ is listed on the NYSE (AZZ)
Markets: Refining, Nuclear, Fossil power, Waste to
Energy, Chemical/Industrial processing, Pulp/Paper,
Steel manufacturing processing
Steel manufacturing
WSI
Innovative maintenance through automatic
weld repair solutions
PQR/WPS development (600+ procedures)
Welding plans (1500+) / repair plans
2013: 800 scopes executed in 35 countries
WSI Global Footprint
Galvanizing
Electrical & Industrial
WSI/SMS
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Our capabilities
WSI is a specialized global service company offering innovative maintenance through
Automated Weld Repair Solutions that extend the lifetime and maximize the value of
our customers' assets in the Energy Industry
Qualified QA programs
Requirements/technical review
WPS/PQR
Craft qualification certificates
Testing/inspection procedures and material inspection reports
Non-Nuclear Quality Assurance Programs
NBIC certified R, S, U, U2
EN ISO 3834 3
ASME Section I and VIII, Div. 1 & 2
Ad 2000 Merkblatt HPO, TRD 201
Safety
Automation that allows safety performance
PPE to reduce risk and fatigue
Highly skilled and qualified craft and qualified HSE managers
Human performance-based prevention
Safety equipment and plans
Example quality
Certificate
Ad 2000 Merkblatt
HPO, TRD 201
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Our products
Lakeside UK - Boiler, October 2013
UT Readings Ultrasone Testing
Welding engineers involved
in every step of our work
Shop products - fabrication of front and floor tube panel
using UNIFUSE 625/CS overlay tubes and membrane bar
Field services on site weld overlay
Tie-in finishing after replacement
Field Services
Waterwall overlay, re-overlay
Tie in
Shop fabrication
Panel
Tubes
superheater, evaporator, etc
Inspection and maintenance program:
QA Inspectors
Welding engineer
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Biomass challenges
Biomass as collected/harvested and dried
Semi-processed biomass (pellets, etc)
The ready availability of waste biomass in many countries differs from one to other:
Straw
Differnt wood sources
Harvested product depending
on the area: pine, eucaliptus,
olive, rice, etc
Corrosion on biomass facilities has
turned into a real challenge. Every
plant shows different behaviour:
Operational parameters
Waste composition
Relative new technology
Need to establish a relationship
between: manufacturers, end
user, maintenance providers, R&D
Black liqour or mixed fuel also
containing municipal waste, industrial
waste, animal residues, sewage, etc
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Biomass fuel and boiler
Biomass fuel
Chemical composition: agricultural wastes typically contain more alkali metals and
chlorine than conventional fuels
Fuel characteristic: chips, rejected wood, straw, or fuel characteristic in general may
cause ashes leading to erosion
Fuel procedence: harvested fuel as in pine and eucaliptus brings also sand, leading
to erosion
Corrosion Erosion
Every plant may have a dominant
wear phenomena, depending on
fuel, operational paramenters, etc
Chlorine causing accelerated
corrosion and fouling
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Corrosion problem at waterwall and superheater
1) Chlorine, potassium, sodium and sulfur ashes deposited on pressure boundary
bringing heat steam to higher temperature levels
2) Surrounding corrosive flue gases
3) Operational temperature factors: depending on the temperature:
- Alkali salts molten on tube surface reacting with protective oxides
- Alkali salts forming low melting temp. eutectics with other ash materials
(ex. KCl is more corrosive than NaCl and has a lower melting temperature)
Operational parameter:
Reduction of steam and
metal temperatures
Fuel characteristics:
Reduce chlorine content
by mixing or using
additives
Improve metallurgy on
evaporator and SH tubes,
heat exchangers and hot
gas paths
Metal alloy for corrosion protection has to be commercial available, economically
efficient and easy to apply
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Protection for Waterwall
Welding overlay with alloy 625 ON-SITE
Welding overlay with alloy 625 on shop panels for replacement + on site TIE-IN
Shop panel protection on-site installation + tie-in
On site weld overlay on both
CS or on old 625 is possible
Old fatigued alloy 625 grinded off until smooth
surface, then automatic weld overlay
Panel replacement when tube
thickness is too low.
Replacement panels protected
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Improve metallurgy on pressure parts shop and field both:
Preventive
Currative
sCases from boilers in Sweden
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Showcase- MW Power- Vattenfall- Jordbro plant
MW Power-Vattenfall Jordbro Biomass power station
Alloy 625 panel weld overlay field (~250m) and shop (~80m)
Project execution in September 2012
Main dimensional boiler data - NEW BUILD on-line June 2010
Fuel: waste wood and forest residue
63MWth / 82 bar / +473 C
Boiler efficiency > 90%; Particulate emissions < 15mg/Nm3
NOx-emissions < 70 mg/MJ
Fuel need: 20.5 tons at 100% load
Bottom fly ashes: 1.2 tons/hour
The challenge
First major maintenance, July 2011: significant erosion/corrosion
tube wastage were detected down to 2,0mm
After the outage decision to upgrade CS water panels with 625
Revision 2012, WOL ~250m projected, 9 days inside the boiler
Existing panels with < 4,0mm tube wall thickness replaced
~80m panels provided with 625 shop overlay Bubbling fluidized bed (BFB)
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Scope of work
Field overlay above refractory cutline up to elevation 18,5 m
Replacement of ~80m prior to weld overlay
Target area 9,2 m to 18,1 m: ~250m proj.
Tie-in work
QA/QC work conducted in accordance with
EN 288
EN-ISO 15614-1
TUV Merkblatt 1156
Quality/Control
Thickness on progress
Thickness
Chemistry: PMI
Sealing: copper sulfate
Showcase- MW Power- Vattenfall- Jordbro plant
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Showcase- ENA AB-Enkping-Sweden
Background
Boiler type: Vibrating grate Burmeister & Wein Energy 80 MW.
Steam pressure: 101 bar
Temperature: 540C
Production: District heating and power
Fuel: Bio fuels mainly residues from logging, waste from sawmills and
paper mills
Why Alloy 625 Weld Overlay?
The boiler has been boosted with approximately 10% RT chips since yr 2010.
Because of the lower price of RT-chips compared to other bio fuels, the plant has plans
to change to 100% RT chips. To make sure the tubes in the boiler can cope with the
increased use of RT-chips, improvement of tube metallurgy has to be carried out.
Alloy 625 panel weld overlay in field
2012 July: ~310m
2013 July: ~250m2
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Field weld overlay
Showcase- ENA AB-Enkping-Sweden
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Protection for superheaters
Welding overlay with alloy 625 for straw and waste wood (temp. limited to 400-540C)
Welding overlay with alloy 310 for recovery boilers
Tig wash process for a smooth surface and to improve ductility. Superheater and or evaporator
bundle made with Unifuse 360 tubes welded together + manual tie-in
No porosity, no disbonding due to metallurgical bond to base material
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Weld overlay corrosion
At high temperatures, Cr2O3 protective layer
is attacked / volatilized by molten salts, allowing
chlorine to attack (ex. as in T22)
Weld overlay to protect against salt deposit. WOL
Life depends on temperature:
Corrosion (due to flue gas flow, salt deposits)
Erosion /corrosion
cross section of a worn 625 overlay waterwall sample
0,5 mm
1,5 mm
Alloy 625
CS tube
SEM and EDX on localized corrosion pit on alloy
625 overlay to understand chem. compositions at
different chloride complex phases
30 m
Severe corroded T22 superheater tube in a
biomass boiler burning hog fuel
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SEM and EDX results
The chemical compositions (wt%) at different phases are:
1: 68% Pb, 11% Mo, 6% Cr, 3% Fe, 3% Ni, 4% S, 3% Cl, and trace elements
2: 63% Pb, 9% S, 6% Cl, 7% Cr, 5% Mo, 2% Fe, 3% Ni, 2% Na, and trace elements
3: 31% Cr, 24% Ni, 2% Fe, 27% Pb, 6% Zn, 5% S, 1% Cl, and trace elements
4: 32% Pb, 14% Cr, 8% Ni, 5% Fe, 10% Mo, 7% Zn, 9% Cl, 5% K, 3% Na, 3% S, and trace elements
5: 52% Pb, 11% K, 13% S, 7% Cl, 6% Mo, 4% Na, 4% Cr, 2% Ni, and trace elements
6: 34% Ni, 23% Cr, 3% Fe, 23% Pb, 7% Zn, 6% Mo, 2% Cl, and trace elements
7: 49% Pb, 12% K, 3% Na, 13% S, 7% Cl, 5% Cr, 6% Mo, 3% Ni, and trace elements
8: 30% Cr, 28% Pb, 13% Ni, 11% Zn, 7% Mo, 6% Cl, 2% K, and trace elements
9: 26% Pb, 22% Ni, 16% Cr, 11% Zn, 7% Cl, 5% Mo, 7% Na, 3% Fe, and trace elements
10: 27% Pb, 19% Cr, 14% Ni, 13% Zn, 9% Mo, 5% Cl, 4% Na, 2% K, and trace elements
11: 54% Ni, 24% Cr, 6% Pb, 5% S, 6% Fe, and trace elements
12: 27% Cr, 19% Ni, 19% Pb, 15% Zn, 9% Mo, 5% Cl, 2% K, 2% Fe, and trace elements
The composition of the deposit and corrosion
products can vary significantly from plant to
plant. In this case, heavy metal corrosion deposits
(Zn and/or Pb) suggest that the corrosion mechanism is
fluxing by molten chloride salts
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Words from the CUSTOMERS
"Solid and professional project execution by WSI"
Showcase- MW Power- Vattenfall- Jordbro plant
Vattenfall
Euromaint
ENA Energi
SYSAV
Coor Service Management
E.ON Hndelverket
Ume Energi
Billerud AB
INEOS A/S
FortumHgdalen AB
Renova
Boliden Mineral AB
Halmstad Energi & Milj
Sdra Cell AB
Valmet (Metso) Power AB
Foster Wheeler Oy
BW Vlund
Andritz
Rautaruki Steel Oy
WSI referens project Nordic 2004 up to day
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Future
Inconel 625 limitation:
Metal temperature
Erosion/Abrasion properties
WSI has a R&D development program for alternative alloys
Questions!
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THANK YOU!