Kraft recovery boilers – Principles and practice

This book was created as postgraduate lecture notes for Lappeenranta University of Technology's special course of steam power plants. But as with anything ever written the ideas shown have nurtured for a long time. Parts of these chapters have appeared elsewhere as individual papers or work documents. One of the most helpful episodes have been presentations and discussions during Pohto Operator training seminars. Input from those sessions can be seen in chapter firing. You who run recovery boilers, I salute you. The purpose of this text is to give the reader an overview of recovery boiler operation. Most parts of the recovery boiler operation are common to boilers burning other fuels. The furnace operation differs significantly from operation of other boiler furnaces. Oxygen rich atmosphere is needed to burn fuel efficiently. But the main function of recovery boiler is to reduce spent cooking chemicals. Reduction reactions happen best in oxygen deficient atmosphere. This dual, conflicting nature of recovery furnace makes understanding it so challenging. To understand the processes happening in the recovery furnace one must try to understand the detailed processes that might occur and their limitations. Therefore chapters on materials, corrosion and fouling have been added.

Water chemistry management for future large experimental facilities

The thesis focuses on the water chemistry of the experimental test facilities and their reference VVER reactors. The main objective of the thesis is to provide recommendations for water chemistry management for laboratory facilities (VEERA, PACTEL) simulating the VVERs and for the large future facilities of the Lappeenranta University of Technology. In the beginning, the concept of nuclear power generation and the applicability of the nuclear power usage is discussed. Next, different water chemistry and water purification systems in primary and secondary circuits currently used at the power plant have been outlined. Also the construction geometry and design of test facilities PACTEL and VEERA, as well as the operation principles of their main equipment has been described. Finally, the appropriate water chemistry and water treatment system have been proposed for the existing and future experimental facilities of LUT.

Weldability of high strength aluminium alloys

The need for reduced intrinsic weight of structures and vehicles in the transportation industry has made aluminium research of interest. Aluminium has properties that are favourable for structural engineering, including good strength-to-weight ratio, corrosion resistance and machinability. It can be easily recycled saving energy used in smelting as compared to steel. Its alloys can have ultimate tensile strength of up to 750 MPa, which is comparable to steel. Aluminium alloys are generally weldable, however welding of high strength alloys like the 7xxx series pose considerable challenges. This paper presents research on the weldability of high strength aluminium alloys, principally the 7xxx series. The weldability with various weld processes including MIG, TIG, and FSW, is discussed in addition to consideration of joint types, weld defects and recommendations for minimizing or preventing weld defects. Experimental research was carried out on 7025-T6 and AW-7020 alloys. Samples were welded, and weld cross sections utilized in weld metallurgy studies. Mechanical tests were carried out including hardness tests and tensile tests. In addition, testing was done for the presence of Al2O3 on exposed aluminium alloy. It was observed that at constant weld heat input using a pulsed MIG system, the welding speed had little or no effect on the weld hardness. However, the grain size increased as the filler wire feed rate, welding current and welding speed increased. High heat input resulted in lower hardness of the weld profile. Weld preheating was detrimental to AW- 7020 welds; however, artificial aging was beneficial. Acceptable welds were attained with pulsed MIG without the removal of the Al2O3 layer prior to welding. The Al2O3 oxide layer was found to have different compositions in different aluminium alloys. These findings contribute useful additional information to the knowledge base of aluminium welding. The application of the findings of this study in welding will help reduce weld cost and improve high strength aluminium structure productivity by removing the need for pre-weld cleaning. Better understanding of aluminium weld metallurgy equips weld engineers with information for better aluminium weld design.

Paperikoneen kuivatusosan olosuhteiden vaikutus viiranjohtotelojen vaipan materiaalin ja pinnoitteen valintaan korroosiovaurion ehkäisemiseksi

Diplomityön tavoitteena on löytää UPM Kymin paperikone 8:n ensimmäisen kuivatusryhmän johtoteloihin kulumis- ja korroosiokestävämpi materiaali ja pinnoite vallitsevaan olosuhteeseen. Teloihin muodostuu pistemäistä korroosiota ja korroosioalue on paikallinen. Korroosiota syntyy kuivatusviiran alueella, jossa ei ole paperirainaa. Työssä suoritetaan kuivatusosan olosuhdemittauksia ja tutkitaan niiden vaikutuksia korroosion muodostumiseen. Suoritettavat olosuhdemittaukset ovat huuvan ilmatase, paineen 0-taso sekä lämpötilat ja kosteudet eri huuvan osissa. Savukaasumittauksen avulla tutkitaan huuvan ilmankiertoa ensimmäisen kuivatusryhmän viiranjohtotelojen läheisyydessä. Kuivatusviiran ilmanläpäisymittauksen avulla saadaan tietoa viiran ilmanläpäisykyvystä. Hypoteesina viiran tukkeutuminen johtuu pölyävästä kuivaus-prosessista ja kosteudesta. SEM/EDS-alkuainemittauksen avulla pystytään analysoimaan korrosiivisia alkuaineita niin korroosioalueella kuin ympäristössä. Työn tutkimuksen perusteella korroosion muodostuminen aiheutuu tukkeutuneen viiran muodostamasta happipitoisuuseroalueesta. Viiran saostumat sisältävät korrosiivisia kemikaaleja, kuten kloridia, rikkiä ja mangaania. Nämä kiihdyttävät korroosiota happipuutosalueella. Huuvan olosuhdemittauksien perusteella huuvan paineen 0-taso on vino. Savukaasu- ja kosteusmittauksien avulla huomattiin kostean ilman jäävän telojen läheisyyteen. Työssä kehitettiin paineilmapuhdistin viiran reuna-alueen puhdistamiseen. Kaavattaviin telapositioihin valittiin kobolttikromiseostettu volframikarbidipinnoite PTFE -fluoripolymeeritiivistyksellä. Muihin telapositioihin valittiin ETFE –fluori-polymeeripinnoite korroosion ehkäisemiseksi. Pinnoitteiden ja paineilmapuhdistimen avulla telojen käyttöaika nousee nykyisestä kahdesta vuodesta tavoiteltuun 10 vuoteen.

Sähkökemiallisten mittausmenetelmien hyödyntäminen optimaalisessa kunnossapidossa

Sähkökemiallisia korroosionopeuden mittausmenetelmiä, yhdistettynä rakennema-teriaalien ohenemaseurantaan, on edelleen harvoin hyödynnetty toimilaitteiden ja rakenteiden elinkaarihallintaan liittyvässä kunnossapidossa. Tässä diplomityössä selvitetään sähkökemiallisten korroosiomittausten käyttöä optimaalisen kunnossapidon apuvälineenä. Työssä selvitetään erityisesti sähkö-kemiallisten mittausjärjestelmien soveltuvuutta voimalaitosten tulistinalueen kor-roosion sekä kylmäpään happo- ja vesikastepisteen mittaamiseen ja kriittisen kas-tepistelämpötilan määrittämiseen. Lisäksi selvitetään mittausten soveltuvuut-ta voimalaitosten polttoainehallinnan optimointiin sekä teknis-taloudellisuuteen perustuvaan prosessin säätämiseen. / Electrochemical corrosion rate measuring methods have been used years in indus-trial maintenance research. Still electrochemical corrosion rate measurement methods are rarely used in the industrial maintenance work related to the life cycle of equipment and structures. This work will study the suitability and use of electrochemical corrosion meas-urements in the optimum maintenance. The work will specifically address the suitability of electrochemical measuring systems for power plants super heater and the cold end corrosion monitoring. Study focus on acid and water dew point monitoring and the determination of the critical dew point temperature. In addi-tion, study the suitability of measurements of power plant fuel management as well as techno-economics based on the process of adjustment.

Voimalaitosten kattilaputkien sisäpuolisten kerrostumien paksuuden mittaaminen ultraäänimenetelmällä

Höyryvoimalaitoksen käyttöönotossa muodostuu kattilaputkien sisäpinnoille niitä korroosiolta suojaava ohut metallioksidikerros. Tämän kerroksen päälle kasvaa kattilan käytön aikana haitallista kerrostumaa paikallisen korroosion tai kattilavedessä olevien epäpuhtauksien kerääntymisen tai kiteytymisen seurauksena. Kerrostuma haittaa lämmönsiirtoa tulipesästä putkiseinämän läpi kattilaveteen. Putkien lämpötilan nousu suunniteltua korkeammaksi kasvattaa putkivaurioiden ja sisäpuolisen korroosion riskiä. Tästä johtuen paksuksi kasvaneet kerrostumat pyritään poistamaan happokäsittelyllä eli peittauksella ennen vaurioiden syntyä. Perinteisesti kerrostumapaksuus on määritetty kattilasta irrotetuista näyteputkista mikroskoopilla. Työn tavoitteena oli tutkia uudenlaisen ultraäänimittauksen teoriaa ja selvittää sen toimivuus höyrystinputkien kerrostumapaksuusmittauksissa. Lisäksi tavoitteena oli tutkia voimalaitoksen höyrystimen sisäpuolisten kerrostumien muodostumista ja niiden vaikutuksia sekä kattilan peittaustarpeen arviointia. Höyrystimen kerrostumien kasvunopeuteen vaikuttavat eniten voimalaitostyyppi, käytetty vesikemia ja kattilaveteen kulkeutuvien epäpuhtauksien määrä. Kasvunopeus vaihtelee laitosten välillä suuresti ja eroaa myös tulipesän eri kohdissa. Kattilaveden epäpuhtauspitoisuus ja kerrostumapaksuus vaikuttavat molemmat korroosiovaurioiden todennäköisyyteen. Peittauspaksuuden ohjearvoissa tulisi huomioida kattilan käyttöpaine, kattilatyyppi ja riski kattilaveden laadun heikkenemiselle. Putkinäytteistä ja laitoksilla suoritettujen mittauksien perusteella uusi ultraäänitekniikka tuottaa luotettavia tuloksia tavanomaisten kerrostumien mittauksessa. Vain yhdellä laitoksella esiintyi irtonaisen sakan kaltaista kerrostumaa, jota mittaus ei kyennyt havaitsemaan. Mittaustulokset kerrostumista tulipesän eri osissa antavat hyvän perustan peittaustarpeen arviointiin.

Bearing-spesific complications of total hip arthroplasty: characterization and treatment

Hip resurfacing arthroplasty (HRA) and large head metal-on-metal total arthroplasty (LDH MoM THA) gained popularity during the last decade. Adverse reaction to metal debris (ARMD) is a unique complication of metal bearings. ARMD is a complex reaction caused by metal debris from metal-on- metal bearing surfaces and from trunnion corrosion of modular junctions. We analyzed survivorship of 8059 LDH MoM THAs based on data of the Finnish Arthroplasty Register. We found relatively high short-term survivorship for some LDH MoM THAs, but there were remarkable differences between the devices studied. After some alarming reports of failing MoM THAs, we studied the first 80 patients who had received a ReCap-M2a-Magnum implant at our institution and evaluated the prevalence of ARMD. We found a high prevalence of pseudotumors, and, because of this, we discontinued the use of MoM bearings and followed up all patients with a MoM THA. Bone loss due infection, osteolysis or fracture poses a great challenge for reconstructive and fracture surgery. Onlay allografting for both revision and fracture surgery provides mechanical stability and increases bone stock. Bone loss and implant stability must be assessed preoperatively and adequately classified; this provides guidelines for the operative treatment of periprosthetic fractures and revision THA. In our studies on structural allografts union rates were high, although the rates of infections and dislocations were marked. In summary, early results of the use of LDH MoM devices were encouraging. However, the survival of the LDH MoMs varied. The prevalence of adverse reaction to metal debris was high after application of the ReCap-Magnum THA. New implants should be introduced carefully and under close surveillance by University clinics and arthroplasty registers.

Ohutlevykotelon valmistettavuuden ja pinnoitettavuuden huomioiminen suunnittelussa

Korkean IP-luokituksen ohutlevykotelointi on haastava kokonaisuus. Koteloinnin tiivistys ruiskutettavalla polyureapinnoitteella edellyttää usean osa-alueen samanaikaista hallintaa. Kotelo on alusta alkaen suunniteltava pinnoitettavaksi, sillä pinnoitus asettaa lukuisia vaatimuksia ja rajoituksia esimerkiksi käytettäville muodoille, rakenteille ja liittämismenetelmille. Polyurea on elastomeeri, josta valmistettua pinnoitetta voidaan levittää erityisellä ruiskutuslaitteistolla. Polyureapinnoite sallii kotelon asentamisen vaikeisiin olosuhteisiin, sillä se kestää kemikaaleja, kulutusta ja iskuja sekä tarjoaa tiiveyden lisäksi korroosiosuojan koteloinnille. Pinnoitteen ominaisuuksia, kuten kovuutta, elastisuutta ja kemikaalien sekä UV-säteilyn kestoa voidaan räätälöidä käyttökohteen mukaan. Polyurepinnoitteeella pinnoitettavat pinnat on pyrittävä pitämään mahdollisimman yksinkertaisina, mikä tarkoittaa käytännössä kaikenlaisten kohoumien, ulkonevien osien, reikien ja muiden epäjatkuvuuskohtien välttämistä. Kaikki epäjatkuvuuskohdat vaativat erityishuomiota pinnoituksen aikana, sillä epäjatkuvuuskohtien onnistunut pinnoitus vaatii ruiskutusta useasta suunnasta, mikä lisää virhemahdollisuuksia ja siten vaarantaa koteloinnin tiiveyden. Liittämismenetelmät ovat yksinkertaisten muotojen ohella avainasemassa pinnoituksen onnistumisen kannalta. Menetelmistä tulee suosia sellaisia, joiden pinnoitettavaan pintaan aiheuttama epäjatkuvuuskohta on mahdollisimman vähäinen. Tällaisia menetelmiä ovat esimerkiksi vastuspistehitsaus ja puristeruuvi.

Microfacies analysis of the lower paleocene beda formation in Western Concession 59 and Block 59F, Sirte Basin, Libya /

The rock sequence of the Tertiary Beda Formation of S. W. concession 59 and 59F block in Sirte Basin of Libya has been subdivided into twelve platformal carbonate microfacies. These microfacies are dominated by muddy carbonates, such as skeletal mudstones, wackestones, and packstones with dolomites and anhydrite. Rock textures, faunal assemblages and sedimentary structures suggest shallow, clear, warm waters and low to moderate energy conditions within the depositional shelf environment. The Beda Formation represents a shallowing-upward sequence typical of lagoonal and tidal flat environments marked at the top by sabkha and brackish-water sediments. Microfossils include benthonic foraminifera, such as miliolids, Nummulites, - oerculina and other smaller benthonics, in addition to dasycladacean algae, ostracods, molluscs, echinoderms, bryozoans and charophytes. Fecal pellets and pelloids, along with the biotic allochems, contributed greatly to the composition of the various microfacies. Dolomite, where present, is finely crystalline and an early replacement product. Anhydrite occurs as nodular, chickenwire and massive textures indicating supratidal sabkha deposition. Compaction, micr it i zat ion , dolomit izat ion , recrystallization, cementation, and dissolution resulted in alteration and obliteration of primary sedimentary structures of the Beda Formation microfacies. The study area is located in the Gerad Trough which developed as a NE-SW trending extensional graben. The Gerad trough was characterized by deep-shallow water conditions throughout the deposition of the Beda Formation sediments. The study area is marked by several horsts and grabens; as a result of extent ional tectonism. The area was tectonically active throughout the Tertiary period. Primary porosity is intergranular and intragranular, and secondary processes are characterized by dissolution, intercrystalline, fracture and fenestral features. Diagenesis, through solution leaching and dolomitization, contributed greatly to porosity development. Reservoir traps of the Beda Formation are characterized by normal fault blocks and the general reservoir characteristics/properties appear to be facies controlled.

Study of colossal magnetoresistance and pressure effects in La2/3Ca1/3MnO2 thin films /

The main purpose of this thesis is to study properties of La2/3Cai/3Mn03, both polycrystalline ceramics and thin films. This material has striking related electrical and magnetic properties. Thin films show colossal negative magnetoresistance (CMR) near transition from an insulating to a metallic state accompanied closely by transition from a paramagnetic to a ferromagnetic state. The double exchange mechanism (DE) and the Jahn-Teller deformations play an important role in CMR effect. Applied pressure has a very similar effect as does an applied magnetic field, except, at low temperatures (Tintergranular spin-dependent scattering of DE electrons. Oxygen stoichiometry plays an important role in the magnitude and position of MR(T) maximum. The distortions of structure and Mn-O-Mn bonds in applied pressure axe discussed. The fabrication of La2/3Cai/3Mn03 thin films by pulsed laser deposition was successfully developed. The films grown on (100) SrTiOs substrate are c-axis oriented and exhibit negative magnetoresistance Ap/p(H) of over 400% at 245°C and 4200% at 90 K.

Relargage d’ions métalliques après l’arthroplastie de la hanche à grand diamètre avec couple de frottement métal sur métal

La dégénérescence articulaire sévère de la hanche est une pathologie fréquente et son traitement ultime est le remplacement prothétique. L’arthroplastie la plus répandue au monde est la prothèse totale de hanche (PTH) avec un couple de frottement métal-sur-polyéthylène (MPE). Cependant ce type d’intervention présente une longévité limitée à cause de l’usure de PE et ne convient pas aux patients actifs souffrant de coxarthrose sévère tôt dans leur vie. Afin de palier à ce problème, une nouvelle génération de surfaces de frottement métal-sur-métal (MM) est actuellement employée. Ces surfaces de frottement sont utilisées en PTH avec tête de 28 mm, en resurfaçage (RH) et avec la PTH à tête de grand diamètre. Alors qu’il y a beaucoup d’évidence à l’égard du bon fonctionnement des implants PTH 28 mm et du RH, les données quant aux performances in vivo des PTH MM à grand diamètre manquent. Malgré cela, ces implants sont utilisés à grande échelle. Dans un premier temps, l’objectif de ce travail de recherche était d’évaluer l’effet et de comparer les taux d’ions chrome (Cr) et cobalt (Co) chez des sujets porteurs de PTH MM à grand diamètre à ceux de 64 porteurs de RH, tous deux possédant des surfaces de frottement aux propriétés tribologiques identiques. Dans un deuxième temps, nous avons comparé les taux ioniques (Cr, Co et titane (Ti)) entre quatre PTH MM à grand diamètre provenant de fabricants différents (Zimmer, DePuy, Smith & Nephew et Biomet). Les mesures d’ions étaient effectuées dans le sang entier dans un laboratoire indépendant par la technique de spectrophotométrie de masse à haute résolution HR-ICP-MS, pour l’ensemble de ce travail de recherche. Les deux comparaisons ont démontré le rôle crucial joué par la modularité au niveau de la jonction tête-col des PTH MM à grand diamètre. En effet, des écarts considérables dans les concentrations ioniques de Co ont été retrouvés entre les RH et PTH Durom ayant un couple de frottement identique, ainsi qu’entre les 4 différents designs de PTH MM à grand diamètre comparés entre eux. La PTH MM à grand diamètre Durom était la moins favorable alors que celle de Biomet était la plus performante. Nos observations démontrent que des sources inattendues comme la jonction tête-col de certains implants PTH MM à grand diamètre peuvent contribuer au relargage ionique systémique. Une meilleure compréhension de ce phénomène est indispensable avant l’utilisation clinque de nouveaux implants de ce type.

Tailored Ion Imprinted Polymer Materials for the Preconcentrative Separation of Noble Metals

Tailored ion imprinted polymer materials for the preconcentrative separation of noble metals. This study deals with the synthesis, separation,characterization and analytical application of the noble metals especially palladium and platinum. Platinum group metals(PGM) are currently receiving world wide attention. This group include Palladium(Pt),rhodium(Rh), ruthenium(Ru), iridium(Ir) and osmium(Os).PGM are used as catalysts for a wide variety of hydrogenation, oxidation, isomerization,cyclization,dehydrogenation and dehalogenation reactions.The corrosion resistance of PGM enables them to use in jewellery,electrical and glass industries,extrusion of synthetic fibres,manufacture of laboratory utensils,dental and medical devices. This study clearly establishes selective recovery of platinum from other noble and transition elements.

Influvence of Alloying Additions on the Structure and Properties of Ai-7Si-0.3Mg Alloy

Cast Ai-Si alloys are widely used in the automotive, aerospace and general engineering industries due to their excellent combination of properties such as good castability, low coefficient of thermal expansion, high strength-to-weight ratio and good corrosion resistance. The present investigation is on the influence of alloying additions on the structure and properties of Ai-7Si-0.3Mg alloy. The primary objective of this present investigation is to study these beneficial effects of calcium on the structure and properties of Ai-7Si-0.3Mg-xFe alloys. The second objective of this work is to study the effects of Mn,Be and Sr addition as Fe neutralizers and also to study the interaction of Mn,Be,Sr and Ca in Ai-7Si-0.3Mg-xFe alloys. In this study the duel beneficial effects of Ca viz;modification and Fe-neutralization, comparison of the effects of Ca and Sr with common Fe neutralizers. The casting have been characterized with respect to their microstructure, %porosity and electrical conductivity, solidification behaviour and mechanical properties. One of the interesting observations in the present work is that a low level of calcium reduces the porosity compared to the untreated alloy. However higher level of calcium addition lead to higher porosity in the casting. An empirical analysis carried out for comparing the results of the present work with those of the other researchers on the effect of increasing iron content on UTS and % elongation of Ai-Si-Mg and Ai-Si-Cu alloys has shown a linear and an inverse first order polynomial relationships respectively.

ANALYSIS, MODIFICATION, AND EVALUATION OF THE COLD FLOW PROPERTIES OF VEGETABLE OILS AS BASE OIL FOR INDUSTRIAL LUBRICANTS

Poor cold flow properties of vegetable oils are a major problem preventing the usage of many abundantly available vegetable oils as base stocks for industrial lubricants. The major objective of this research is to improve the cold flow properties of vegetable oils by various techniques like additive addition and different chemical modification processes. Conventional procedure for determining pour point is ASTM D97 method. ASTM D97 method is time consuming and reproducibility of pour point temperatures is poor between laboratories. Differential Scanning Calorimetry (DSC) is a fast, accurate and reproducible method to analyze the thermal activities during cooling/heating of oil. In this work coconut oil has been chosen as representative vegetable oil for the analysis and improvement cold flow properties since it is abundantly available in the tropics and has a very high pour point of 24 °C. DSC is used for the analysis of unmodified and modified vegetable oil. The modified oils (with acceptable pour points) were then subjected to different tests for the valuation of important lubricant properties such as viscometric, tribological (friction and wear properties), oxidative and corrosion properties.A commercial polymethacrylate based PPD was added in different percentages and the pour points were determined in each case. Styrenated phenol(SP) was added in different concentration to coconut oil and each solution was subjected to ASTM D97 test and analysis by DSC. Refined coconut oil and other oils like castor oil, sunflower oil and keranja oil were mixed in different proportions and interesterification procedure was carried out. Interesterification of coconut oil with other vegetable oils was not found to be effective in lowering the pour point of coconut oil as the reduction attained was only to the extent of 2 to 3 °C.Chemical modification by acid catalysed condensation reaction with coconut oil castor oil mixture resulted in significant reduction of pour point (from 24 ºC to -3 ºC). Instead of using triacylglycerols, when their fatty acid derivatives (lauric acid- the major fatty acid content of coconut oil and oleic acid- the major fatty acid constituents of monoand poly- unsaturated vegetable oils like olive oil, sunflower oil etc.) were used for the synthesis , the pour point could be brought down to -42 ºC. FTIR and NMR spectroscopy confirmed the ester structure of the product which is fundamental to the biodegradability of vegetable oils. The tribological performance of the synthesised product with a suitable AW/EP additive was comparable to the commercial SAE20W30 oil. The viscometric properties (viscosity and viscosity index) were also (with out additives) comparable to commercial lubricants. The TGA experiment confirmed the better oxidative performance of the product compared to vegetable oils. The sample passed corrosion test as per ASTM D130 method.

Performance Evaluation of Commercially Important Indian and Imported Fishing Hooks

Fishing Technology Division, Central Institute of Fisheries Technology