The PRENFLO pressurised entrained-flow gasification process is now clo
se to commercial application. A demonstration plant was operated in Fu
rstenhausen, Germany for more than 10 000 hours and construction of th
e first commercial 300 MWe IGCC plant is nearing completion in Spain.
In this paper we will first provide a brief overview of the PRENFLO pr
ocess and its major components, followed by a discussion of materials
experience in the demonstration plant. Formal materials exposure progr
ams were carried out in cooperation with EPRI and KEMA. Some results h
ave been reported already, therefore we will concentrate here on new r
esults. Overall conclusions on materials usage for the waste heat boil
er section are: Carbon and low alloy steels are not suitable in the te
mperature range of 320-570 degrees C. Most stainless steels have satis
factory performance at evaporator temperatures, 320-450 degrees C. How
ever at the high end of this temperature range stainless steels with a
chromium content greater than 25% are preferred. Alloy 28 showed espe
cially low corrosion rates. At superheater temperatures (>500 degrees
C) most common stainless steels experience accelerated corrosion. Sili
con containing alloys show improved performance in this temperature ra
nge.