Corrosion is a fact of nature – and an expensive one. We, Mission Energy Foundation, a not-for-profit authority in the energy space estimate that India loses around $70 billion or equivalent to 4 per cent of its gross domestic product (GDP) to corrosion.

Coal is a complex and relatively dirty fuel that contains varying amounts of sulfur and a substantial fraction of non-combustible mineral constituents, commonly called ash. Corrosion of metallic and ceramic structural materials is a potential problem at elevated temperatures in the presence of complex gas environments and coal derived solid/liquid deposits. Hot corrosion and erosion are recognized as serious problems in coal based power generation plants in India. The coal used in Indian power stations has large amounts of ash (about 35 - 50%) which contain abrasive mineral species such as hard quartz (up to 15%) which increase the erosion propensity of coal. Hot corrosion and erosion in boilers and related components are responsible for huge losses, both direct and indirect, in power generation. An understanding of these problems and thus to develop suitable protective system is essential for maximizing the utilization of such components.

A number of factors have renewed interest in both low- and high temperature corrosion in power generation equipment including traditional coal-fired boilers, gas-fired boilers, natural gas-fired combined-cycle plants, heat recovery steam generators, geothermal plants, environmental control systems, water treatment systems, aging transmission and distribution infrastructure, and new novel power cycles.

The two day workshop “Water Chemistry” is intended to promote a robust exchange of information on the latest research between engineers and scientists on an international scale. Learning and practical experiences shall be shared during the two extensive days of this certified workshop.

GENERATORS - Maintain low humidity levels of 35 percent or lower using a closed-loop system.

PIPES - Install insulation with a jacket or protective coating, replace pipes with more resistant materials or improve the piping design so it has better flow geometries.

WATER CHEMISTRY CHANGES - When chemicals or organic agents in the water (e.g., anaerobic bacteria) lead to corrosion, a water-conditioning agent may be helpful. Replacing steel components with composite lines may also be effective, particularly in nuclear plants.

TURBINES - Seal openings as tightly as possible.

CONTROLLING WATER & STEAM - Use drains or vacuums to prevent water pooling. Dehumidifiers are good for air that passes through a turbine, drying pockets of water and reducing relative humidity (rH) levels. Oil-fired boilers: Use an open system and a dehumidifier to dry the air to 20 percent rH after shutting down a boiler.

PROTECTIVE COATING - Use protective coatings on components exposed to water, the outside environment, or in areas that may experience condensation or moisture. Protective coatings or surfaces are also helpful for preventing erosion-related wear.

COOLING STACKS - Install a windshield or protective liner to prevent chemical attacks and thermal shock.

INSPECTIONS - Regularly inspect and test components that are at risk for corrosion, even if they have protective surfaces. Such components include turbines, ducts, pipes, welded areas, areas with demineralise water and scrubber modules.