Wear surface studies on coal water slurry nozzles in industrial boilers

In this study, Al2O3/(W,Ti)C ceramic, WC/Co cemented carbide, and 1Cr18Ni9Ti stainless steel were produced to be used as nozzle materials in coal water slurry (CWS) industry boilers. Coal water slurry burning tests with these nozzles were carried out. The wear surface features of the nozzles made from these materials were examined. The results showed that the wear mechanisms of nozzles varied from entry to exit. The material removal of Al2O3/(W,Ti)C ceramic nozzle in CWS atomizing and burning is attributed to a mixed mode damage by brittle fracture, polishing, thermal cracking and chipping. The nozzle entry section appears to be entirely brittle in nature with evidence of large scale-chipping. The centre bore area showed a polishing effect with a very smooth surface. While the exit section exhibits cracking owing to the large thermal shock. Examination of the eroded bore surface of the WC/Co cemented carbide nozzles demonstrated that the wear occurred through preferential removal of the metal binder (Co) followed by pluck-out of the exposed WC grains at the entry zone, while the center and the exit zone showed polishing action. The primary wear mechanisms of 1Cr18Ni9Ti stainless steel nozzle exhibited plastic deformation at the entry zone, and plowing and micro-cutting at the other zones by the eroded particles.