High-temperature Corrosion-Resistant Alloy for Waste-to-energy Plants: Alloy Designing, Fabrication, and Possible Corrosion-Resistance Mechanism

Terrence Wenga,Willis Gwenzi,Imtiaz Ali Jamro,Wenchao Ma

Heliyon（2024）

Univ Zimbabwe | Leibniz Inst Agrartechn & Biookon e V ATB | Tianjin Engineering Research Centre of Bio Gas/Oil Technology | Key Laboratory of Agro-Forestry Environmental Processes and Ecological Regulation of Hainan Province

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Abstract

This study designed a novel high-temperature corrosion-resistant alloy through thermodynamic equilibrium computations. The strength was determined by the integration of precipitation-strengthening species of nickel boride and tungsten solid solution strengthening, while high-temperature corrosion-resistant property was realized through optimized compositional design. Phase stability was enabled by the presence of a face-centered cubic structure. The alloy was fabricated and its corrosion-resistance performance was experimentally compared with other commercially available nickel- and iron-based alloys under simulated municipal solid waste combustion. The designed alloy with a composition of Ni-5B-6W-28Cr-13Al showed a low corrosion rate of ∼72 % < 13CrMo4-5TS and 1.08 % > Inconel 625. Economic analysis showed that Ni-5B-6W-28Cr-13Al has a cost-effectiveness ratio of 1:1.57 with respect to Inconel 625 and 1:0.09 with respect to 13CrMo4-5TS. Corrosion-resistance mechanism was explored using scanning electron microscopy coupled with energy dispersive spectroscopy, x-ray diffractometer, and DFT computations. The corrosion resistance occurred through the formation of a uniform tungsten-chromium-oxide film which inhibits inward diffusion of corrosive chlorine species. These findings provide insights into the development of alloys for high-temperature technologies.

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Key words

High-temperature corrosion,Thermodynamic equilibrium calculation,Corrosion-resistant alloy,DFT computations,Corrosion-resistant mechanism

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