Practical limitations in improving power generation efficiency: Challenges of boiler materials and the response of heat resistant steel

Zengzhi Wei, Xingyuan Liang, Lei Wang, Zhicheng Yuan and Lijun Wu

Renewable and Sustainable Energy Reviews, 2025, vol. 222, issue C

Abstract: The global transformation of the energy structure imposes increasingly stringent requirements on the efficiency and sustainability of power plants. Among various constraints, the performance of boiler materials has become the most critical factor limiting thermal efficiency. Enhancing steam parameters to achieve higher power output inevitably subjects these materials to extreme service conditions, significantly increasing the risk of severe degradation mechanisms, including overheating, corrosion, wear, fatigue, steam oxidation, and stress corrosion cracking. Enhancing the performance of heat resistant steels remains the most effective strategy to mitigate failure risks in boiler systems operating under increasingly extreme conditions. The central design philosophy focuses on tailoring the chemical composition by strategically balancing elements such as Cr, Ni, Mn, Si, W, Mo, Nb, V, C, B, and N, thereby improving creep rupture strength, corrosion and oxidation resistance, and wear durability to meet the stringent demands of advanced steam parameters. This review provides a comprehensive overview of the failure types and mechanisms encountered by boiler materials under evolving service conditions, and highlights the compositional design philosophy underpinning the enhancement of heat resistant steels, to address current limitations in power generation efficiency.

Keywords: Boiler; Failure mechanisms; Heat resistant steel; Elements; Design philosophy (search for similar items in EconPapers)
Date: 2025
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DOI: 10.1016/j.rser.2025.115973

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