Project No: FC26-07NT43097
Performer: Babcock & Wilcox Power Generation Group, Inc.

Robert Romanosky
Advanced Research Technology Manager
National Energy Technology Laboratory
3610 Collins Ferry Road
P.O. Box 880
Morgantown, WV 26507-0880

Vito Cedro III
Project Manager
National Energy Technology Laboratory
626 Cochrans Mill Road
P.O. Box 10940
Pittsburgh, PA 15236-0940

Steven C. Kung
Principal Investigator
Babcock & Wilcox
20 South Van Buren Avenue
Barberton, OH 44203-3522

Award Date:  08/14/2007
Project Date:  08/31/2014

DOE Share: $2,103,543.00
Performer Share: $525,886.00
Total Award Value: $2,629,429.00

Performer website: Babcock & Wilcox Power Generation Group, Inc. -

Crosscutting Research - Plant Optimization Technologies

Development of Computational Capabilities to Predict the Corrosion Wastage of Boiler Tubes in Advanced Combustion Systems

Project Description

Staged combustion produces reducing/sulfidizing conditions that are particularly corrosive to the lower furnace walls. On the other hand, the conditions at superheaters/reheaters are typically oxidizing. However, due to relatively high metal temperatures, the superheater/reheater tubes tend to suffer from severe coal ash corrosion attack due to alkali metals contained in the ash. The problem will be further intensified when the steam outlet temperatures of advanced combustion systems are to increase significantly. To address these corrosion concerns, Babcock & Wilcox (B&W) intends to develop corrosion models in this program that are capable of predicting lower furnace and superheater/reheater corrosion wastage. Because corrosion attack is thermally activated, the effect of temperature will also be investigated. Ohio State University (OSU) faculty will support B&W's efforts by contributing their technical expertise in the area of high temperature corrosion.

Program Background and Project Benefits

This project will develop computational models to predict corrosion associated with staged combustion techniques used to reduce NOx emissions. This project will aid in the design and maintenance of boilers, especially those operating at elevated temperatures, and will contribute to attainment of DOE targets for increased efficiency and reduced emissions in power plants.


Major accomplishments to date include (1) all eight (8) sample coals were pulverized and delivered to Brigham Young University; (2) all eight (8) coal tests have been completed in the BFR burner: Illinois #6, Powder River Basin (PRB), Indiana #6, Ohio Mahoning #7, Kentucky #11, Pittsburgh #8, Ohio Gatling, and Beulah Zap (ND lignite) coals; (3) ash deposits of all eight (8) coals were obtained from the BFR burner and analyzed for chemical composition, particle size distribution and particle morphology; (4) gas composition sampling and analysis in the BFR reducing and oxidizing zones was completed for all eignt (8) coals burned in the BFR; and (5) laboratory-scale corrosion testing is underway on PRB, Ohio Mahoning #7, Beulah Zap lignite and Illinois #6 coals in conditions simulating the upper furnace (oxidizing zone) and lower furnace (reducing zone) regions of a coal-fired boiler using these coal types.