Resistance of Nanostructured Environmental Barrier Coatings to the Movement of Molten Salts

Corrosion of components in a recovery boiler is a major problem faced by the pulp and paper industry. The superheater tubes become severely corroded due to the presence of sulfidic gases in the boiler and molten salts which are deposited on the surface of the tubes. As a result, the boiler must be decommissioned for expensive maintenance and repairs. Yttria-stabilized zirconia (YSZ) coatings have been shown to provide corrosion resistance when applied on gas turbines operating at high temperatures. Air plasma-sprayed YSZ environmental barrier coatings on Type 309 stainless steel were exposed to three different corrosive environments: Test A??600?°C, salt vapors, flue gases, 168?h; Test B??600?°C, molten salt, air, 168?h; and Test C??600?°C, molten salt, flue gases, 168?h. Two different types of YSZ coatings??conventional YSZ and nanostructured YSZ??were tested to study their resistance to corrosion and molten salt penetration. The performances of both types of coatings were evaluated, and a comparative study was conducted. It was found that the nanostructured YSZ samples protected the stainless steel substrate better than their conventional counterparts. This superior performance was attributed to the presence of semi-molten nano-agglomerates present in the coating microstructure, which acted as collection points for the penetrating molten salts.