WO2004079034A1 - Ecran resistant a l'usure - Google Patents

Ecran resistant a l'usure Download PDF

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Publication number
WO2004079034A1
WO2004079034A1 PCT/IB2004/000605 IB2004000605W WO2004079034A1 WO 2004079034 A1 WO2004079034 A1 WO 2004079034A1 IB 2004000605 W IB2004000605 W IB 2004000605W WO 2004079034 A1 WO2004079034 A1 WO 2004079034A1
Authority
WO
WIPO (PCT)
Prior art keywords
screen
coating
substrate
wear resistant
resistant coating
Prior art date
Application number
PCT/IB2004/000605
Other languages
English (en)
Inventor
Iain Hall
Original Assignee
Metalspray International L.C.
De Villiers, Christopher, Murray
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Metalspray International L.C., De Villiers, Christopher, Murray filed Critical Metalspray International L.C.
Priority to US10/547,611 priority Critical patent/US20060210721A1/en
Publication of WO2004079034A1 publication Critical patent/WO2004079034A1/fr

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
    • F01N3/0226—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous the structure being fibrous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/10—Filter screens essentially made of metal
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • THIS invention relates to a method of manufacturing a screen used to block the passage of particulate material, and to a screen manufactured by the method.
  • SCR Selective Catalytic Reduction
  • the SCR system comprises two principal components. The first is an ammonia injection system, and the second, situated downstream of the ammonia injection system, is a bank of catalytic material that encourages a reaction between ammonia and nitrous oxide, forming harmless nitrogen gas and water.
  • a practical problem experienced in operating such a system is the presence of fine particulate material or fly-ash which can agglomerate to form larger clumps of material entrained in the flue gas, which can block the honeycomb catalyst structure, decreasing the efficiency of nitrous oxide control.
  • screens can be installed upstream of the SCR assemblies, in order to catch particulates above a certain size that could block the catalyst structures.
  • the fly-ash passing through and impacting upon the screens is erosive, eventually causing failure of the screens.
  • the potentially corrosive nature of the flue gas can increase the rate of the wastage mechanism generated in conjunction with this erosivity. This can cause damage to the SCR components, or at least necessitate maintenance and possibly shut down of the plant. It is an object of the invention to provide a screen suitable for use in the above application and which is resistant to wear.
  • a method of manufacturing a screen used to block the passage of particulate material in a gas flow path comprising:
  • a wear resistant coating to the substrate by thermal spraying, the coating comprising a relatively soft metallic base material and a hard phase in the base material.
  • the material of the substrate may be metallic.
  • the substrate may comprise a steel mesh of woven wire, a perforated plate or alternatively a grid or grate.
  • the geometry of the holes may be rectangular, round or any other polygonal shape.
  • the screen structure of the substrate preferably defines apertures having a size selected to be within a predetermined range after application of the wear resistant coating in the substrate.
  • the apertures may be rectangular, round or polygonal in shape.
  • the screen will typically be a screen used upstream of a Selective Catalytic Reduction (SCR) system in an exhaust conduit of a fossil fuel fired plant, such as a power or heat generating plant, with the range of size of the apertures being selected accordingly.
  • SCR Selective Catalytic Reduction
  • the wear resistant coating may be applied by one of several thermal spraying techniques.
  • agglomerated metal/carbide powders may be applied with an oxygen/fuel thermal spray system.
  • blended metal/carbide materials may be applied with an oxygen/fuel thermal spray system.
  • wear resistant metal alloys with hard phase precipitates in the form of wires may be applied with Arc and Hybrid Arc spray systems or in the form of powders in oxygen/fuel thermal spray systems.
  • powder cored feedstock wires may be applied with either Arc/Hybrid Arc or oxygen/fuel thermal spray systems.
  • thermal spray techniques and materials are exemplary and non-limiting.
  • the wear resistant coating may be applied to at least one side of a generally planar substrate.
  • the coating is applied to the substrate at a predefined angle relative to a plane defined by the substrate, to ensure uniform coating of the substrate with a desired extent of coating of individual elements of the substrate.
  • the coating may be applied by one or a plurality of spray heads.
  • An angle of inclination of the spray head or heads relative to the plane of the screen of between 15 and 45 degrees is generally preferred, with an angle of approximately 30 degrees being used in the preferred embodiment.
  • the coating is applied by a plurality of spray heads arranged in a predetermined relationship, each being inclined relative to the screen and being aimed at a common point on the screen.
  • each spray head was mounted in a spaced apart relationship so as to lie at intervals of 90 degrees on a circle adjacent and parallel to the plane of the screen, with each spray head being inclined at an angle relative to the plane of the screen so that the spray heads were aimed at a common point on the screen.
  • the wear resistant coating may be applied to the opposite side of the screen to allow for increased lateral coverage on the sides of individual elements of the screen.
  • multiple passes of the spray head or heads are made over the screen to attain the coating thickness required.
  • the invention extends to a screen manufactured by the method of the invention.
  • Figure 1 is a schematic side view of a portion of an exhaust gas conduit of a fossil fuel fired power or heat generating plant, showing an SCR emission control system thereof;
  • Figure 2 is a pictorial view of a screen according to the invention, for use in the SCR system of Figure 1 ;
  • Figure 3 is a set of comparative photographs showing the relative wear resistance characteristics of three different screen coating materials compared with untreated screen material
  • Figure 4 is a graph comparing the wear resistance of four different coating materials to that of steel screen material
  • FIGS 5A to C are photographs of sections of screen wire elements coated by the method of the invention.
  • Figure 6 is a comparative photograph, showing a portion of a screen substrate comprising a woven wire mesh treated by the method of the invention (left) with a section of untreated screen material (right);
  • Figure 7 is a similar comparative photograph, showing a portion of a screen substrate comprising a perforated metal plate treated by the method of the invention (left) with a section of untreated screen material (right).
  • Nitrous oxides are emitted by the combustion of fossil fuels as a source of energy for electric power and heating. The same emissions are also produced in the petro-chemical, pulp and paper industries. Nitrous oxide (NOx) emission is regulated under the Clean Air Act of 1990 in the USA, similar legislation in most parts of the Europe, and by other environmental agencies worldwide. As a consequence, emission control technologies are necessarily implemented by these industries. The present invention, although applicable across these industry sectors, inter alia, is described here in the context of fossil fuel fired power and heat generating plants.
  • Nitrous oxides may be controlled by passing the combustion exhaust (flue) gas through Selective Catalytic Reduction (SCR) systems. These are normally situated downstream of heat extraction systems of a boiler, and upstream of air pre-heaters, ash separation and control equipment, as shown schematically in Figure 1. This equipment is comprised of two principle components. The first is an ammonia injection system, and the second, situated downstream of this, is a bank of catalytic material that encourages the reaction between ammonia and nitrous oxides to form harmless nitrogen gas and water,
  • SCR Selective Catalytic Reduction
  • the process takes place in a temperature window between 600 °F and 780 °F. At temperatures above this, the catalytic process continues, but ammonia (NH 3 ) adversely oxidizes to form nitrous oxide (NOx) and water (H 2 O). Below this, the presence of sulphur dioxide and sulphur trioxide (SOx) with ammonia in the flue gas result in the formation of ammonia bisulphate or ammonia hydrogen sulphate. These salts form undesirable deposits in downstream systems. In order for the nitrous oxide reduction mechanism to take place, flue gas needs to come into contact with the catalyst. To facilitate this, a number of restricted, or small diameter gas paths are created with catalytic walls.
  • the flue gas also contains a significant percentage of solid, mostly fine (10 - 300 ⁇ ) post combustion particulate, known as "fly-ash”.
  • This ash can agglomerate to form larger clumps of material entrained in the gas path. These can block the catalyst material either at the surface or deep within the structure. This reduces the total area available for reaction to occur and blocks the gas path. Decreased efficiencies result, and sulphate salts can form from excess ammonia 'slipping' through the bed and reacting with sulphates at lower temperatures downstream.
  • screens or gratings are installed upstream of the SCR assemblies to catch particulate above a certain size that could block the catalyst in the system. Any material passing through the screens would be small enough to pass through the catalyst material. These screens are mounted such that the gas and particulate flow through them, either normally or at some inclination. The fly ash that passes through the screens is erosive and erodes the screen material at elevated temperature and velocity. When screen failure occurs, damage and blockage to SCR components result, requiring extensive maintenance and possible shut down of plant operations should emission levels exceed preset limits.
  • the screen material is provided with a protective coating, extending the time to failure or serviceable life expectancy of the screen.
  • the protection is afforded by the application of a hard, erosion resistant thermal spray coating to the screen material.
  • Thermal spray may be defined as encompassing the activities and related technologies required to identify, develop and implement a process by which finely divided material in a molten (or semi-molten) condition is sprayed onto a substrate to form a coating. Feedstocks used in such a process typically take the form of a powder, wire or rod.
  • Impinging particulate tends to erode the SCR upstream screens preferentially. This erosion mechanism removes material predominantly from the front and the sides of the screen cross-section. A thermal spray coating is therefore applied to these areas to prevent wastage of the screen material. As the coating material contains both hard (e.g. carbides, borides) and soft metallic phases (e.g. Nickel, Chrome), the relative erosion resistance of this coating is an order of magnitude greater than that of the screen material.
  • hard e.g. carbides, borides
  • soft metallic phases e.g. Nickel, Chrome
  • the metal matrix that binds coating hard phases together imparts toughness to the coating that prevents cracking, an inherent failure mechanism of hard, brittle materials.
  • the matrix material also serves to prevent the permeation of corrosive gas species through the coating that would attack the substrate material and cause the coating to disbond and fail.
  • the coating material may be applied with the use of singular or multiple coating systems.
  • the use of multiple systems allows simultaneous coating of the screen around the leading edge. This forms a coating with a mechanically contiguous structure and greatly increases adherence (see Figure 3).
  • the coating process may be conducted on the screens already installed in the SCR unit (in-situ), or in a workshop prior to screen installation.
  • blended metal/carbide materials applied with an oxygen/fuel system comprising
  • Figure 2 shows a planar rectangular screen 10 of the kind in question, comprising steel wire mesh 12 and a supporting peripheral frame 14.
  • the screen 10 is used as a substrate to be sprayed.
  • the solution of coating the screens with an erosion resistant coating was investigated and a proprietary metal/carbide cermet material, UTEx 1-021, was specified.
  • a proprietary metal/carbide cermet material UTEx 1-021
  • Several other coating processes were considered, by testing the behavior of the coatings on wire segments similar to those used to fabricate the screens.
  • the wire elements comprising the screen mesh 12 were 2mm diameter cold drawn, low carbon steel.
  • the accelerated erosion testing in this instance was performed with a 200 ft/s stream of air entraining 12oz of boiler ash erodent at 570 °F.
  • the coating test materials to be placed in the path of the erodent were applied to a representative section of screen material. As a cylinder placed transversely to the erodent path presents a full range of incident angle from 0 to 90 degrees all erosion conditions could be evaluated. Photographs of the erosion of three different coatings are shown in Figure 3. The erosion test results for four coatings are given in Figure 4. A photograph of the samples after testing is also shown in Figure 5.
  • An agglomerated metal carbide/cermet powder material applied by an oxygen-fuel system, the UTEx 1-021 coating performed the best under these conditions and was selected as the preferred material for this application. This material also provided desirable corrosion resistance properties.
  • the screens On arrival at the coating site the screens were subject to initial quality control acceptance criteria to ensure that the surface to be coated was free of defects that could generate poor conditions to good coating deposition.
  • An aluminum oxide grit (grade 24) was employed in an oil and water free grit blasting process to remove any surface oxidation and to provide a suitable profile.
  • the screens were placed in automated coating assemblies in batches and concurrently sprayed with four HVOF (High Velocity Oxygen-Fuel) Excalibur 4000 processes at four different optimized spray angles to provide acceptable coating distribution around the wire. This was required to provide protection from the plant process flow conditions within the previously stated 30 degree installation window. The distribution had to generate protection irrespective of orientation of the screen after installation as the screens were rectangular units and correct orientation could not be guaranteed.
  • HVOF High Velocity Oxygen-Fuel
  • the four spray heads were mounted in a spaced apart relationship in an assembly so as to lie at intervals of 90 degrees on a circle adjacent and parallel to the plane of the screen, with each spray head being inclined at an angle relative to the plane of the screen so that the spray heads were aimed at a common point on the screen.
  • the coating procedure can be repeated on the opposite side of the screen. The main purpose of this would be to increase the lateral coating coverage of the sides of the screen holes.
  • An angle of inclination of the spray heads relative to the plane of the screen from 15 to 45 degrees is generally preferred, with an angle of approximately 30 degrees being used in the present example.
  • Figures 6 and 7 shows sections of coated (left) and uncoated (right) screen material.
  • the screen material in Figure 6 is a woven wire mesh, while that in Figure 7 comprises a perforated metal plate.
  • An in-line production sample of the screen shown in Figure 6 was taken for analysis.
  • a wire section from the screen was analyzed micrograp ically. Analysis of these production samples highlighted the need for critical control of the coating angle to minimize the deleterious effect of increased porosity and inter- particle bonding of the coating.
  • the screen material need not be a woven mesh or perforated plate, as described by way of example above, but could instead be a grid, grate or other screen element.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Coating By Spraying Or Casting (AREA)

Abstract

L'invention concerne un procédé de production d'un écran utilisé pour bloquer le passage de matières particulaires dans le chemin d'un courant de gaz. Un substrat, typiquement constitué d'un filet, d'une grille ou d'une plaque perforée en acier, est enduit par vaporisation thermique de sorte qu'un enduit constitué d'un matériau de base métallique relativement souple et d'une phase dure dans le matériau de base soit appliqué. L'invention décrit plusieurs matières de base pour le processus de vaporisation thermique. De préférence, l'enduit est appliqué par un nombre de têtes de vaporisation inclinées par rapport au plan de l'écran avec un angle compris entre 15 et 45 degrés, de façon à enduire chaque partie de l'écran sur plus de 180 degrés. Les écrans obtenus peuvent être utilisés dans des systèmes d'échappement d'installations alimentées en combustibles fossiles, en amont d'un système de réduction catalytique sélective (SCR).
PCT/IB2004/000605 2003-03-07 2004-03-05 Ecran resistant a l'usure WO2004079034A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US10/547,611 US20060210721A1 (en) 2003-03-07 2004-03-05 Wear resistant screen

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US45249403P 2003-03-07 2003-03-07
US60/452,494 2003-03-07

Publications (1)

Publication Number Publication Date
WO2004079034A1 true WO2004079034A1 (fr) 2004-09-16

Family

ID=32962723

Family Applications (1)

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PCT/IB2004/000605 WO2004079034A1 (fr) 2003-03-07 2004-03-05 Ecran resistant a l'usure

Country Status (2)

Country Link
US (1) US20060210721A1 (fr)
WO (1) WO2004079034A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1690588A1 (fr) * 2005-02-14 2006-08-16 STEAG encotec GmbH Dispositif pour séparer de cendres grossières d'un courant de gaz de fumée

Families Citing this family (6)

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Publication number Priority date Publication date Assignee Title
US7794783B2 (en) * 2005-02-07 2010-09-14 Kennametal Inc. Articles having wear-resistant coatings and process for making the same
US8475573B2 (en) * 2009-08-25 2013-07-02 Babcock & Wilcox Power Generation Group, Inc. System and method for protection of SCR catalyst
US8425850B1 (en) * 2010-12-08 2013-04-23 American Electric Power Company, Inc. Large particle ash mitigation system
US10188983B2 (en) * 2016-12-22 2019-01-29 Integrated Global Services, Inc. Systems and methods for catalyst screens in selective catalytic reduction reactors
DE102018132399A1 (de) * 2018-12-17 2020-06-18 Forschungszentrum Jülich GmbH Gasdiffusionskörper
WO2021112613A1 (fr) * 2019-12-05 2021-06-10 대보마그네틱 주식회사 Tamis à électro-aimants

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US4075376A (en) * 1975-04-11 1978-02-21 Eutectic Corporation Boiler tube coating and method for applying the same
US4555413A (en) * 1984-08-01 1985-11-26 Inco Alloys International, Inc. Process for preparing H2 evolution cathodes
WO1998020181A1 (fr) * 1996-11-06 1998-05-14 Molten Metal Technology, Inc. Procede de projection par plasma de restes ceramiques
EP0961017A2 (fr) * 1998-05-28 1999-12-01 Mitsubishi Heavy Industries, Ltd. Revêtement de protection résistant aux températures élevées
WO2001011094A1 (fr) * 1999-08-10 2001-02-15 Engelhard Corporation Recuperation de metaux precieux
US6254704B1 (en) * 1998-05-28 2001-07-03 Sulzer Metco (Us) Inc. Method for preparing a thermal spray powder of chromium carbide and nickel chromium

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JPS62188769A (ja) * 1986-02-13 1987-08-18 Yoshiki Tsunekawa 複合溶射法による複合材料製造方法
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US4075376A (en) * 1975-04-11 1978-02-21 Eutectic Corporation Boiler tube coating and method for applying the same
US4555413A (en) * 1984-08-01 1985-11-26 Inco Alloys International, Inc. Process for preparing H2 evolution cathodes
WO1998020181A1 (fr) * 1996-11-06 1998-05-14 Molten Metal Technology, Inc. Procede de projection par plasma de restes ceramiques
EP0961017A2 (fr) * 1998-05-28 1999-12-01 Mitsubishi Heavy Industries, Ltd. Revêtement de protection résistant aux températures élevées
US6254704B1 (en) * 1998-05-28 2001-07-03 Sulzer Metco (Us) Inc. Method for preparing a thermal spray powder of chromium carbide and nickel chromium
WO2001011094A1 (fr) * 1999-08-10 2001-02-15 Engelhard Corporation Recuperation de metaux precieux

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Publication number Priority date Publication date Assignee Title
EP1690588A1 (fr) * 2005-02-14 2006-08-16 STEAG encotec GmbH Dispositif pour séparer de cendres grossières d'un courant de gaz de fumée
US7531143B2 (en) 2005-02-14 2009-05-12 Evonik Energy Services Gmbh Arrangement for separating coarse ash out of a flue gas stream
US8062600B2 (en) 2005-02-14 2011-11-22 Evonik Energy Services Gmbh Arrangement for separating coarse ash out of a flue gas stream

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