CN109722617B - Preparation method of composite coating used in high-temperature, high-chlorine and high-scouring environment - Google Patents
Preparation method of composite coating used in high-temperature, high-chlorine and high-scouring environment Download PDFInfo
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Abstract
The invention relates to a preparation and use method of a composite coating consisting of zircon powder, titanium dioxide and monazite powder in a high-temperature, high-chlorine and high-scouring environment, wherein the method comprises the following steps: and (3) performing roughening treatment, supersonic flame spraying a bottom layer, electric arc spraying a self-healing intermediate coating, supersonic flame spraying a composite coating and hole sealing treatment on the base layer from bottom to top in sequence. The composite powder coating is prepared by mixing zircon powder, titanium dioxide and monazite powder. The obtained composite coating has good corrosion resistance and erosion resistance in a high-temperature high-chlorine and solid-scouring environment, and is suitable for being used in the high-temperature high-chlorine and high-scouring environment.
Description
Technical Field
The invention belongs to the field of corrosion and protection, and particularly relates to a preparation method of a composite coating used in a high-temperature, high-chlorine and high-scouring environment.
Technical Field
In chemical production, severe corrosion environments are often encountered, such as chlorine corrosion, high-temperature oxygen corrosion, scouring corrosion and the like, and the disclosed patents are respectively applied to protection methods for corrosion in one or more aspects, but few methods can simultaneously solve all the corrosion problems, particularly in high-temperature gas environments with high chlorine content and more solid particles, such as a device for preparing chlorine by catalytic oxidation of HCl and incinerator gas incineration equipment for incinerating high chlorine content. The former is a device for catalytically oxidizing HCl into chlorine gas by using a fluidized catalyst under a high-temperature condition, and the latter is a device for incinerating solid waste or waste liquid with high chlorine content, such as an incinerator for chlorobenzene, PVC and the like, wherein the chlorine content and the oxygen content are high, and the device contains certain catalyst particles, fly ash and the like. The problem of corrosion of such devices is a key factor that limits the long-term stable operation of the devices.
High activity of chlorine makes itCan react with almost all metals under high temperature conditions, and the presence of chlorine increases the partial pressure of oxygen required to form a protective oxide film, so that the oxide film cracks and becomes porous, reducing its effective adhesion and protection. When metal chlorides are contained in the system, corrosion processes of "activation oxidation" also occur, such as 2Cl-+Cr2O3+O2＝2CrO4 2-+Cl2The chloride can dissolve part of the passivation film at high temperature, and can diffuse to the base layer to react with Fe, Ni and the like in the base layer to generate chloride, the generated chloride has a low boiling point, can volatilize to the outer layer at high temperature, and can react to generate oxide at a high oxygen partial pressure, and the generated oxide has poor compactness and can crack and fall off due to stress generated by volume change.
The corrosion environment is similar to the corrosion environment of a power plant boiler, and corrosion protection patents applied to the environment are reported more, for example, CN103060737A discloses a powder core wire containing a nanostructure for a high-temperature oxidation corrosion resistant coating, and CN101418427A discloses a Fe-Mn-Cr-Al arc spraying powder core wire for preventing high-temperature oxidation corrosion; patent CN102134694B discloses a high temperature chlorine corrosion resistant powder core wire and a preparation method of a cladding layer, CN101994076B discloses an iron-based chlorine corrosion resistant electric arc spraying powder core wire which is used for surface protection of a heated metal pipe wall in a waste incineration circulating fluidized bed boiler, CN101914766A discloses a double powder core wire which is used for preparing a high temperature chlorine corrosion resistant cladding layer on the outer surface of the boiler, and CN102994935A discloses a high temperature chlorine corrosion resistant electric arc spraying powder core wire which is used for surface protection of equipment in a high temperature chlorine-containing environment.
Patent CN105924171A discloses a protective sleeve with both oxidation corrosion resistance and thermal shock resistance and a preparation method thereof, which is suitable for high-temperature oxygen atmosphere, but in high-chlorine high-scouring environment, graphite, carbon-containing resin powder and the like in the protective sleeve react to cause large-area corrosion.
Patent CN104164625A discloses a chlorine corrosion resistant heat resistant steel used under high temperature working condition and a using method thereof, the developed heat resistant steel is especially suitable for inner barrel parts (850 ℃ -950 ℃ and Cl-containing element is about 3%) of a cyclone of preheater equipment for cement production, the service life is prolonged, but in higher Cl element and solid scouring atmosphere, a passive film formed by the steel can be continuously damaged, and corrosion can continuously occur.
Patent CN103045982A discloses a special high-chlorine corrosion resistant arc spraying wire for amorphous nanocrystalline, which mainly contains Fe, Cr, Mo, W and B, and is subjected to arc spraying to obtain a surface amorphous alloy structure, wherein the corrosion resistance of the wire is about 1.5 times that of Inconel625, and experiments prove that the corrosion rate of the Inconel625 in a high-temperature scouring oxidation environment is as high as 2mm/a, and the wire can not be used in the above severe environment.
The research shows that the high-temperature chlorine corrosion has repeated characteristics as long as HCl and Cl are contained2And the corrosion is continued all the time due to the continuous supplement of chloride and the like, and the passivation film on the surface under the condition of solid scouring is continuously damaged and peeled off, so that the continuous corrosion is caused. Although a large number of documents report methods for protecting against high-temperature chlorine corrosion, severe corrosion still exists in a high-temperature high-chlorine high-scouring environment, particularly in an incinerator device for preparing chlorine gas by catalytic oxidation of HCl and incinerating waste liquid with high chlorine content, so that normal operation of the device is restricted.
Disclosure of Invention
The invention aims to solve the technical problems and provides a method for preparing a composite coating on the surface of a device in a severe working condition environment with high temperature, high chlorine and high scouring at the same time.
In order to achieve the purpose, the technical scheme of the invention is as follows:
a preparation method of a composite coating used in a high-temperature, high-chlorine and high-scouring environment comprises the following steps: a preparation method of a composite coating used in a high-temperature, high-chlorine and high-scouring environment comprises the following steps: and (3) performing roughening treatment, supersonic flame spraying a bottom layer, electric arc spraying a self-healing intermediate coating, supersonic flame spraying a composite powder coating and hole sealing treatment on the base layer from bottom to top in sequence.
In the invention, the composite powder coating is prepared by mixing zircon powder, titanium dioxide and monazite powder, and the mass fractions of the zircon powder, the titanium dioxide and the monazite powder in the composite powder are respectively 40-65%, 30-55% and 1-15%.
In the invention, raw materials for preparing the composite powder coating are mixed and ground in a ball mill for 10-20 minutes to obtain composite powder; drying the composite powder in an oven at the temperature of 100-150 ℃ to remove moisture, and preparing the uniform composite powder with the granularity of 20-50 mu m.
In the invention, the base layer is one or more of carbon steel, stainless steel and nickel-based alloy.
In the invention, the roughening treatment comprises derusting, degreasing and sand blasting. The sand blasting firstly sprays coarse sand (12-18 meshes) and then sprays the coarse sand (20-22 meshes).
In the invention, the roughened base layer needs to be preheated, and the preheating method is to directly preheat the surface of the substrate layer by using supersonic spray gun flame and simultaneously play roles in blowing soot and evaporating water vapor. The temperature of the base layer is controlled between 50 and 60 ℃ after preheating.
In the invention, the base layer after roughening treatment is sprayed with supersonic flame, the base layer adopts NiAl alloy powder, the pressure of fuel gas propane is 0.30-0.50MPa during supersonic flame spraying, the flow rate of combustion-supporting gas oxygen is 1600-1800SCFH, the powder feeding speed is 50-80g/min, the gun distance is 300-500mm, the spraying times are 1-6 times, and the average thickness of the sprayed NiAl alloy base layer is 20-120 mu m.
In the invention, the self-healing intermediate coating is sprayed on the bottom layer by electric arc, the self-healing intermediate coating adopts yttrium oxide and/or zirconium oxide powder, the gun distance is 400mm during electric arc spraying, the spraying frequency is 1-6 times, and the average thickness of the self-healing intermediate coating after spraying is 0.1-0.2 mu m.
In the invention, the supersonic flame spraying composite powder coating is adopted on the self-healing intermediate coating, the pressure of fuel gas propane is 0.30-0.50MPa, the flow of combustion-supporting gas oxygen is 1600-1800SCFH, the powder feeding speed is 50-80g/min, the gun distance is 300-500mm, the spraying times are 6-10 times, and the average spraying thickness of the composite powder coating is 0.1-0.6 mm.
In the invention, the surface of the composite coating is subjected to hole sealing treatment by using a hole sealing agent, and the hole sealing agent adopts NiCrAlY metal powder.
The method is preferably used for preparing the surface composite coating of the device for preparing chlorine by catalytic oxidation of HCl or incinerating waste liquid with high chlorine content.
The high-temperature high-chlorine high-scouring resistant composite coating prepared by the method is subjected to corrosion and scouring experiments in fluidized bed small-scale test equipment, wherein the atmosphere contains Cl2、HCl、O2The average particle size of NaCl used for scouring the solid is 80 μm, and the scouring speed is 0.2 m/s. The experiment is carried out at 420 ℃, and the composite coating has no obvious change in quality and no peeling phenomenon after 240-hour continuous experimental evaluation. Compared with a contrast hanging piece, the coating disclosed by the invention has excellent corrosion resistance in a high-temperature and high-chlorine scouring chlorine corrosion environment, and can meet the requirement on the corrosion resistance of a coating material.
In the present invention, the pressures are gauge pressures.
The invention has the positive effects that:
(1) the problems of poor corrosion resistance and short service life of common alloy and coating on the surface of the device in a severe working condition environment with high temperature, high chlorine and high scouring are solved, and the composite coating has no obvious change in quality and no peeling phenomenon after 240-hour continuous experimental evaluation;
(2) the preparation process of the composite coating is simple, and the cost calculated according to the service life is low.
Drawings
FIG. 1: example 1 coating before and after experiment morphology (left: before experiment; right: after experiment)
FIG. 2: appearance before and after the Inconel600 experiment of example 1 (left: before experiment; right: after experiment)
FIG. 3: comparative example 1 coating before and after the experiment (left: before the experiment; right: after the experiment)
Detailed Description
The present invention is further illustrated by the following specific examples, which should not be construed as limiting the invention.
The zircon powder, the titanium dioxide and the monazite powder are respectively purchased from Shandong refractory material company, Tetrakistrodon python company and Xiangjiang rare earth company, the yttrium oxide and the zirconium oxide are chemical pure medicines, and the gas adopted in the scouring corrosion experiment is high-purity gas with the purity of more than 99%.
The selected carbon steel, stainless steel, nickel-based alloy and other base materials are all commercially available standard alloy materials, wherein the carbon steel is selected from Q345R, the stainless steel is selected from 316L, and the nickel-based alloy is selected from Inconel600 or Inconel 625.
The corrosion rate measuring method comprises the steps of removing corrosion products and attachments, accurately weighing mass change by using a Mettler balance, measuring the size of a hanging piece by using a vernier caliper, and calculating the surface area.
In the following examples,% by weight, unless otherwise indicated.
Example 1
Respectively weighing zircon powder, titanium dioxide and monazite powder according to the mass fractions of 42%, 54% and 4%, and fully grinding the mixed powder in a ball mill to obtain composite powder with uniform composition. Drying the prepared composite powder in a 120 ℃ oven, wherein the granularity of the prepared composite powder is 20-50 mu m.
And carrying out roughening treatment on the 316L base layer, wherein the roughening treatment comprises derusting, deoiling and sand blasting, and the sand blasting is carried out for firstly spraying coarse sand (12-18 meshes) and then spraying the coarse sand (20-22 meshes). Preheating the coarsened 316L base layer, and directly preheating the surface of the base layer by using a supersonic speed spray gun flame. The temperature of the preheated substrate is controlled to be 50-60 ℃.
The base layer is sprayed with a bottom layer by supersonic flame, the bottom layer adopts NiAl alloy powder, and the parameters of the supersonic flame spraying technology are as follows: the pressure of fuel gas propane is 0.3MPa, the flow of combustion-supporting gas oxygen is 1600SCFH, the powder feeding speed is 50g/min, the gun distance is 300mm, the spraying times are 2 times, and the average spraying thickness of the NiAl alloy layer is 32 μm.
The self-healing intermediate coating is sprayed on the bottom layer by electric arc spraying, the self-healing intermediate coating adopts yttria/zirconia composite powder, and the electric arc spraying parameters are as follows: the gun distance is 300mm, the spraying times are 2 times, and the average spraying thickness of the obtained yttrium oxide/zirconium oxide composite coating is 0.1 mm.
And (3) spraying the composite coating on the intermediate layer by adopting supersonic flame, wherein the pressure of fuel gas propane is 0.3MPa, the flow of combustion-supporting gas oxygen is 1600SCFH, the powder feeding speed is 50g/min, the gun distance is 300mm, the spraying times are 6 times, and the average spraying thickness of the composite powder coating is 0.12 mm. And carrying out hole sealing treatment on the surface of the prepared composite coating by using a hole sealing agent. The hole sealing agent adopts NiCrAlY metal powder, so that the porosity of the coating is further reduced.
The composite coating prepared in this example was subjected to corrosion and erosion experiments in a fluidized bed bench test apparatus in which the atmosphere contained Cl2、HCl、O2The average particle size of NaCl used for scouring the solid is 80 μm, and the scouring speed is 0.2 m/s. The experiment is carried out at 420 ℃, and the composite coating has no obvious change in quality and no peeling phenomenon after 240-hour continuous experimental evaluation. Compared with Inconel600 and Inconel625 coupons, the corrosion rates of the two are as high as 1.8mm/a and 2.0 mm/a. The coating disclosed by the invention has excellent corrosion resistance in a high-temperature and high-chlorine scouring chlorine corrosion environment, and can meet the requirement on the corrosion performance of a coating material. The appearance of the coating before and after the experiment (left: before the experiment and right: after the experiment) is shown in the attached figure 1, and the appearance of the Inconel600 before and after the experiment (left: before the experiment and right: after the experiment) is shown in the attached figure 2.
Example 2
Respectively weighing zircon powder, titanium dioxide and monazite powder according to the mass fractions of 55%, 32% and 13%, and fully grinding the mixed powder in a ball mill to obtain composite powder with uniform composition. Drying the prepared composite powder in an oven at 130 ℃ to obtain the composite powder with the granularity of 20-50 mu m.
And (3) roughening the Inconel600 base layer, wherein the roughening treatment comprises derusting, deoiling and sand blasting, and the sand blasting is carried out for firstly spraying coarse sand (12-18 meshes) and then spraying the coarse sand (20-22 meshes). Preheating the coarsened Inconel600 base layer, and directly preheating the surface of the base layer by using a supersonic speed spray gun flame. The temperature of the preheated substrate is controlled to be 50-60 ℃.
The base layer is sprayed with a bottom layer by supersonic flame, the bottom layer adopts NiAl alloy powder, and the parameters of the supersonic flame spraying technology are as follows: the pressure of fuel gas propane is 0.4MPa, the flow of combustion-supporting gas oxygen is 1700SCFH, the powder feeding speed is 60g/min, the gun distance is 400mm, the spraying times are 3 times, and the average spraying thickness of the NiAl alloy layer is 60 micrometers.
The self-healing intermediate coating is sprayed on the bottom layer by electric arc spraying, the self-healing intermediate coating adopts yttria/zirconia composite powder, and the electric arc spraying parameters are as follows: the gun distance is 350mm, the spraying times are 4 times, and the average spraying thickness of the obtained yttrium oxide/zirconium oxide composite coating is 0.15 mm.
And (3) spraying the composite coating on the intermediate layer by adopting supersonic flame, wherein the pressure of fuel gas propane is 0.4MPa, the flow of combustion-supporting gas oxygen is 1700SCFH, the powder feeding speed is 60g/min, the gun distance is 400mm, the spraying times are 8 times, and the average spraying thickness of the composite powder coating is 0.46 mm. And carrying out hole sealing treatment on the surface of the prepared composite coating by using a hole sealing agent. The hole sealing agent adopts NiCrAlY metal powder, so that the porosity of the coating is further reduced.
The composite coating prepared in this example was subjected to corrosion and erosion experiments in a fluidized bed bench test apparatus in which the atmosphere contained Cl2、HCl、O2The average particle size of NaCl used for scouring the solid is 80 μm, and the scouring speed is 0.2 m/s. The experiment is carried out at 420 ℃, and the composite coating has no obvious change in quality and no peeling phenomenon after 240-hour continuous experimental evaluation. Compared with Inconel600 and Inconel625 coupons, the corrosion rates of the two are as high as 1.8mm/a and 2.0 mm/a. The coating disclosed by the invention has excellent corrosion resistance in a high-temperature and high-chlorine scouring chlorine corrosion environment, and can meet the requirement on the corrosion performance of a coating material.
Example 3
Respectively weighing zircon powder, titanium dioxide and monazite powder according to the mass fractions of 60%, 32% and 8%, and fully grinding the mixed powder in a ball mill to obtain composite powder with uniform composition. Drying the prepared composite powder in an oven at 140 ℃ to obtain the composite powder with the granularity of 20-50 mu m.
And (3) performing roughening treatment on the Q345R base layer, wherein the roughening treatment comprises derusting, deoiling and sand blasting, and the sand blasting is performed by firstly spraying coarse sand (12-18 meshes) and then spraying the coarse sand (20-22 meshes). Preheating the coarsened Q345R base layer, and directly preheating the surface of the base layer by using a supersonic speed spray gun flame. The temperature of the preheated substrate is controlled to be 50-60 ℃.
The base layer is sprayed with a bottom layer by supersonic flame, the bottom layer adopts NiAl alloy powder, and the parameters of the supersonic flame spraying technology are as follows: the pressure of fuel gas propane is 0.5MPa, the flow of combustion-supporting gas oxygen is 1800SCFH, the powder feeding speed is 75g/min, the gun distance is 500mm, the spraying times are 6 times, and the average spraying thickness of the NiAl alloy layer is 110 micrometers.
The self-healing intermediate coating is sprayed on the bottom layer by electric arc spraying, the self-healing intermediate coating adopts yttria/zirconia composite powder, and the electric arc spraying parameters are as follows: the gun distance is 400mm, the spraying times are 3 times, and the average spraying thickness of the obtained yttrium oxide/zirconium oxide composite coating is 0.2 mm.
And (3) spraying the composite coating on the intermediate layer by adopting supersonic flame, wherein the pressure of fuel gas propane is 0.5MPa, the flow of combustion-supporting gas oxygen is 1800SCFH, the powder feeding speed is 75g/min, the gun distance is 500mm, the spraying times are 10 times, and the average spraying thickness of the composite powder coating is 0.55 mm. And carrying out hole sealing treatment on the surface of the prepared composite coating by using a hole sealing agent. The hole sealing agent adopts NiCrAlY metal powder, so that the porosity of the coating is further reduced.
The composite coating prepared in this example was subjected to corrosion and erosion experiments in a fluidized bed bench test apparatus in which the atmosphere contained Cl2、HCl、O2The average particle size of NaCl used for scouring the solid is 80 μm, and the scouring speed is 0.2 m/s. The experiment is carried out at 420 ℃, and the composite coating has no obvious change in quality and no peeling phenomenon after 240-hour continuous experimental evaluation. Compared with Inconel600 and Inconel625 coupons, the corrosion rates of the two are as high as 1.8mm/a and 2.0 mm/a. The coating disclosed by the invention has excellent corrosion resistance in a high-temperature, high-chlorine and high-scour corrosion environment, and can meet the requirement on the corrosion performance of a coating material.
Comparative example 1
The method disclosed by patent CN102586714A is used for spraying on the surface of the nickel-based alloy Inconel600 to prepare the coating, and the method mainly comprises the following steps: cleaning and roughening the metal surface; within 3-4 hours after sand blasting, carrying out electric arc spraying and priming by adopting high-nickel alloy wires; spraying nickel-chromium-molybdenum alloy wire material by adopting a supersonic electric arc spraying technology to manufacture a coating; and sealing the hole on the surface of the coating by using an organic silicon sealant. The sample produced is shown in the left panel of FIG. 3.
The sample was subjected to corrosion and erosion experiments in a fluidized bed pilot plant in which the atmosphere contained Cl2、HCl、O2The average particle size of NaCl used for scouring the solid is 80 μm, and the scouring speed is 0.2 m/s. The experiment is carried out at 420 ℃, and after 240-hour continuous experiment evaluation, the coating on the surface of the hanging piece is seriously corroded and peeled off, and a part of the area is exposed out of the base material. As shown in the right diagram of FIG. 3, the method is not suitable for high-temperature, high-chlorine and high-scouring environments.
Claims (10)
1. A preparation method of a composite coating used in a high-temperature, high-chlorine and high-scouring environment comprises the following steps: carrying out roughening treatment, supersonic flame spraying a bottom layer, electric arc spraying a self-healing intermediate coating, supersonic flame spraying a composite powder coating and hole sealing treatment on the base layer from bottom to top in sequence;
the composite powder coating is prepared by mixing zircon powder, titanium dioxide and monazite powder, wherein the mass fractions of the zircon powder, the titanium dioxide and the monazite powder in the composite powder are respectively 40-65%, 30-55% and 1-15%.
2. The method according to claim 1, wherein the raw materials for preparing the composite powder coating are mixed and ground in a ball mill for 10-20 minutes to obtain a composite powder; drying the composite powder in an oven at the temperature of 100-150 ℃ to remove moisture, and preparing the uniform composite powder with the granularity of 20-50 mu m.
3. The method of claim 1 or 2, wherein the base layer is one or more of carbon steel, stainless steel, and a nickel-based alloy.
4. The method of claim 1, wherein the roughening treatment comprises rust removal, oil removal, and sand blasting.
5. The method as claimed in claim 1, wherein the base layer is formed by spraying supersonic flame on the roughened base layer, the base layer is formed by NiAl alloy powder, the pressure of propane fuel gas is 0.30-0.50MPa during supersonic flame spraying, the flow rate of oxygen combustion-supporting gas is 1600-1800SCFH, the powder feeding speed is 50-80g/min, the gun distance is 300-500mm, the spraying times are 1-6 times, and the average thickness of the sprayed NiAl alloy base layer is 20-120 μm.
6. The method according to claim 1, wherein the self-healing intermediate coating is sprayed on the primer layer by arc spraying, the self-healing intermediate coating is formed by yttrium oxide and/or zirconium oxide powder, the spraying is performed 1 to 6 times, and the self-healing intermediate coating has an average thickness of 0.1 to 0.2 μm after spraying.
7. The method as claimed in claim 1, wherein the self-healing intermediate coating is coated with a composite powder coating by supersonic flame spraying, the pressure of propane as fuel gas is 0.30-0.50MPa during supersonic flame spraying, the flow rate of oxygen as combustion-supporting gas is 1600-.
8. The method of claim 1, wherein the composite coating surface is sealed with a sealing agent comprising NiCrAlY metal powder.
9. Use of the method according to any one of claims 1 to 8 for the preparation of composite coatings on the surfaces of devices in a high-temperature, high-chlorine and high-scouring environment.
10. The use according to claim 9, wherein the method is used for preparing a composite coating on the surface of a device for preparing chlorine gas by catalytic oxidation of HCl or a composite coating on the surface of an incinerator device for incinerating waste liquid with high content of chlorine elements.
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| FR2795748B1 (en) * | 1999-07-02 | 2002-03-01 | Electricite De France | IMPROVED SURFACE COATING COMPOSITION |
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| CN101575693B (en) * | 2009-06-18 | 2010-09-08 | 河南理工大学 | Method for spraying and preparing high temperature sulfidation resistant alloy layer on the surface of cast iron |
| CN102586714A (en) * | 2012-03-22 | 2012-07-18 | 江西恒大高新技术股份有限公司 | Electric arc spraying process of chloride corrosion preventing alloy coating of garbage incinerator heating surface |
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