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Electrodeposited nickel coatings for exceptional corrosion mitigation in industrial grade molten chloride salts for concentrating solar power

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  • Kondaiah, P.
  • Pitchumani, R.

Abstract

Molten chloride salt eutectics are attractive candidates for use as thermal energy storage media and heat transfer fluids in generation-three concentrating solar thermal power (Gen3 CSP) plants. However, corrosion of alloys in molten chloride salts, especially at high temperatures, is an extremely challenging problem that studies focus on lower temperatures, shorter durations, or analytical grade, and high-purity, salts. To date, there has been no study on corrosion or corrosion mitigation in an industrial-grade salt at a high temperature such as 750 °C. To alleviate this knowledge gap, the study presents new multiscale fractal-textured Ni coatings on various alloy surfaces for effective corrosion mitigation at 750 °C in molten chloride salts. Using the electrodeposition method, durable double-layer textured coatings were formed on stainless steel alloys (SS316, SS310, and SS347) and In800H. The corrosion performance of the coatings is investigated in both analytical-grade purity and, for the first time, practically relevant industrial-grade chloride salts. Ni-coated ferrous alloys showed an exceptionally reduced corrosion rate in the range of 350–480 μm/y in analytical-grade salts, and between 450 and 490 μm/y in purified industrial-grade salts at 750 °C. Ni coatings on ferrous alloys reduced corrosion rates by as much as 70% compared to uncoated surfaces and were comparable to the expensive Ha230 alloy with a high Ni content. By the use of innovative fractal corrosion mitigation coatings, for the first time, low-cost structural alloys are rendered viable for use with industrial-grade chloride salts, which is profoundly beneficial in practical systems.

Suggested Citation

  • 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).
  • Handle: RePEc:eee:rensus:v:189:y:2024:i:pb:s1364032123007062
    DOI: 10.1016/j.rser.2023.113848
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    References listed on IDEAS

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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. Vignarooban, K. & Xu, Xinhai & Wang, K. & Molina, E.E. & Li, P. & Gervasio, D. & Kannan, A.M., 2015. "Vapor pressure and corrosivity of ternary metal-chloride molten-salt based heat transfer fluids for use in concentrating solar power systems," Applied Energy, Elsevier, vol. 159(C), pages 206-213.
    3. Wei, Xiaolan & Song, Ming & Wang, Weilong & Ding, Jing & Yang, Jianping, 2015. "Design and thermal properties of a novel ternary chloride eutectics for high-temperature solar energy storage," Applied Energy, Elsevier, vol. 156(C), pages 306-310.
    4. 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.
    5. Vignarooban, K. & Xu, Xinhai & Arvay, A. & Hsu, K. & Kannan, A.M., 2015. "Heat transfer fluids for concentrating solar power systems – A review," Applied Energy, Elsevier, vol. 146(C), pages 383-396.
    6. 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).
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