Evaluation of Flow Accelerated Corrosion in Typical Recovery Boiler Environments of Energy Production Industries

Flow accelerated corrosion (FAC) is a steel degradation that occurs in heat recovery steam generators in the power industry. The mechanism of this corrosion comprises an electrochemical dissolution of the semi-protective magnetite layer (Fe3O4) that is formed within the pipes employed in the boilers. The FAC is influenced by different factors such as fluid velocity, pH and dissolved oxygen concentration. In this context, Rotating Cage tests were used to evaluate the influence of pH and dissolved oxygen content on FAC of A210, P11 and P22 steels. General corrosion was lower for P11 and P22 steels, an effect consistent with the presence of chromium in their compositions. General corrosion was most critical at pH 8.5. The corrosion intensity decreased for the three steels when the dissolved oxygen concentration increased, at 2 m/s. This behavior is coherent considering the most effective precipitation of Fe2O3 inside the pores of the Fe3O4 layer in a more oxidizing environment. For 3 m/s, the corrosion intensity increased for both materials when oxygen increased, showing the shear stress effect. These behaviors were more significant at pH 8.5. About pitting corrosion, the analyzes show localized attack in the majority of coupons, however with very low number of pits.