Erosion-fatigue of steam turbine blades

The premature failure of steam turbine rotor blades, manufactured in forged 12% Cr-NiMoV martensitic stainless steel, was investigated using visual inspection non-destructive testing, macro and microfractography, microstructural characterization, EDS microanalysis, chemical analysis, micro hardness and tensile testing. The blades belonged to the last stage of a thermoelectric plant steam turbine generator (140 MV A). The results indicated that the failure of the blades was promoted by foreign-particle erosion, which attacked preferentially the low-pressure side of the lower trailing edge of the blades. The resulting wear grooves acted as stress raisers and promoted the nucleation of fatigue cracks, which probably grew during the transition events of the steam turbine operation. Finally, water drop erosion was observed on the blade upper leading edge (low-pressure side). (C) 2009 Elsevier Ltd. All rights reserved.

The kinetics of NO and N2O reduction over coal chars in fluidised-bed combustion

This paper presents a comprehensive and critical review of the mechanisms and kinetics of NO and N2O reduction reaction with coal chars under fluidised-bed combustion conditions (FBC). The heterogeneous reactions of NO and N2O with char/carbon surface have been well recognised as the most important processes in reducing both NOx and N2O in situ FBC. Compared to NO-carbon reactions in FBC, the reactions of N2O with chars have been relatively less understood and studied. Beginning with the overall reaction schemes for both NO and N2O reduction, the paper extensively discusses the reaction mechanisms including the effects of active surface sites. Generally, NO- and N2O-carbon reactions follow a series of step reactions. However, questions remain concerning the role of adsorbed phases of NO and N2O, and the behaviour of different surface sites. Important kinetics factors such as the rate expressions, kinetics parameters as well as the effects of surface area and pore structure are discussed in detail. The main factors influencing the reduction of NO and N2O in FBC conditions are the chemical and physical properties of chars, and the operating parameters of FBC such as temperature, presence of CO, O-2 and pressure. It is shown that under similar conditions, N2O is more readily reduced on the char surface than NO. Temperature was found to be a very important parameter in both NO and N2O reduction. It is generally agreed that both NO- and N2O-carbon reactions follow first-order reaction kinetics with respect to the NO and N2O concentrations. The kinetic parameters for NO and N2O reduction largely depend on the pore structure of chars. The correlation between the char surface area and the reactivities of NO/N2O-char reactions is considered to be of great importance to the determination of the reaction kinetics. The rate of NO reduction by chars is strongly enhanced by the presence of CO and O-2, but these species may not have significant effects on the rate of N2O reduction. However, the presence of these gases in FBC presents difficulties in the study of kinetics since CO cannot be easily eliminated from the carbon surface. In N2O reduction reactions, ash in chars is found to have significant catalytic effects, which must be accounted for in the kinetic models and data evaluation. (C) 1997 Elsevier Science Ltd.

Coupled experimental and thermodynamic modeling studies for metallurgical smelting and coal combustion slag systems

An extensive research program focused on the characterization of various metallurgical complex smelting and coal combustion slags is being undertaken. The research combines both experimental and thermodynamic modeling studies. The approach is illustrated by work on the PbO-ZnO-Al2O3-FeO-Fe2O3-CaO-SiO2 system. Experimental measurements of the liquidus and solidus have been undertaken under oxidizing and reducing conditions using equilibration, quenching, and electron probe X-ray microanalysis. The experimental program has been planned so as to obtain data for thermodynamic model development as well as for pseudo-ternary Liquidus diagrams that can be used directly by process operators. Thermodynamic modeling has been carried out using the computer system FACT, which contains thermodynamic databases with over 5000 compounds and evaluated solution models. The FACT package is used for the calculation of multiphase equilibria in multicomponent systems of industrial interest. A modified quasi-chemical solution model is used for the liquid slag phase. New optimizations have been carried out, which significantly improve the accuracy of the thermodynamic models for lead/zinc smelting and coal combustion processes. Examples of experimentally determined and calculated liquidus diagrams are presented. These examples provide information of direct relevance to various metallurgical smelting and coal combustion processes.

Soil carbon determination by high temperature combustion - A comparison with dichromate oxidation procedures and the influence of charcoal and carbonate carbon on the measured value

The measurement of organic carbon in soils has traditionally used dichromate oxidation procedures including the Wakley and Black and the Heanes methods. The measurement of carbon in soils by high temperature combustion is now widely used providing a rapid automated procedure without the use of toxic chemicals. This procedure however measures total carbon thus requiring some means of correction for soil samples containing carbonate and charcoal forms of carbon. This paper examines the effects of known additions of charcoal to a range of soil types on the results obtained by the Walkley and Black, Heanes and combustion methods. The results show, that while the charcoal carbon does not react under Walkley and Black conditions, some proportion does so with the Heanes method. A comparison of six Australian Soil and Plant Analysis Council reference soil samples by the three methods showed good agreement between the Heanes method, the combustion method and only slightly lower recoveries by the Walkley and Black procedure. Carbonate carbon will cause an overestimation of soil organic carbon by the combustion method thus requiring a separate determination of carbonate carbon to be applied as a correction. This work shows that a suitable acid pre-treatment of alkaline soils in the sample boats followed by a drying step eliminates the carbonate carbon prior to combustion and the need for an additional measurement. The measurement of carbon in soils by high temperature combustion in an oxygen atmosphere has been shown to be a rapid and reliable method capable of producing results in good agreement with one of the established dichromate oxidation procedures.

Experimental study of the deposition of combustion aerosols in the human respiratory tract

The total deposition of environmental tobacco smoke (ETS), diesel and petrol smoke in the respiratory tract of 14 non-smokers between the ages of 20 and 30 was determined experimentally. A scanning mobility particle sizer (SMPS) measuring a size range of 0.016-0.626 mu m was used to characterise the inhaled and exhaled aerosol during relaxed nasal breathing over a period of 10 min. The ETS, diesel, and petrol particles had average count median diameter (and geometric standard deviation) of 0.183 mu m (1.7), 0.125 mu m (1.7), and 0.069 mu m (1.7), respectively. The average total number deposition of ETS was 36% (standard deviation 10%), of diesel smoke 30% (standard deviation 9%), and of petrol smoke 41% (standard deviation 8%). The analysis of the deposition patterns as a function of particle size for the three aerosols in each individual showed that there is a significant difference between each aerosol for a majority of individuals (12 out of 14). This is an important result as it indicates that differences persist regardless of inter-subject variability. (C) 2005 Elsevier Ltd. All rights reserved.

Fuel stagnation temperature effects on mixing with supersonic combustion flows

An experimental study of the effect of fuel stagnation temperature on mixing in a supersonic hydrogen-air flame is described, The combustor consisted of a constant-area rectangular duct with a centrally located fuel-injection strut that spanned the width. A high-enthalpy stream of air was supplied by a free-piston shock tunnel, and heated hydrogen fuel, supplied by a gun-tunnel, was injected into the freestream as a coflowing planar jet. The freestream total enthalpies were 5.6, 6.5, and 9 MJ/kg, and fuel stagnation temperatures were 300, 450, and 700 K, Raising the fuel stagnation temperature increased the fuel velocity to be near that of the airstream and resulted in a decrease in the mixing rate, Even as the fuel and air velocities became equal, significant mixing still occurred because of a large difference in density, Increasing the freestream enthalpy reduced the difference between the initial air temperature and the adiabatic flame temperature, which in turn reduced the heat addition, and subsequently, the amount of pressure rise in the duct.

Effect of resinite on the combustion of New Zealand subbituminous coal

Oligocene resin from New Zealand's Rotowaro coalfield displays DTA and DTG traces similar to those of other fossil resins. It modifies the thermal behaviour of low rank coal in raising the peak combustion temperature and lowering its rate of combustion, a behaviour that may be common among liptinite macerals. The effect is not additive and unlike other coal constituents the resinite component does not deteriorate with time. (C) 1997 Elsevier Science B.V.

Time-dependent master equation simulation of complex elementary reactions in combustion: Application to the reaction of (CH2)-C-1 with C2H2 from 300-2000 K

Computational simulations of the title reaction are presented, covering a temperature range from 300 to 2000 K. At lower temperatures we find that initial formation of the cyclopropene complex by addition of methylene to acetylene is irreversible, as is the stabilisation process via collisional energy transfer. Product branching between propargyl and the stable isomers is predicted at 300 K as a function of pressure for the first time. At intermediate temperatures (1200 K), complex temporal evolution involving multiple steady states begins to emerge. At high temperatures (2000 K) the timescale for subsequent unimolecular decay of thermalized intermediates begins to impinge on the timescale for reaction of methylene, such that the rate of formation of propargyl product does not admit a simple analysis in terms of a single time-independent rate constant until the methylene supply becomes depleted. Likewise, at the elevated temperatures the thermalized intermediates cannot be regarded as irreversible product channels. Our solution algorithm involves spectral propagation of a symmetrised version of the discretized master equation matrix, and is implemented in a high precision environment which makes hitherto unachievable low-temperature modelling a reality.

A proposed maceral index to predict combustion behavior of coal

To predict the combustion performance in pulverized coal-fired boilers, this paper examines existing indices and develops a maceral index (MI). These indices were compared with the data of 68 coals and blends in a range of the mean vitrinite reflectance from 0.25 to 1.63. The results showed that the fuel ratio and the mean vitrinite reflectance could qualitatively indicate the burnout of the coals and blends. The new MI, MI = L + V/R-2/I-1.25(HV/30)(2.5), provides a useful correlation for the burnout of the coals and blends. The correlation coefficient (I-) is 0.982 for the EER data, and 0.808 for the ACIRL data. The MI also has potential to correlate ignition and flame stability of the coals and blends. The MI predicts the burnout better than the other indices. (C) 2001 Elsevier Science Ltd. All rights reserved.

The mechanisms of combustion and continuous reactions during mechanical alloying

Some materials exhibit a combustion event during mechanical alloying, which results in the rapid transformation of reactants into products, while others show a slow transformation of reactants into products, In this paper, the continuous W + C --> WC reaction is compared to the Ti + C --> TiC combustion reaction. Rietveld refinement of X-ray diffraction patterns is used to show that these particular reactions proceed through different pathways, determined by crystallographic factors of the reactants. When a crystallographic relationship exists between the reactants and the products, such as that between W and WC, the product forms slowly over a period of time. In contrast, insertion of C into the Ti structure is associated with atomic rearrangements within the crowded lattice planes and the subsequent catastrophic failure of the reactant lattices results in combustion to form TiC. (C) 2001 Academic Press.

Spontaneous-combustion propensity of New Zealand coals under adiabatic conditions

Pulverised New Zealand coal samples have been tested from an initial temperature of 40 degreesC and reacted adiabatisally in an oven with oxygen to provide a full temperature history of auto-oxidation up to the self-sustained process of combustion. This procedure produces a self-heating rate index, R-70, calculated as the ratio of the time taken to reach 70 degreesC (degreesC/h). The R-70 index is a measure of the coal's propensity to spontaneous combustion. R-70 values for New Zealand coals are much higher than any previously published results. They show a rank dependence, whereby subbituminous coals have the highest propensity to spontaneous combustion (14.91-17.23 degreesC/h). A lignite sample has an R-70 value of 7.76 degreesC/h, and high-volatile bituminous B coals have R-70 values of 0.31-2.23 degreesC/h. Samples stored for 2 years show the same rank trend. The nature of this trend is most likely a function of the internal surface area of the coal that governs the available sites for oxidation. Calculating the Suggate rank; for any New Zealand coal can be used to rare its propensity to spontaneous combustion. Resin bodies in the subbituminous coal show no propensity to spontaneous combustion. (C) 2001 Elsevier Science B.V. All rights reserved.

Ab initio modelling of basal plane oxidation of graphenes and implications for modelling char combustion

Ab initio calculations have been performed to determine the energetics of oxygen atoms adsorbed onto graphene planes and the possible reaction path extracting carbon atorns in the form of carbon monoxide. Front the energetics it is confirmed that this reaction path will not significantly contribute to the gasification of well ordered carbonaceous chars. Modelling results which explore this limit Lire presented. (C) 2002 Elsevier Science Ltd, All rights reserved.

Wells turbine: fiberglass flanges

A introdução desta tese começa por realizar um enquadramento do projecto em mão, apresentando a central de energia das ondas em que se encontram os componentes em fibra de vidro a projectar. Esta central usa o princípio de variação de coluna de água, e encontra-se localizada na ilha do Pico, Açores. São de seguida apresentados os objectivos deste trabalho, que consistem na selecção de materiais de fabrico dos componentes, desenvolvimento de uma metodologia para projectar juntas aparafusadas em materiais compósitos, dimensionamento e comparação de duas juntas concorrentes em materiais compósitos: junta solicitada à tracção e junta solicitada ao corte, validação da análise e estudo das causas dos vários tipos de falha destas juntas. A parte I deste trabalho é o resultado da pesquisa bibliográfica efectuada para levar a cabo os objectivos definidos. Assim, começa por se fazer uma descrição dos materiais e processos de fabrico que mais se adequam ao presente projecto, nomeadamente fibra de vidro, resinas, tecidos, impregnação manual, RTM e infusão por vácuo. Daqui resultou que os materiais mais adequados para esta aplicação são fibra de vidro do tipo E e resina polyester devido ao seu baixo custo e larga utilização em aplicações estruturais marinhas. O processo de fabrico mais eficiente é a infusão por vácuo devido á sua vocação para pequenas séries de produção, a poupança que permite em termos de mão-de-obra, a complacência com normas de emissão de voláteis e as boas propriedades das partes produzidas. No capítulo II da parte I são discutidos os tópicos relacionados com juntas em materiais compósitos. Da pesquisa levada a cabo conclui-se que as grandes vantagens das juntas aparafusadas são a sua facilidade de montagem e desmontagem, facilidade de inspecção e capacidade de ligar quaisquer tipos de materiais. Quanto à furação de compósitos é importante referir a necessidade de utilizar ferramentas resistentes e parâmetros de maquinação que minimizem o dano infligido aos laminados. Isto é possível através da selecção de ferramentas com passos baixos que reduzam igualmente a dimensão do seu centro estático responsável pela força axial exercida sobre o laminado - principal factor causador de dano. Devem-se igualmente utilizar baixas velocidades de avanço e elevadas velocidades de rotação. É importante salientar a importância da realização de pré-furação, de utilização de um prato de suporte na superfície de saída do laminado e a existência de ferramentas especialmente concebidas para a furação de compósitos. Para detectar e quantificar o dano existente num furo destacam-se os métodos de inspecção ultrasónica e a radiografia. Quanto aos parâmetros que influenciaram o comportamento de juntas aparafusadas destacam-se os rácios largura/diâmetro, distância ao bordo/diâmetro, espessura/diâmetro, pré-tensão, fricção, sequência de empilhamento e respectivas proporções, dimensão das anilhas e folga entre o parafuso e o furo. A pesquisa efectuada visando metodologias de projecto fiáveis ditou a necessidade de utilizar métodos que permitiram determinar o parafuso mais carregado de uma junta, efectuar o cálculo de tensões no mesmo, e ainda métodos que permitam determinar a primeira falha que ocorre no laminado bem como a falha final no mesmo. O capítulo III da primeira parte descreve os métodos de análise de tensões necessários para as metodologias de projecto utilizadas. Aqui é apresentada a teoria clássica da laminação, um método para determinação do parafuso mais carregado, um método analítico baseado na teoria da elasticidade anisotrópica de um corpo e o método dos elementos finitos. O método para determinar o parafuso mais carregado - análise global - consiste num modelo bidimensional de elementos finitos em que 2 laminados coincidentes são modelados com elementos lineares de casca com 4 nós, sendo a extremidade de um laminado restringida em todos os graus de liberdade e a extremidade oposta do segundo laminado carregada com a carga pretendida. Os laminados são ligados através de elementos mola que simulam os parafusos, sendo a sua constante de rigidez previamente calculada para este fim. O método analítico modela o contacto assumindo uma distribuição de pressão cosinoidal ao longo de metade do furo, e é válido para laminados simétricos e quasi-isotrópicos. O método dos elementos finitos é o que mais factores permite ter em conta, sendo os modelos tridimensionais com um elemento por camada os que melhor modelam o estado de tensões experienciado por uma junta aparafusada em materiais compósitos. O tópico de análise de falha é abordado no capítulo 4 da primeira parte. Aqui são apresentados os resultados do world wide failure exercice que compara vários critérios de falha existentes até 2004, fazendo-se referência a desenvolvimentos recentes que têm ocorrido nesta área. O critério de Puck surge como aquele que permite previsões de falha mais exactas. O critério de falha de Hashin 3D foi o escolhido para o presente trabalho, devido à sua facilidade de implementação num modelo de elementos finitos, à sua capacidade para detectar modos de falha subcríticos e à sua utilização em trabalhos anteriores que apresentaram previsões de falha muito próximas dos dados experimentais. Também neste capítulo se apresentaram os vários tipos de falha de uma junta aparafusada em materiais compósitos, apresentando as causas de cada uma. Por fim, na última secção, apresenta-se o método de dano progressivo que se desenvolveu para prever a primeira falha final do laminado. Este é muito interessante tendo permitido previsões de falha muito próximas dos resultados experimentais em trabalhos anteriores. Este método é iterativo e encontra-se dividido em 3 passos: Análise de tensões, análise de falha utilizando o critério de Hashin 3D e degradação de propriedades, de acordo com o tipo de falha detectada. Para além dos passos referidos, existe ainda um quarto responsável pelo fim da análise que consiste na aferição da existência ou não de falha final e respectivo tipo de falha (por pressão de contacto, por tensão ou por esforços de corte). No capítulo V da primeira parte é apresentado o resultado de uma pesquisa das normas de teste necessárias para obter as propriedades dos materiais requeridas para a aplicação dos métodos descritos neste trabalho. A parte II deste trabalho consiste na aplicação dos métodos apresentados na parte I ao caso concreto em estudo. Os softwares Microsoft Excel, Matlab e ANSYS foram utilizados para este fim. A junta começa por ser dimensionada estimando a espessura necessária do componente e o número e características dos parafusos. De seguida foi feita uma análise global à flange em estudo determinando a força suportada pelo parafuso mais carregado. Após esta análise desenvolveu-se um modelo tridimensional de elementos finitos da zona em que se encontra o parafuso mais carregado, utilizando elementos sólidos lineares e isoparamétricos de 8 nós e uma malha gerada pelo método directo. Aplicou-se a este modelo o algoritmo de dano progressivo descrito na primeira parte. Começou por se incluir explicitamente o parafuso, anilhas, pré-tensão e a modelação dos vários contactos com fricção posteriormente simplificado o modelo restringindo radialmente os nós da porção carregada do furo, excluindo os factores mencionados inicialmente. Procurou-se validar o modelo utilizando o método de cálculo de tensões descrito na primeira parte, desenvolvendo um programa em Matlab para o efeito. Tal não foi possível tendo-se incluído a tentativa realizada em anexo. Para efeitos de dimensionamento, desenvolveu-se um modelo de elementos finitos de duas dimensões da junta em causa, utilizando elementos de casca lineares de quatro nós isoparamétricos com uma espessura unitária. Através da análise de tensões efectuada com este modelo, e utilizando um método combinado programado em linguagem paramétrica, foi possível dimensionar as duas juntas concorrentes pretendidas. Este método combinado consistiu no cálculo de tensões em pontos localizados sobre uma curva característica e utilização de um critério de falha quadrático para cálculo da espessura necessária para a junta. O dimensionamento ditou que a junta solicitada à tensão necessita de pelo menos 127% das camadas e do custo de uma junta solicitada ao corte equivalente.