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Novel textured surfaces for superior corrosion mitigation in molten carbonate salts for concentrating solar power

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  • Kondaiah, P.
  • Pitchumani, R.

Abstract

Corrosion of metals in contact with molten salts used for thermal energy storage and heat transport at high temperatures is a serious impediment to the development of next-generation concentrating solar thermal systems. Toward addressing this limitation, novel multiscale fractal-textured Ni coatings on a variety of substrate alloys are presented in this study for exceptional corrosion mitigation in molten carbonate salts at a high temperature. Strongly adherent, durable, single-layer, and double-layer multiscale fractal coatings were fabricated using the electrodeposition method. Corrosion performance of the coatings on SS310, SS316, SS347, and In800H was studied in molten carbonate salt (32% Li2CO3+33% Na2CO3+35% K2CO3) at 750 °C. Single-layer coatings are stable up to 300 h immersion, whereas double-layer coatings are stable beyond 750 h. The corrosion rate of double-layer Ni coatings on ferrous alloys was reduced by as much as 60% from that of uncoated surfaces and was about 18% below that of higher cost, high Ni content Ha230. The study represents the first-ever report of corrosion characteristics of alloys in carbonate salts at 750 °C and the first demonstration of a means of dramatically reducing corrosion in carbonate salts at a high temperature. The article is significant in that it provides a viable approach for low-cost structural alloys to be corrosion-resistant to molten carbonate heat transfer fluids and storage media in high-temperature concentrating solar thermal applications. The corrosion-resistant coatings provide opportunities for the use of low-cost, ferritic alloys instead of the expensive nickel-based alloys in practice.

Suggested Citation

  • Kondaiah, P. & Pitchumani, R., 2022. "Novel textured surfaces for superior corrosion mitigation in molten carbonate salts for concentrating solar power," Renewable and Sustainable Energy Reviews, Elsevier, vol. 170(C).
    • Handle: RePEc:eee:rensus:v:170:y:2022:i:c:s1364032122008425
    DOI: 10.1016/j.rser.2022.112961
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    References listed on IDEAS

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    1. Nunes, V.M.B. & Lourenço, M.J.V. & Santos, F.J.V. & Nieto de Castro, C.A., 2019. "Molten alkali carbonates as alternative engineering fluids for high temperature applications," Applied Energy, Elsevier, vol. 242(C), pages 1626-1633.
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    5. Walczak, Magdalena & Pineda, Fabiola & Fernández, Ángel G. & Mata-Torres, Carlos & Escobar, Rodrigo A., 2018. "Materials corrosion for thermal energy storage systems in concentrated solar power plants," Renewable and Sustainable Energy Reviews, Elsevier, vol. 86(C), pages 22-44.
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    1. Kondaiah, P. & Pitchumani, R., 2023. "Progress and opportunities in corrosion mitigation in heat transfer fluids for next-generation concentrating solar power," Renewable Energy, Elsevier, vol. 205(C), pages 956-991.
    2. Kondaiah, P. & Pitchumani, R., 2024. "Electrodeposited nickel coatings for exceptional corrosion mitigation in industrial grade molten chloride salts for concentrating solar power," Renewable and Sustainable Energy Reviews, Elsevier, vol. 189(PB).

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