锅炉受热面高温腐蚀涂层技术研究和应用进展
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摘要
本文综述了电站燃煤锅炉受热面管常见的腐蚀类型,并从新型纳米陶瓷涂层、热喷涂层和堆焊层三大防护涂层技术角度综述了其研究和应用进展。提出了受热面腐蚀防护涂层合理的解决方案是以成本较低的涂层技术为主,例如新型纳米陶瓷涂层或电弧喷涂层;针对局部腐蚀、磨损严重的部件,可采用超音速火焰喷涂技术进行在线施工,或者采购带有堆焊涂层的新品进行替换。本文在综述基础上提出,具有更好防护效果、相对较高生产效率和技术含量的在线自动化电弧堆焊技术及相应的材料技术应该是今后的技术发展方向。
In this paper, the corrosion types frequently encountered in the power plants are introduced. Research and application progresses of three corrosion resistance coatings are reviewed including the new developed nanocomposite ceramic coatings, thermal spray coatings and cladding coatings. It is concluded that the proper solution for heating surface tubes corrosion problem is to apply the lower-price coatings to the major protecting area, such as the new nano-composite ceramic coatings or the arc-spraying coatings, and apply the online high velocity oxygen-fuel(HVOF) spraying coatings or simply replace with new products with welding coatings for the severely corroded or worn parts. The online automatic arc cladding technology with relatively higher production efficiency and higher technological content is considered to be the orientation of technological development.
In this paper, the corrosion types frequently encountered in the power plants are introduced. Research and application progresses of three corrosion resistance coatings are reviewed including the new developed nanocomposite ceramic coatings, thermal spray coatings and cladding coatings. It is concluded that the proper solution for heating surface tubes corrosion problem is to apply the lower-price coatings to the major protecting area, such as the new nano-composite ceramic coatings or the arc-spraying coatings, and apply the online high velocity oxygen-fuel(HVOF) spraying coatings or simply replace with new products with welding coatings for the severely corroded or worn parts. The online automatic arc cladding technology with relatively higher production efficiency and higher technological content is considered to be the orientation of technological development.
引文
[1]叶林,尹嵩,黄科峰,等.热喷涂技术在循环流化床锅炉中的运用与质量控制[J].热喷涂技术,2010,2(1):49-50.
[2]秦明,姜文婷,吴少华.空气分级燃烧炉内壁面硫化物分布的数值模拟[J].动力工程学报,2016,36(2):91-98.
[3]邓中乙,马斌,余永生,等.660MW超超临界锅炉高温腐蚀数值模拟[J].安徽电气工程职业技术学院学报,2012,17(3):71-75.
[4]Yang JG,Zhang QF,Yang Y,et al.The Transformation Mechanism of H2S Beside the Waterwall Under Reducing Condition[J].Advanced Materials Research,2012(512-515):2471-2474.
[5]宋凯,袁鹤,尤坤坤.1000MW机组炉内受热面腐蚀的原因以及治理方案[J].华电技术,2016,38(2):9-10.
[6]刘杰,白宁,潘晴川,等.超临界锅炉末级过热器管外壁腐蚀膜的微观分析[J].失效分析,2014,31(增刊一):125-128.
[7]魏道君.1000 MW锅炉侧墙水冷壁防止高温腐蚀[J].华电技术,2016,38(2):1-5.
[8]张拓,赵现华,詹树新,等.电站锅炉煤灰的高温腐蚀介绍[J].锅炉制造,2014,6:20-24.
[9]段红玲,孟奇.浅谈锅炉水冷壁高温磨损和高温腐蚀的解决措施[J].价值工程,2012,12(077):276-277.
[10]孔祥思,刘猛,桑胜欢.不同过热器金属材料的高温腐蚀特性研究[J].锅炉技术,2014,45(3):47-52.
[11]李灼贤,王准,余春江,生物质锅炉典型过热器金属材料表面钝化膜腐蚀特性研究[J].新能源及工艺,2015,3:34-37.
[12]何玉武,李宇春,张宏亮.T91钢在碱金属氯化物介质中的高温腐蚀行为[J].腐蚀与防护,2015,36(11):1021-1025.
[13]顾雪梅,蔡昌忠.搪瓷管空气预热器的应用[J].发电设备,2003,4:54-57.
[14]侯勇,徐钢,和圣杰,等.电站锅炉空气预热器严重腐蚀的原因[J].腐蚀与防护,2015:36(10):995-999.
[15]曹开玉,于红智,孙启明.薄层保温防腐涂料的研制与应用[J].涂料工业,2007,37(2):36-38.
[16]马壮,孙方红,李智超,等.热化学反应法制备纳米复合陶瓷涂层及性能研究[J].陶瓷学报,2007,28(2):112-116.
[17]穆柏春,张丽娟,谷志刚.化学反应制备陶瓷涂层的研究[J].新技术新工艺,1997,16(6):43-44.
[18]陈健康,屠平亮,周建初.用热化学反应法制备金属陶瓷涂层-涂层技术值得重视的新发展[J].材料工程,1991,(4):17-20.
[19]马壮,黄圣玲,李威,等.固相反应型Si O2基陶瓷涂层耐磨性研究[J].兵器材料科学与工程,2010,33(1):16-20.
[20]华隽石,王进卿,池作和,等.锅炉受热面复合陶瓷涂层抗高温腐蚀性能试验研究[J].电站系统工程,2016,32(1):9-16.
[21]齐佶,王红军,郭晓峰.纳米陶瓷覆层在华电红雁池电厂#4锅炉的应用[J].发电与空调,2015,36(164):16-20.
[22]冉蜀勇,陈涛,汤敏,等.先进复合材料在加热炉及输送管道中的应用研究[J].2014,25(3):25-27.
[23]董世知,闫翠娟,周鹏.热化学反应陶瓷涂层技术研究进展[J].材料热的处理技术,2011,40(22):130-136.
[24]刘志平,范海陆,李辰.电站锅炉沾污结渣的处理方法比较[J].合成材料老化与应用,2015,44(1):122-124.
[25]魏琪,刘旭,李辉,等.抗氧化耐氯腐蚀电弧喷涂铁基粉芯线材[J].中国表面工程,2012,25(2):92-96.
[26]林茂峻.锅炉受热面Ni Cr涂层抗高温热腐蚀机制与性能的研究[J].沈阳工程学院学报(自然科学版),2011,07(3):1603-1673.
[27]王明怡.不同Mo含量Ni Cr Mo系耐蚀合金的制备及特性研究[D],华北电力大学(北京):2011年.
[28]张小辉,毛萍莉,刘正.锅炉受热面3种电弧喷涂层的抗高温腐蚀性能与机理[J].材料保护,2010,43(10):58-60.
[29]王建平,徐连勇,许永泰,等.Fe Cr Al和高镍铬合金涂层的抗高温腐蚀性能研究[J].中国电力,2007,40(4):54-58.
[30]崔崇,胡江,陆冠雄,等.超音速火焰喷涂焰流和粒子流的数值模拟研究[J].2010,2(3):18-23.
[31]叶福兴,崔崇,杨雪,等.Microstructures and properties of submicron structural WC-12Co coatings deposited by HVOF[J].China Welding,2011,20(4):22-27.
[32]V.SENTHILKUM AR,B.THIYAGARAJAN,M.DURAISELVAM,et al.Effect of thermal cycle on NiCr based nanostructured thermal spray coating in boiler tubes[J].Transactions of Nonferrous Metals Society of China,2015,(25):1533-1542.
[33]张展宇,常宇,薛海霞.Ni Cr-Cr3C2超音速火焰喷涂的涂层性能[J].焊接,2004,(12):25-28.
[34]贾永昌.CFB锅炉金属受热面的防磨技术[J].机械工人热加工,2007,5:40-43.
[35]李太江,李巍,刘宇.超音速火焰喷涂Ni Cr金属陶瓷涂层的高温硫腐蚀性能[J].材料保护,2011,11(20):9-12.
[36]李太江,李巍,李勇.超音速火焰喷涂制备Ni Cr金属陶瓷涂层的抗高温硫腐蚀与冲蚀磨损性能[J].中国电机工程学报,2012,32(20):120-125.
[37]李贵智,崔兴国,孙允利.热喷焊在锅炉膜式水冷壁中的应用[J].焊接,2000,11:29-31.
[38]孙焕焕,刘爱国,孟凡玲.堆焊Inconel625合金的锅炉膜式水冷壁组织和性能[J].材料热处理学报,2013,34(S2):96-99.
[2]秦明,姜文婷,吴少华.空气分级燃烧炉内壁面硫化物分布的数值模拟[J].动力工程学报,2016,36(2):91-98.
[3]邓中乙,马斌,余永生,等.660MW超超临界锅炉高温腐蚀数值模拟[J].安徽电气工程职业技术学院学报,2012,17(3):71-75.
[4]Yang JG,Zhang QF,Yang Y,et al.The Transformation Mechanism of H2S Beside the Waterwall Under Reducing Condition[J].Advanced Materials Research,2012(512-515):2471-2474.
[5]宋凯,袁鹤,尤坤坤.1000MW机组炉内受热面腐蚀的原因以及治理方案[J].华电技术,2016,38(2):9-10.
[6]刘杰,白宁,潘晴川,等.超临界锅炉末级过热器管外壁腐蚀膜的微观分析[J].失效分析,2014,31(增刊一):125-128.
[7]魏道君.1000 MW锅炉侧墙水冷壁防止高温腐蚀[J].华电技术,2016,38(2):1-5.
[8]张拓,赵现华,詹树新,等.电站锅炉煤灰的高温腐蚀介绍[J].锅炉制造,2014,6:20-24.
[9]段红玲,孟奇.浅谈锅炉水冷壁高温磨损和高温腐蚀的解决措施[J].价值工程,2012,12(077):276-277.
[10]孔祥思,刘猛,桑胜欢.不同过热器金属材料的高温腐蚀特性研究[J].锅炉技术,2014,45(3):47-52.
[11]李灼贤,王准,余春江,生物质锅炉典型过热器金属材料表面钝化膜腐蚀特性研究[J].新能源及工艺,2015,3:34-37.
[12]何玉武,李宇春,张宏亮.T91钢在碱金属氯化物介质中的高温腐蚀行为[J].腐蚀与防护,2015,36(11):1021-1025.
[13]顾雪梅,蔡昌忠.搪瓷管空气预热器的应用[J].发电设备,2003,4:54-57.
[14]侯勇,徐钢,和圣杰,等.电站锅炉空气预热器严重腐蚀的原因[J].腐蚀与防护,2015:36(10):995-999.
[15]曹开玉,于红智,孙启明.薄层保温防腐涂料的研制与应用[J].涂料工业,2007,37(2):36-38.
[16]马壮,孙方红,李智超,等.热化学反应法制备纳米复合陶瓷涂层及性能研究[J].陶瓷学报,2007,28(2):112-116.
[17]穆柏春,张丽娟,谷志刚.化学反应制备陶瓷涂层的研究[J].新技术新工艺,1997,16(6):43-44.
[18]陈健康,屠平亮,周建初.用热化学反应法制备金属陶瓷涂层-涂层技术值得重视的新发展[J].材料工程,1991,(4):17-20.
[19]马壮,黄圣玲,李威,等.固相反应型Si O2基陶瓷涂层耐磨性研究[J].兵器材料科学与工程,2010,33(1):16-20.
[20]华隽石,王进卿,池作和,等.锅炉受热面复合陶瓷涂层抗高温腐蚀性能试验研究[J].电站系统工程,2016,32(1):9-16.
[21]齐佶,王红军,郭晓峰.纳米陶瓷覆层在华电红雁池电厂#4锅炉的应用[J].发电与空调,2015,36(164):16-20.
[22]冉蜀勇,陈涛,汤敏,等.先进复合材料在加热炉及输送管道中的应用研究[J].2014,25(3):25-27.
[23]董世知,闫翠娟,周鹏.热化学反应陶瓷涂层技术研究进展[J].材料热的处理技术,2011,40(22):130-136.
[24]刘志平,范海陆,李辰.电站锅炉沾污结渣的处理方法比较[J].合成材料老化与应用,2015,44(1):122-124.
[25]魏琪,刘旭,李辉,等.抗氧化耐氯腐蚀电弧喷涂铁基粉芯线材[J].中国表面工程,2012,25(2):92-96.
[26]林茂峻.锅炉受热面Ni Cr涂层抗高温热腐蚀机制与性能的研究[J].沈阳工程学院学报(自然科学版),2011,07(3):1603-1673.
[27]王明怡.不同Mo含量Ni Cr Mo系耐蚀合金的制备及特性研究[D],华北电力大学(北京):2011年.
[28]张小辉,毛萍莉,刘正.锅炉受热面3种电弧喷涂层的抗高温腐蚀性能与机理[J].材料保护,2010,43(10):58-60.
[29]王建平,徐连勇,许永泰,等.Fe Cr Al和高镍铬合金涂层的抗高温腐蚀性能研究[J].中国电力,2007,40(4):54-58.
[30]崔崇,胡江,陆冠雄,等.超音速火焰喷涂焰流和粒子流的数值模拟研究[J].2010,2(3):18-23.
[31]叶福兴,崔崇,杨雪,等.Microstructures and properties of submicron structural WC-12Co coatings deposited by HVOF[J].China Welding,2011,20(4):22-27.
[32]V.SENTHILKUM AR,B.THIYAGARAJAN,M.DURAISELVAM,et al.Effect of thermal cycle on NiCr based nanostructured thermal spray coating in boiler tubes[J].Transactions of Nonferrous Metals Society of China,2015,(25):1533-1542.
[33]张展宇,常宇,薛海霞.Ni Cr-Cr3C2超音速火焰喷涂的涂层性能[J].焊接,2004,(12):25-28.
[34]贾永昌.CFB锅炉金属受热面的防磨技术[J].机械工人热加工,2007,5:40-43.
[35]李太江,李巍,刘宇.超音速火焰喷涂Ni Cr金属陶瓷涂层的高温硫腐蚀性能[J].材料保护,2011,11(20):9-12.
[36]李太江,李巍,李勇.超音速火焰喷涂制备Ni Cr金属陶瓷涂层的抗高温硫腐蚀与冲蚀磨损性能[J].中国电机工程学报,2012,32(20):120-125.
[37]李贵智,崔兴国,孙允利.热喷焊在锅炉膜式水冷壁中的应用[J].焊接,2000,11:29-31.
[38]孙焕焕,刘爱国,孟凡玲.堆焊Inconel625合金的锅炉膜式水冷壁组织和性能[J].材料热处理学报,2013,34(S2):96-99.