Energy Materials 2017 (eBook)

The Minerals, Metals & Materials Society (TMS) is a member-driven international professional society dedicated to fostering the exchange of learning and ideas across the entire range of materials science and engineering, from minerals processing and primary metals production, to basic research and the advanced applications of materials. Included among its nearly 13,000 professional and student members are metallurgical and materials engineers, scientists, researchers, educators, and administrators from more than 70 countries on six continents. 

Preface 5
Contents 7
About the Editors 12
Energy and Environmental Issues in Materials Manufacturing and Processing: Opportunities in the Steel Industry 22
1 Waste Energy Recovery Technology of Iron and Steel Industry in China 23
Abstract 23
Introduction 23
Waste Energy Recovery Technologies 25
Coke Dry Quenching (CDQ) 25
Blast Furnace Top Gas Recovery Turbine Unit (TRT) 26
Power Generation from Sintering Waste Heat 27
Steelmaking Process Waste Heat Recovery 28
Combined Cycle Power Plant (CCPP) 29
Brief Summary 30
The Advanced Waste Heat Recovery Technology 30
Vertical Tank Cooling System 30
Blast Furnace Slag Quenching Water Waste Heat Recovery 32
Conclusions 33
References 34
2 Green Manufacturing Process of Shougang Jingtang Steel Plant 36
Abstract 36
Introduction 37
Process Flow Design and Structure Optimization 37
Analysis of Iron and Steel Manufacturing Process 37
Physical Essential and Feature of Iron and Steel Manufacturing Process 37
Characteristic Element of Dynamic Operation of Iron and Steel Manufacturing Process 38
Operation Characteristics of Iron and Steel Manufacturing Process 38
Optimization of Elements 39
Optimized Structure 40
Function Expansion and Efficiency Optimization 41
Establishment and Optimization of Flow Network 42
Establishment of Flow Network 42
Energy Flow Network of Iron and Steel Manufacturing Process 43
Development and Application of Interface Technology 44
Operation Practice 44
Conclusion 47
References 48
3 The Introduction and Process Optimization Research of Oxygen Blast Furnace Ironmaking Technology 49
Abstract 49
Introduction 50
The Necessity and Characteristics of the OBF Ironmaking Process 50
OBF Process Research 52
OBF Process Optimization Research 52
Different Process Characteristics 52
The Establishment of Energy-Mass Balance Mathematical Model of OBF 53
The Calculation Results About Carbon Saving Ability of Different OBF Process 53
The Optimization and Calculation Research of FOBF Process 54
The Improvement OBF Process 54
The Calculation Results of the Improved FOBF Process Under Different Oxygen Enrichment Rate Condition 55
Conclusion 56
Acknowledgements 56
References 56
4 Prediction and Optimal Scheduling of Byproduct Gases in Steel Mill: Trends and Challenges 58
Abstract 58
Introduction 58
The Byproduct Gas Prediction and Scheduling System 59
Byproduct Gas System in Steel Plant 59
Byproduct Gas Prediction and Scheduling System 60
Progresses and Emerging Trends in Byproduct Gas Prediction 61
Progresses and Emerging Trends in Byproduct Gas Scheduling 63
Summary and Conclusions 65
Acknowledgements 66
References 66
5 Processing Non-oriented Electrical Steels Using Inclined/Skew Rolling Schemes 68
Abstract 68
Introduction 69
Experimental 69
Results and Discussion 70
Inclined Rolling 70
Skew Rolling 72
Summary and Conclusions 75
Acknowledgements 75
References 75
6 A Possible Way for Efficient Utilization of Coal Energy: The Combined Process of Ironmaking with Gasoline Synthesis and Electricity Generation 77
Abstract 77
Introduction 77
Integrated System Configuration 78
Simulation Method 80
Results and Discussion 82
Conclusions 86
Acknowledgements 86
References 86
7 The Influence of Water Vapour on the Fuming Rate in a Ferromanganese System 88
Abstract 88
Introduction 88
Theory 89
Experimental 91
Results and Discussion 92
Relative Mass Fluxes 92
Temperature Profiles 94
X-ray Diffraction Analysis (XRD) 95
Conclusion 97
Relative Mass Fluxes 97
Temperature Profiles 97
X-ray Diffraction Analysis (XRD) 97
Acknowledgements 97
References 98
Energy and Environmental Issues in Materials Manufacturing and Processing: Opportunities in Aluminum Production, Waste Heat and Water Recovery 99
8 Approach for Pyrolysis Gas Release Modelling and Its Potential for Enhanced Energy Efficiency of Aluminium Remelting Furnaces 100
Abstract 100
Introduction 100
Pyrolysis 102
Kinetic Modelling 104
Approach 105
Implementation 106
Discussion 107
Summary and Outlook 107
Acknowledgements 108
References 108
9 Numerical Approach for the Implementation of the Interaction of Pyrolysis Gases and Combustion Products in an Aluminium Melting Furnace 109
Abstract 109
Introduction 110
Flameless Combustion 110
Numerical Simulations 110
General Modelling Approach 111
Real Furnace and Model Set-Up 111
Combustion 112
Properties 113
Heating Sequence 114
Holding Sequence 115
Results and Validation 116
Acknowledgements 118
References 118
10 Fluoropolymer Coated Condensing Heat Exchangers for Low-Grade Waste Heat Recovery 119
Abstract 119
Introduction 120
Material Selection 120
Coating Method and Experimental Procedure 121
Results and Discussion 121
Coating of Finned Heat Exchangers 121
Corrosion Resistance of the Composite Coating 123
Thermal Conductivity of the Composite 124
Adhesion Strength of the Composite Coating 125
Cross-Sections After Corrosion Testing 125
Summary and Conclusions 126
Acknowledgements 127
References 127
11 Nitrate and Other Anion Removal from Waste Water Using the Hydroflex Technology 128
Abstract 128
Introduction 128
Field Demonstration: Liquid-Liquid Extraction and Recovery of Sulfate from Mine Water 129
Nitrate Removal Process 131
Experimental Design 132
Loading and Stripping of Nitrate, Sulfate, and Selenate 133
Loading Isotherms 133
Stripping Results 136
Discussion 138
Economic Analysis 138
Capital Estimate Summary 138
Operating Cost Estimate 139
Conclusion 139
References 140
12 Mechanical Analysis of Raceway Formation in Bulk Bed of Blast Furnace 141
Abstract 141
Introduction 141
Mechanical Analysis 142
Model Formulation 142
Force Exerted by the Gas 144
Frictional Force 144
Elemental Force Balance (Cartesian System) 144
Elemental Force Balance (Radial System) 145
Experiment and Discussion 146
Conclusion 148
Acknowledgements 148
References 148
Materials for Coal-Based Power: Materials For Coal-Based Power: Session I 150
13 Ni-Fe Based Alloy GH984G Used for 700 °C Coal-Fired Power Plants 151
Abstract 151
Introduction 151
Experimental Procedures 152
Results and Discussions 153
Material Development and Structural Characteristics 153
Thermal Stability 154
Stress Rupture Properties 155
High Temperature Corrosion/Oxidation Resistance 156
Acknowledgements 157
References 157
Materials for Coal-Based Power: Materials for Coal-Based Power: Session II 159
14 Creep Strength and Oxidation Resistance of Industrially Made G115 Steel Pipe 160
Abstract 160
Introduction 160
Boiler Materials Spectra for 630–700 °C A-USC PP 161
Strengthening Mechanism of G115 Martensitic Steel 162
Industrial Manufacturing of G115 Tubes and Pipes 163
Creep Rupture Strength and Oxidation Resistance of G115 Steel Pipe 163
The Application and Prospect of G115 Steel 165
Conclusive Summary 166
Acknowledgements 166
References 166
15 Accelerated Creep Test for New Steels and Welds 167
Abstract 167
Introduction 167
An Accelerated Creep Test—ACT 168
Results of the ACT on F-FB2 Welds 169
Metallography of F-FB2 Welds 171
Study on Optimizing HAZ 174
Conclusions 175
References 175
Materials for Coal-Based Power: Materials for Coal-Based Power: Session III 177
16 The Reliability Analysis of 12Cr1MoVG and T23 Used for USC Water Wall 178
Abstract 178
Introduction 178
Performance Comparison of 12Cr1MoVG and T23 179
The Wall Thickness Calculation of USC Water Wall 179
The Operation Reliability Comparison of 12Cr1MoV and T23 Water Wall 182
Conclusions 185
References 185
Materials for Coal-Based Power: Poster Session 186
17 Effect of High-Frequency Induction Hardening on Stress Corrosion of a 12%Cr Martensitic Stainless Steel 187
Abstract 187
Introduction 188
Experiments and Data Evaluation 188
Results and Discussion 189
Conclusion 195
References 195
18 Fireside Corrosion Behaviors of Inconel 740H Superalloy in Various SO2 Contents 197
Abstract 197
Introduction 197
Experimental Produce 199
Materials 199
Corrosion Tests 199
Results 200
Mass Gain Curves 200
Corrosion Products 201
Corrosion Morphologies 201
Discussion 203
Conclusions 204
Acknowledgements 205
References 205
19 High Cycle Fatigue Behavior of HAYNES282 Superalloy 206
Abstract 206
Introduction 206
Samples Preparations and Test Methods 207
Materials 207
Method of HCF Tests 207
Determination of S-N Curve 209
Methods of Microstructure Observation 209
The Testing Results and Analysis 210
Fatigue Characteristic of HAYNES282 210
Observation of the Fatigue Fracture 211
The Microstructures 212
The Microstructures Analyzed by OM 212
The Microstructures Analyzed by TEM 213
Conclusions 214
References 215
20 Recent Development in the Characteristics of Alloy 625 for A-USC Steam Turbine Casting 216
Abstract 216
Introduction 216
Trial Production 217
Experimental Procedure 217
Results and Discussion 218
Chemical Composition and Microstructure 218
Tensile Properties at Room Temperature and Evaluated Temperature 220
Creep Rupture Strength 221
Homogenization Heat Treatment 222
Thermal Stability 223
Conclusions 225
References 225
Materials for Gas Turbines: Coatings 227
21 Evolution of the Thermal Conductivity of Sm2Zr2O7 Under CMAS Attack 228
Abstract 228
Introduction 228
Experimental 229
Sample Fabrication 229
Thermal Conductivity Measurement 229
Characterization 231
Results and Discussion 231
Conclusions 235
References 235
Materials for Gas Turbines: Hot Corrosion and New Materials 237
22 Development of a New High Strength and Hot Corrosion Resistant Directionally Solidified Superalloy DZ409 238
Abstract 238
Alloy Design 238
Materials Processing 241
Mechanical Properties 241
Microstructural Stability 242
Hot Corrosion Resistance 245
Conclusions 246
References 246
Materials for Gas Turbines: Microstructure and Processing 248
23 Modeling the Diffusion of Minor Elements in Different MCrAlY—Superalloy Coating/Substrates at High Temperature 249
Abstract 249
Introduction 250
Model Set-up 251
Results and Discussion 252
Conclusion 260
Acknowledgements 260
References 260
24 On Healing Mechanism of Cast Porosities in Cast Ni-Based Superalloy by Hot Isostatic Pressing 262
Abstract 262
Introduction 263
Experimental Procedure 264
Results and Discussion 264
Effect of HIP on the Porosity Healing 264
Healing Mechanism of the Porosity 267
Effect of HIP on the Microstructure and Property 268
Conclusion 270
References 270
25 The Influence of Dendritic Segregation Degree to the Recrystallization Nucleation in U4720LI 273
Abstract 273
Introduction 273
Materials and Methods 274
Results and Discussion 275
Conclusions 281
References 281
Materials for Gas Turbines: Poster Session 283
26 Stress Rupture Properties of Alloy 783 284
Abstract 284
Introduction 284
Experimental and Materials and Procedures 285
Results and Discussion 286
Experiment Results 286
Experiment Results and Discuss 286
Conclusions 288
References 289
27 Study on the Undercoolability and Single Crystal Castability of Nickel-Based Superalloys 290
Abstract 290
Introduction 290
Materials and Experimental Procedures 291
Results and Discussion 292
The Influence of Chemical Compositions to the Undercoolability 292
The Influence of Mould Materials to the Undercoolability 295
The Influence of the Remelting-Cycle to the Undercoolability 295
Conclusions 296
References 296
Materials for Nuclear Energy: Materials for Nuclear Applications I 298
28 Enhancing the High-Cycle Fatigue Property of 316 Austenitic Stainless Steels Through Introduction of Mechanical Twins by Cold-Drawing 299
Abstract 299
Introduction 300
Experiment 300
Results and Discussion 301
Initial Microstructure 301
Fatigue Property 303
Fractography 304
Cyclic Deformation Microstructure 304
Conclusion 306
References 307
Materials for Nuclear Energy: Materials for Nuclear Applications II 308
29 Microstructure Evolution of a Reactor Pressure Vessel Steel During High-Temperature Tempering 309
Abstract 309
Introduction 309
Materials and Methods 310
Results and Discussions 311
Hardness 311
General Microstructure Evolution 312
Decomposition of M/A Constituent 312
Principle of Carbides Evolution 315
Formation of New Austenite 316
Conclusions 317
Acknowledgements 317
References 317
Materials for Nuclear Energy: Environmental Effects 319
30 Effect of Steam Pressure on the Oxidation Behaviour of Alloy 625 320
Abstract 320
Introduction 321
Material and Experimental Procedures 322
Results 322
Weight Change 322
Surface Morphology and Oxide Formation on Alloy 625 324
Samples Tested in SCW at 29 MPa 324
Samples Tested in Sub-critical Water at 8 MPa 326
Samples Tested in Steam at 0.1 MPa 326
Discussion 326
Conclusion and Recommendation 331
Acknowledgements 331
References 331
31 Friction Stir Processing of Degraded Austenitic Stainless Steel Nuclear Fuel Dry Cask Storage System Canisters 333
Abstract 333
Introduction 333
Experimental Approach 334
SCC Repair 334
Heat Affected Zone Sensitization Remediation 335
Results and Discussion 336
SCC Repair 336
Heat Affected Zone Sensitization Remediation 339
Conclusions 340
Future Work 340
References 341
Materials for Nuclear Energy: Accident Tolerant Fuels & Irradiation Effects
32 The Mechanical Response Evaluation of Advanced Claddings During Proposed Reactivity Initiated Accident Conditions 343
Abstract 343
Introduction 344
Materials and Experimental Methods 345
Results and Discussion 348
Conclusions 351
Acknowledgements 352
References 352
33 First Principles Investigations of Alternative Nuclear Fuels 354
Abstract 354
Introduction 355
Methodology 356
Electronic Thermal Transport 356
Thermo-Mechanical and Ground State Properties 357
Lattice Thermal Conductivity 358
Results and Discussion 358
Ground State Properties 358
Thermal Conductivity 359
Summary 361
Acknowledgements 362
References 362
34 Comparative Study of Thermal Conductivity of SiC and BeO from Ab Initio Calculations 364
Abstract 364
Introduction 364
Methodology 365
Thermal Conductivity 365
Computational Details 366
Results and Discussion 367
Ground State Properties 367
Thermal Conductivity (?L) 367
Summary 369
Acknowledgements 369
References 369
Materials for Oil and Gas and AMREE Oil & Gas III
35 Anisotropic Behaviors for X100 High Grade Pipeline Steel Under Stress Constraints 373
Abstract 373
Introduction 373
Full Scale Burst Test and BTC Model 374
Improved Gurson Model 377
SENT Test 378
Microstructure Analysis 378
Simulation 381
Conclusion 383
Acknowledgements 383
References 384
36 Co-relation of Microstructural Features with Tensile and Toughness Characteristics of X70 Grade Steel 385
Abstract 385
Introduction 385
Chemical Composition of X70 Grade Steel 386
Processing of Line Pipe Steel 390
Micro Structural Aspects and Its Behaviour on Mechanical Properties 392
Conclusion 399
Acknowledgements 399
References 399
37 Development and Applications of New Generation Ni-Containing Cryogenic Steels in PR China 400
Abstract 400
Introduction 400
Experimental Procedures 401
Manufacture Process of 9% Ni Steel 402
Manufacture Process of 5% Ni Steel 404
Conclusions 407
References 408
38 Microstructure Analysis and Weldability Investigation of Stainless Steel Clad Plate 409
Abstract 409
Introduction 410
Experimental Procedures 410
Results and Discussions 412
Conclusions 416
Acknowledgements 416
References 417
39 Microstructure and Properties of High Performance Pipeline Steels 418
Abstract 418
Introduction 418
Microstructure and Properties of Ultrahigh Strength X90/X100/X120 Pipeline Steels 419
Microstructure and Properties of Strain Based Design of High Strength with High Deformability Pipeline Steel X70HD and X80HD 420
Microstructure and Properties of Submarine Heavy Wall Pipeline Steel 423
Microstructure and Properties of Ø1422 mm Extra Large Diameter X80 Linepipe 424
Microstructure and Properties of X65 Low Mn Pipeline Steel for Sour Service 427
Summary 429
References 429
40 Sensitivity Variation of Nanomaterials at Different Operating Temperature Conditions 430
Abstract 430
Introduction 430
Materials and Experiments 431
Results and Discussion 432
Conclusion 434
References 435
Author Index 436
Subject Index 438