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<p>This study examines repeated failures in a 33-year-old waste heat recovery boiler made of ASTM A204-Grade A steel. Cracks and NOx leakage reoccurred 3.2&#xa0;years after repairs, with inspections revealing branched intergranular cracks near weld seams due to prolonged high-temperature exposure. Microstructural analysis identified spheroidized carbides, pearlite disintegration, and creep cavity formation, weakening the material. Elevated internal surface temperatures calculated using the Larson–Miller parameter (<i>P</i><sub>LM</sub>) and heat retention from oxide scale buildup accelerated degradation. The findings underscore the need for strict design adherence, effective thermal management, and regular inspections to maintain WHRB integrity and prevent future failures.</p>

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Failure Analysis of Waste Heat Recovery Boiler in a Nitric Acid Production Facility

  • 期刊论文

  • 发表日期：

    2025年6月8日

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  • K. M. Deen,
  • U. H. Shah,
  • A. R. Chopra,
  • Akbar Niaz

摘要

This study examines repeated failures in a 33-year-old waste heat recovery boiler made of ASTM A204-Grade A steel. Cracks and NOx leakage reoccurred 3.2 years after repairs, with inspections revealing branched intergranular cracks near weld seams due to prolonged high-temperature exposure. Microstructural analysis identified spheroidized carbides, pearlite disintegration, and creep cavity formation, weakening the material. Elevated internal surface temperatures calculated using the Larson–Miller parameter (PLM) and heat retention from oxide scale buildup accelerated degradation. The findings underscore the need for strict design adherence, effective thermal management, and regular inspections to maintain WHRB integrity and prevent future failures.