High temperature corrosion of thermally sprayed NiCr and FeCr coatings covered with a KCl–K 2 SO 4 salt mixture

Current boiler tube materials and designs are sensitive to changes in process conditions. The desire to increase efficiency through the increase in process temperature and the use of high-chlorine and alkali containing fuels such as biomass is challenging. The alloying of steel to increase the corrosion resistance leads to a significant increase in cost. Thermally sprayed coatings offer promising, effective, flexible and cost efficient solution to fulfil the material needs for the future. However, some heat exchanger design alterations have to be overcome before global commercialization.