Oxidation Behaviors of Different Grades of Ferritic Heat Resistant Steels in High-Temperature Steam and Flue Gas Environments

doi:10.1007/s40195-021-01338-7

Abstract

Abstract:

For steam tubes used in thermal power plant, the inner and outer walls were operated in high-temperature steam and flue gas environments respectively. In this study, structure, microstructure and chemical composition of oxide films on inner and outer walls of ex-service low Cr ferritic steel G102 tube and ex-service high Cr ferritic steel T91 tube were analyzed. The oxide film was composed of outer oxide layer, inner oxide layer and internal oxidation zone. The outer oxide layer on the original surface of tube had a porous structure containing Fe oxides formed by diffusion and oxidation of Fe. More specially, the outer oxide layer formed in flue gas environment would mix with coal combustion products during the growth process. The inner oxide layer below the original surface of tube was made of Fe-Cr spinel. The internal oxidation zone was believed to be the precursor stage of inner oxide layer. The formation of internal oxidation zone was due to O diffusing along grain boundaries to form oxide. There were Fe-Cr-Si oxides discontinuously distributed along grain boundaries in the internal oxidation zone of G102, while there were Fe-Cr oxides continuously distributed along grain boundaries in that of T91.

Key words: Ferritic heat resistant steels, High temperature service, Oxide layer, Steam, Flue gas, Oxidation evolution

Xiaogang Li, Qu Liu, Shanlin Li, Yu Zhang, Zhipeng Cai, Kejian Li, Jiluan Pan. Oxidation Behaviors of Different Grades of Ferritic Heat Resistant Steels in High-Temperature Steam and Flue Gas Environments[J]. Acta Metallurgica Sinica (English Letters), 2022, 35(7): 1103-1116.

Figures/Tables 14

Fig. 1 Cross-sectional structures of the oxide scale of G102 after exposure in high-temperature steam: a BSE image; b-f EBSD analysis results, located in the red box in (a). IQ map, IPF + IQ map, phase + IQ map, boundary figure (BF) + IQ map and kernel average misorientation (KAM) + IQ map were revealed by EBSD with 0.5 μm step size

Fig. 2 Chemical compositional analyses of the oxide scale of G102 after exposure in high-temperature steam: a SEM and corresponding EDX mapping images, located in the red box in Fig. 1a; b chemical composition profile across the oxide scale, obtained by EPMA. The space between adjacent EMPA quantitative positions was 6 μm

Fig. 3 Morphology, structure and chemical composition at the oxide layer-matrix interface of G102 after exposure in high-temperature steam: a SEM image; b EPMA of the interested points; c EBSD analysis; d EDX mapping images. The analysis location was in the blue box in Fig. 2a and the step for EBSD was 0.35 μm

Fig. 4 Chemical composition profile across the matrix, internal oxidation zone and inner oxide layer of G102 after exposure in high-temperature steam, obtained by EPMA. The space between adjacent EMPA quantitative positions was 2 μm

Fig. 5 Cross-sectional structures of the oxide scale of T91 after exposure in high-temperature steam: a BSE image; b-f EBSD analysis results, located in the red box in (a). The step for EBSD was 0.4 μm

Fig. 6 Chemical compositional analyses of the oxide scale of T91 after exposure in high-temperature steam: a SEM and corresponding EDX mapping images, located in the blue box in Fig. 5b; b chemical composition profile across the oxide scale, obtained by EPMA. The space between adjacent EMPA quantitative positions was 6 μm

Fig. 7 Morphology, structure and chemical composition at the oxide layer-matrix interface of T91 after exposure in high-temperature steam: a SEM image; b EBSD analysis; c EDX mapping images; d EPMA of the interested points. The analysis location was in the blue box in Fig. 6a and the step for EBSD was 0.15 μm

Fig. 8 Chemical composition profile across the matrix, internal oxidation zone and inner oxide layer of T91 after exposure in high-temperature steam, obtained by EPMA. The space between adjacent EMPA quantitative positions was 2 μm

Fig. 9 Chemical compositional analyses of the oxide scale of G102 after exposure in high-temperature flue gas: a SEM and corresponding EDX mapping images; b chemical composition profile across the oxide scale, obtained by EPMA. The space between adjacent EMPA quantitative positions was 6 μm

Fig. 10 Morphology, structure and chemical composition at the oxide layer-matrix interface of G102 after exposure in high-temperature flue gas: a SEM image; b EPMA of the interested points; c EBSD analysis; d EDX mapping images. The analysis location was in the blue box in Fig. 9a and the step for EBSD was 0.28 μm

Fig. 11 Chemical composition profile across the matrix, internal oxidation zone and inner oxide layer of G102 after exposure in high-temperature flue gas, obtained by EPMA. The space between adjacent EMPA quantitative positions was 2 μm

Fig. 12 SEM and corresponding EDX mapping images of the oxide scale of T91 after exposure in high-temperature flue gas

Fig. 13 Structure and chemical composition at the oxide layer-matrix interface of T91 after exposure in high-temperature flue gas: a-e EBSD analysis results; f EPMA of the interested points. The step for EBSD was 0.15 μm

Table 1 Summary of the oxide characteristics of G102 and T91

Material	Location	Environment	Oxide thickness (μm)
Material	Location	Environment	Oxide layer containing coal combustion products	Outer oxide layer	Inner oxide layer	Internal oxidation zone
G102	Inner wall	Steam	-	143	98	15
G102	Outer wall	flue gas	60	72	58	22
T91	Inner wall	Steam	-	58	54	4
T91	Outer wall	flue gas	50	-	60	15

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