1. High Temperature Alloys for Power Plant Applications
ARIPPA Meeting
April 26th, 2005
Jason Wilson
Rolled Alloys

2. Nominal Chemistries Alloy UNS Ni Cr Fe Si Other 304 SS S30400 9 18.370
RA253MA
S30908 11 21 65
1.7
Ce, N
309 SS
S30815 13 23 62
0.8
310 SS
S31008 20 25 52
0.5
RA330®
N08330 35 19 43
1.25
RA353MA
S35315 36
1.2
Alloy 601
N06601
61.5
22.5 14
0.2 Al

3. High Temperature Concerns
Distortion
Creep Deformation
Thermal Expansion
Corrosion
Oxidation
Temperature Limitations
Erosion
Sulfidation
Molten Salts

4. Stress Do not subject alloys to undue stress Uneven Heating
Thermal Expansion
Thermal Shock

5. Uneven Heating Uneven Thermal Expansion Typical Causes
Buckling/Warping
Cracking
Typical Causes
Flame Impingement
Large variation in cross section
Sharp temperature gradients
HOT
COOL
RA 253 MA Burner Can

6. Thermal Expansion At 1800F, a 20 foot RA330 pipe expands over 4 inches
Keys
Major
Allow for expansion in the design
Minor
Higher strength alloy
Lower coefficient of thermal expansion
Alloy 600 (3.75 in)
Railroad on a hot day

7. Coefficient of Thermal Expansion (in/in°F x 10-6)
Alloy
% Nickel
1600oF
304 SS 8
11.0
309 SS 13
10.1
RA253MA 11
10.6
310 SS 20
10.15
800HT 32
10.2
RA330 35
9.8
RA353MA
9.86
Alloy 601 61
9.5

8. Strength Ensure adequate alloy strength at temperature
Review Creep-Rupture data
Short Term Data is not representative of how the alloy will act in long term service.

9. Strength Raising Creep Strength Carbon Nitrogen Nickel Others
Use H grades
Min 0.4% Carbon & Coarse Grains
Nitrogen
RA 253 MA and RA 353 MA
Nickel
Others
Co, Mo, W

10. Strength Creep Demonstration RA 253 MA, 601, 310, 321
0.040” thick rings
Temperature: 1832F
Time: 35 hours

11. Strength Creep occurs above roughly 1000oF
Permanent Deformation or Flow
Time Dependent
Lower Stress than Y.S.

12. 10,000 Hr Average Stress to Rupture
Alloy
UNS Number
1600oF
1800oF
1900oF
2000oF
304 SS
S30400
1,400
309 SS
S30908
1,600
560
RA253MA
S30815
2,500
1,150
860
680
310 SS
S31008
1,500
660
800HT
N08811
3,500
1,300
890
480
RA330
N08330
1,700
630
400
280
RA353MA
S35315
2,600
930
Alloy 601
N06601
1,200
620

13. Strength Incinerator bed 1920oF (Average) Replaced RA330
6 months life
RA 353 MA lasting 8-9 months

14. Strength Horizontal Radiant U-tubes. 6 inch OD and 11ga wall.
Condition after 10 months.
Batch Annealing at 1800°F.
Exothermic Atmosphere.
Operation 5 days/week 3 shifts

15. 253MA Circulating Fluidized Bed
8-1/2 foot diameter x 23 foot long dip tubes.
Two per boiler, eight boilers on site
°F Temperatures
Fuel – 70% Illinois Coal, 30% Powder River Basin, Tire Chips
Dip tubes installed in 1999, Others in since 1998,
- 310 Stainless lasted 2 years prior to removal due to distortion

16. Strength - RA253MA pans for the production of foam glass insulation
Previous alloy used type 309 stainless
Process temperature 1600°F

17. Strength RA 353 MA pack coating retort. 36 in. diameter 48 in. high
3/8 inch thick
°F – Argon on inside
Photo after 24 months in service
RA330 typically distorted 8 months

18. Tube Supports Fired Boilers
RA353MA heavy plate used as a header support.
Replaced RA330

19. High Temperature Corrosion

20. Temperature Limitations
All alloys have their limits.
Limiting Factors
Oxidation
Not melting point
Strength
310SS at 2100F

21. Oxidation Spallation of the protective oxide scale Enhancers Thinning
Internal oxide penetration
Enhancers
Chromium
Silicon
Aluminum
Cerium
Type 310 stainless thermocouple tube oxidized from operation at 2100 deg F

22. Suggested Temperature Limits (Air)
1000
1200
1400
1600
1800
2000
2200
2400
304SS
309SS
310SS
RA 253 MA®
RA330
Alloy 600
RA 353 MA®
Alloy 601
RA333®
RA 602 CA™

23. Oxidation Resistance Cyclical Testing 1600 Hrs

24. Oxidation Resistance Cyclic Testing 3000 Hrs

25. Tube Spacers RA353MA hand cuff bars on a packaged boiler
firing with natural gas.

26. Cyclones Western U.S. Coke Plant
Alloy 353 MA alloy used since 1999
3 installation areas
Average months of service
Still in good condition. Evaluating weld repair of suspension tabs and reuse.
½” thick material
RA353MA shown after 1 year service during inspection °F typical

27. Sulfidation Attack by sulfur compounds Molten Ni-Ni-S eutectic
SO2, H2S
At 1200°F and above
Molten Ni-Ni-S eutectic
Higher nickel alloys most susceptible
Sulfidation of cast heat resistant alloy used for a tire drop chute (Cement)

28. Sulfur/Chlorine AttackoF
Slab Reheat Furnace Recuperator
11 Months Exposure
RA353MA replaced 309 with high silicon
Increased life from 7 months to over 24 months
19Cr-11Ni-2Si

29. Sulfidation

30. Chloride Attack Chloride Attack Thick Porous Scale Rapid Thinning
Intergranular Attack
310 stainless tubeshield from refuse fired boiler.

31. Tube Supports – Escatron (Spain)
Replaced RA253MA
Pressurized Fluid Bed Boiler
6.8% Sulfur Lignite
Earlier Units <3.6% Sulfur
TIDD, Vartan
RA253MA successful
Coupon Testing
11 months °F
RA353MA – 0.1 mm
RA253MA – 1.1 mm

32. Flap Gates Cement Kilns Feeding of Scrap Tires
RA353MA in use in 3 cement plants to date in North & South America

33. 1292oF (700oC)

34. Coal Tips 253MA used extensively for coal nozzles
309 or 310 SS commonly used for the air nozzles
353MA used at some plants for upper elevations of the boiler
353MA used at a Midwestern utility
Specified since 2000
Replaced 253MA

35. Tube Shields RA353MA used in supercritical boilers
Specified at one US Utility for hottest area of superheater
Replaced type 309 stainless
Service life of 6 years

36. Tube Shields – Paper Mill
Fuel
Propane – Start up
Waste Oils
Hog Fuel
Bunker C
S35315 used since 1998
1 year life expectancy

37. Tube Shields S35315 used in CFB boiler
Protect primary superheater tubes
1616 deg F
High S, High Cl coal
Extensive Soot Blowing due to fouling
Replaced 309 SS
Still in service after 28 months.

38. Erosion 63 inch diameter 353MA cyclone Temperatures Refuse fired
1750 to 2192°F
Refuse fired
Initial unit in service for 1 year
Redesigned cyclone made of 353MA

39. Erosion
Pressurized Fluidized
Bed Combustor Cyclone
AEP TIDD Project

40. Erosion
RA253MA Witch’s Hat
Fluid Bed Boiler System

41. Municipal Utility - Wisconsin
Foster Wheeler CFB
Fuel
Petcoke/Paper Pellets
Replaced RA253MA
Transfer Line
Fuel feed chute
Ash Drains
Installed Early 2004
Selected for
Abrasion/Distortion Areas

42. Relative Costs Alloy Relative Cost RA309 1.00 RA 353 MA 2.70 RA 253 MA
1.30
RA601
3.60
RA310
1.35
RA 330
2.20
Ratios based on plate pricing during Spring 2005

43. Summary Distortion Corrosion Allow for Thermal Expansion
Minimize uneven heating
Investigate Higher Strength Alloys
H grades
MA grades
Nickel alloys
Corrosion
Oxidation/Erosion
High Chromium
Ce, Si, Al Additions
Sulfidation
Lower Nickel
Chlorides
Higher Nickel
Moderate Chromium