Novel Corrosion Sensor for Vision 21 Systems

Advanced sensor technology is identified as a key component for advanced power systems for future energy plants that would have virtually no environmental impact. This project intends to develop a novel high temperature corrosion sensor and subsequent measurement system for advanced power systems. Fireside corrosion is the metal loss caused by chemical reactions on surfaces exposed to the combustion environment. Such corrosion is the leading mechanism for boiler tube failures and has emerged to be a significant concern for current and future energy plants due to the introduction of technologies targeting emissions reduction, efficiency improvement, or fuel/oxidant flexibility. Corrosion damage can lead to catastrophic equipment failure, explosions, and forced outages. Proper management of corrosion requires real-time indication of corrosion rate. However, short-term, on-line corrosion monitoring systems for fireside corrosion remain a technical challenge to date due to the extremely harsh combustion environment. The overall objective of this project is to develop a technology for on-line corrosion monitoring based on a new concept. This objective is to be achieved by a laboratory development of the sensor and instrumentation, testing of the measurement system in a laboratory muffle furnace, and eventually testing the system in a coal-fired furnace. The initial plan for testing at the coal-fired pilot-scale furnace was replaced by testing in a power plant, because the operation condition at the power plant is continuous and more stable. The first two-year effort was completed with the successful development sensor and measurement system, and successful testing in a muffle furnace. Because of the potential high cost in sensor fabrication, a different type of sensor was used and tested in a power plant burning eastern bituminous coals. This report summarize the experiences and results of the first two years of the three-year project, which include laboratory development and testing, and experiences and results of power plant testing