Investigation into high-temperature corrosion in a large-scale municipal waste-to-energy plant

► High-temperature corrosion in the superheater of a large-scale waste-to-energy plant was investigated. ► Nickel-/iron-based alloys and austenitic stainless steel probes were placed in the furnace, some with an aluminide coating. ► Aluminide coatings is a promising technique for minimising superheater corrosion. High-temperature corrosion in the superheater of a large-scale waste-to-energy plant was investigated. A comparison of nickel-/iron-based alloys and austenitic stainless steel probes placed in the furnace demonstrated that temperature and particle deposition greatly influence corrosion. Nickel-based alloys performed better than the other metal alloys, though an aluminide coating further increased their corrosion resistance. Sacrificial baffles provided additional room for deposit accumulation, resulting in vigorous deposit-induced corrosion. Computational modelling (FLUENT code) was used to simulate flow characteristics and heat transfer. This study has shown that the use of aluminide coatings is a promising technique for minimising superheater corrosion in such facilities.