电弧焊过程的环境负荷评价

将LCA环境评估方法引入电弧焊加工过程,提出对焊接过程环境负荷评价的工艺参数为单位体积或质量的焊缝金属(焊接产品)所涉及的能源、资源和废弃物的物资量,为定量化研究焊接环境负荷提供了一种新的方法.通过对CO2气体保护焊环境负荷的评定,表明废弃物因子项是焊接对环境影响的关键项,该因子应为主要控制和改进因素.获得的CO2气体保护焊的能源因子项与电炉炼钢工艺过程相关项有较好的相对可比性,这也表明该评估模型是合理的,并使得材料实现全寿命周期的定量评估成为可能.     

Integration of product entropy and LCA to screen the potential environmental impacts of complex product systems at the end-of-life stage

Applying life cycle assessment (LCA) early in the development of technologies is essential to anticipate potential unforeseen environmental consequences. Modelling the lifecycle of a complex product is nevertheless challenging, as the data required is usually scarce. The approach presented in this paper integrates product entropy into end-of-life modelling for LCA. This enables anticipating the fate of a product after its end-of-use leading to a more realistic allocation of environmental impacts. The approach is demonstrated for the case study of recycling traction batteries with emerging traction battery cell chemistries.     

风电塔筒探伤经验介绍及相关建议

近年来,随着全球能源和环境问题的日益突出,全球气候变暖的威胁日益明显。风能是最有前途的可再生清洁能源,在世界发达国家已成功应用十几年,各国也相继投巨资发展风电产业。风力发电作为环保清洁的分散型电源,被喻为绿色电力,已经成为增长速度最快的新型清洁电力能源。开发和利用风力发电是风能利用的主要形式。我国的"十二五"规划中明确鼓励发展包括风能在内的清洁能源,加快能源结构调整,所以风力发电在今后的一段时期内都会是大力发展的对象。风力发电设备的质检工作十分重要,介绍了风电塔筒无损检测过程中发现的质量问题,并简要分析了其产生的原因。     

Evaluating the relationship between use phase environmental impacts and manufacturing process precision

The environmental impact of most consumer products is dominated by their use phase. However, these impacts tend to be driven by the manufacture of the product's components since components fabricated with higher precision typically allow the product to operate at higher efficiencies. This paper investigates the relationship between precision and life cycle environmental impacts by extending the traditional LCA methodology to evaluate the impact of manufacturing process precision on the functional performance of a product during its use phase. The implications of this relationship to manufacturing decision-making are also discussed as sustainability concerns may support the use of higher precision processes.     

Development of thermal sprayed layers for high temperature areas in waste incineration plants

Corrosion and wear in the hot gas area of thermal energy plants are severe problems, which often cause premature damage of components. In general, the most components of plants are made of materials, which are not stable under corrosive conditions. For corrosion protection (and also wear protection) and lifetime extension of these components, coatings with more resistant materials are applied. Because of the high concentration of corrosive species and the alternating composition of the atmosphere near to the components, the waste incineration plant is the “worst case” of high temperature corrosion. Nowadays, the most usual coating process to protect pipes in the waste incineration plants is cladding. In the last few years, alternative processes are under investigation because cladding is very cost‐intensive. The specific costs of thermal spraying are much lower than those of cladding. In addition, the coating by thermal spraying reduces the risk of the dilution of substrate and coating material, different materials can be combined (e.g. metal alloys, ceramics) and the thickness of the layer for an acceptable resistance according to corrosion and wear can be drastically reduced. Thermal spraying has the potential to create cost‐efficient coatings to protect components in the critical zones of incineration plants. Since many years, ATZ Entwicklungszentrum is involved in the development and/or advancement of materials, technologies and applications of thermal spraying for corrosion and/or wear protection in thermal energy plants. The main focuses of the investigations are layers for components in high temperature areas of waste incineration plants. On the basis of the present results, different coatings (metal alloys, ceramics) and different spray technologies (e.g. HVOF, APS) have been tested by different strategies (corrosion tests under laboratory scale, air cooled material probes inside the hot gas area of an incineration plant and coated pipes in operation as part of the superheater of incineration plants). This paper will give an overview about the current results of these corrosion tests, in which the focus are the investigations with material probes. First results showed that with the combination of different thermal sprayed layers a significant corrosion protection can be achieved.     

Mechanistic-Based Lifetime Predictions for High-Temperature Alloys and Coatings

Increasing efficiency is a continuing goal for all forms of power generation from conventional fossil fuels to new renewable sources. However, increasing the process temperature to increase efficiency leads to faster degradation rates and more components with corrosion-limited lifetimes. At the highest temperatures, oxidation-resistant alumina-forming alloys and coatings are needed for maximum lifetimes. However, lifetime models accurate over the extended application durations are not currently available for a wide range of candidates and conditions. Increased mechanistic understanding and relevant long-term data sets will assist in model development and validation. Current progress is outlined for applying a reservoir-type model to Fe-base alloys and coatings. However, more work is needed to understand environmental effects, such as the presence of H₂O, and to extend the current model to NiCrAl and NiCr alloys. As the critical performance factors are better understood, it will be easier to evaluate new materials in laboratory screening experiments.     

低压蒸汽差压发电技术应用

钢厂低压蒸汽在减温减压处理过程中没有有效收集利用会造成能源浪费,该文提出了低压蒸汽差压发电技术,利用螺杆膨胀动力机回收蒸汽的势能做功发电,并介绍了该螺杆发电机组的螺杆膨胀动力机、控制系统、动力系统等。经试验验证,该技术能有效回收低品位能源处理过程中损失的能耗。     

High-Temperature Corrosion in Fossil Fuel Power Generation: Present and Future

Fossil fuels have historically represented two-thirds of all electricity generation in the United States and are projected to continue to play a similar role despite historically low projected growth rates in electricity demand and the recent dramatic shift from coal to more natural gas usage. Economic and environmental drivers will require more reliable and efficient fossil fuel generation systems in the future, likely with new system designs, higher operating temperatures, and more aggressive environments. Some of the current corrosion issues in power plants are reviewed along with research on materials solutions for systems envisioned for the near future, such as coal gasification and oxy-fired coal boilers.     

从有机废料中回收铑的技术进展

有机铑废料中的铑具有很高的价值,且铑资源十分匮乏,从有机废料中回收铑意义重大。目前从含铑有机废料中回收铑的技术主要包括火法工艺、湿法工艺以及其他工艺。火法工艺中焚烧法具有技术简单,铑回收率较高等特点,是目前含铑有机废料回收常用的方法,但焚烧过程温度控制要求比较严格,且存在着环保问题;湿法工艺相对简单,但主要存在铑回收率低等问题;其他工艺尚未得到应用。开发高效清洁的新工艺是今后含铑有机废料回收技术发展的重要方向。     

Simplified Lifecycle Assessment for the Early Design Stages of Industrial Products

Simplified Lifecycle Assessment (LCA) methodologies are very useful tools in the early design stages for estimating the environmental Impacts of product alternatives and for predicting environmental costs or burdens for manufacturers. A new methodology, presented in this paper, is based on the analysis of full LCA case studies. It calculates the product's Environmental Performance Indicator by using two sets of energy-based and material-based Impact Drivers. Further simplification can be achieved by grouping the products according to their material/energy ratio and by using simple regression equations. A wide range of case studies is used to compare the simplified results with the full LCA results.     

System interaction,System of Systems,and environmental impact of products

Product-systems interact with their surrounding systems and together form a System-of-Systems (SoS). The interactions lead to emerging behaviour from the SoS, including rebound effects that influence the actual environmental impact of changes in the product-systems. Accordingly, the SoS impact can be higher than the sum of impacts from its interacting product-systems. This paper proposes a modelling approach for life cycle assessment of a product-system considering emerging behaviours in its SoS context beyond what is normally considered in a consequential LCA. The applicability of the proposed approach is demonstrated on a transportation system case study.     

垃圾焚烧电厂过热器腐蚀影响因素及防护涂层研究进展

垃圾焚烧电厂过热器管道的高温腐蚀一直是制约电厂焚烧温度的关键问题,因此研究开发耐高温、耐腐蚀、长寿命的关键服役材料是保证垃圾焚烧炉正常有序运转及安全生产的关键。对近年来垃圾焚烧电厂腐蚀问题的研究现状进行了梳理,对近期垃圾焚烧电厂过热器腐蚀与防护的研究成果进行了综述。首先,从过热器腐蚀影响因素的角度,归纳了焚烧环境中存在氯、硫、温度、水蒸气等诸多因素影响下的腐蚀特点,对各个影响因素下的腐蚀机理进行了概述,氯作为影响腐蚀的关键因素,重点对氯导致腐蚀的活性氧化机理和电化学机理进行了阐述。其次,讨论了应用在过热器表面的涂层制备技术的发展,包括热喷涂、热扩散、堆焊、激光熔覆等,探讨了制备方法,以及应用技术的优缺点。分析了材料成分(Ni、Mo、Cr、Al、Si、Pt等元素)的添加与涂层耐腐蚀性能之间的关系。再次,从焚烧垃圾预处理的角度,进一步讨论前期可通过对垃圾脱水、添加共燃剂等方法,达到脱硫、脱氯的目的,以此降低烟气中硫、氯的含量,减小其对腐蚀的影响。最后,对垃圾焚烧电厂过热器管道材料和涂层的选择进行了总结和展望。     

Research on Standard Flow for materials life cycle assessment

For the sake of objectivity of the interpretation in life cycle assessment (LCA), the concept and the design proposal of Standard Flow were put forward. Standard Flow was defined as the collection of related environmental load parameters that represent the specific development degree of certain industrial process(es) by the function unit. A novel methodological approach called the Standard Flow Comparing, was developed for LCA. The indicator for potential of process improvement and its weighting factor were derived. To a certain degree the problem of the identification and selection of process development objects in LCA was solved. The concept of Standard Flow and the method of Standard Flow Comparing are introduced, formulized and analyzed.     

Phase diagram of Fe-Cu-Si ternary system above 1523 K

Fe-Cu-Si ternary alloy phases are commonly formed during melting in a treatment process of domestic waste incineration that is currently being developed. The alloy phases appear in the incineration residue. Experiments were performed to observe phase equilibria in solid Fe+liquid, solid Si+liquid, the compound of FeSi liquid, and so forth, in the range 1523 to 1723 K. Then the phase diagram of Fe-Cu-Si ternary was thermodynamically assessed based on the present experimental results and literature data. It was found that this system has a wide liquid miscibility gap, and this two-liquid region is stable up to about 1900 K. The phase diagram of Fe-Cu-Si system assessed in the present work is much different from an earlier proposed diagram, but is very close to one recently evaluated. From the results obtained, the appropriate condition is discussed for the operation of the melting furnace for ash from municipal solid waste incinerators.     

Phase diagram of Fe-Cu-Si ternary system above 1523 K

Fe-Cu-Si ternary alloy phases are commonly formed during melting in a treatment process of domestic waste incineration that is currently being developed. The alloy phases appear in the incineration residue. Experiments were performed to observe phase equilibria in solid Fe+liquid, solid Si+liquid, the compound of FeSi liquid, and so forth, in the range 1523 to 1723 K. Then the phase diagram of Fe-Cu-Si ternary was thermodynamically assessed based on the present experimental results and literature data. It was found that this system has a wide liquid miscibility gap, and this two-liquid region is stable up to about 1900 K. The phase diagram of Fe-Cu-Si system assessed in the present work is much different from an earlier proposed diagram, but is very close to one recently evaluated. From the results obtained, the appropriate condition is discussed for the operation of the melting furnace for ash from municipal solid waste incinerators.     

Corrosion properties of in situ laser remelted NiCrBSi coatings comparison with hard chromium coatings

This study aims at evaluating the effect of an in situ laser remelting treatment of NiCrBSi coatings, deposited by plasma spraying. Life Cycle Assessment (LCA) method was used to estimate the environmental impacts of coating processes. It was demonstrated with this LCA that the in situ remelting process was clean. Microstructural results were also evaluated. A good metallurgical bond was formed at the remelted coating interface. Scanning electron microscopy observation revealed also that laser treatment induces a change of the microstructure from lamellar to columnar dendritic. The dependence between the microstructure of NiCrBSi coatings, which was modified by laser treatment, and corrosion resistance has been evaluated by potentiodynamic polarization curves. Results show that, the corrosion resistance was increased because of a finer structure and higher densities of the coatings, but corrosion mechanisms occurring in all cases were different. From the electrochemical experiments in NaCl solution it can be deduced that laser remelting of as-sprayed coatings does not affect their corrosion rate. Corrosion evolves due to a progressive penetration of the electrolyte through the disturbed structure of the as-sprayed samples, whereas the substrate surface of remelted coating is not reached, because of a higher density. But ClMO intermediate species were formed on the surface, because Cl⁻ can destroy the protective film on the coating. The hybrid plasma/laser process was cleaner than hard chromium plating and its corrosion behavior is superior too.     

Hochlegierte korrosionsbeständige Stähle für Chemie‐, Energie‐ und Meerestechnik – Rückblick und Ausblick

High‐alloyed corrosion resistant steels for the chemical process industry, power engineering and marine technology – past and future Today's most common high‐alloyed corrosion resistant steels are in their majority characterised by very low contents of carbon and sulphur and, in many cases, by substantial amounts of nitrogen as an alloying constituent. Their broad use in the chemical process industry, power generation and marine technology has become possible when new metallurgical processes for steel making had been introduced in the 1960s. The time before had seen mainly stabilised grades, being highly alloyed with copper in many cases, which have disappeared to a large extent in our days. The superferritic grades (ferritic steels with ≥ 25% chromium) had been the materials of great expectations in the 1970s, but have found a very limited application only in the chemical industry since then, e.g. for the handling of hot concentrated sulphuric acid, due to the high risks of low ductility cracking of these materials at greater wall thickness. These risks can be managed better if the highly alloyed ferritic phase is present in a finely dispersed compound with an austenitic phase where the ferritic part is adding its advantages, higher strength and resistance to stress corrosion cracking, to the duplex compound. This can result in low weight and corresponding cost saving. The application of the corrosion resistant duplex grades will expand further as much as users will better learn the special requirements of manufacturing of these materials and to take advantage of their unique properties. However, the most important alloy developments since the 1960s have been seen in the field of the austenitic stainless steels being highly alloyed with chromium, molybdenum and nitrogen. Especially the austenitic 6% Mo grades as e.g. X1NiCrMoCuN25‐20‐7 – alloy 926 (1.4529) have found many applications in chemical process industry, power generation and marine technology. Higher alloyed grades as e.g. X1NiCrMoCu32‐28‐7 – alloy 31 (1.4562) are excelling in extraordinary resistance to corrosion by acids and pitting attack. In addition today's upper limits of alloying austenitic corrosion resistant grades have been explored with grade X1CrNiMoCu33‐32‐1 – alloy 33 (1.4591) for chromium additions up to about 33% and with grade X1NiCrSi24‐9‐7 – alloy 700 Si (1.4390) for additions of silicon up to about 7%, providing a high corrosion resistance mainly in oxidising acids. When considering the prospects of further development of the corrosion resistant duplex grades the ferritic phase within these materials is both offering chances and setting limits. The high‐alloyed austenitic corrosion resistant steels have a potential being unexplored so far in the alloy range where molybdenum and nitrogen are becoming more prominent compared to the chromium content.     

Applying environmental life-cycle analysis to materials

The life-cycle analysis (LCA) of products is essentially the LCA of materials: both are concurrently and interdependently analyzed and assessed according to their environmental effects. This approach provides a framework to measure the extrinsic environmental properties of materials. In the following, three properties—gross energy requirement, global-warming potential, and solid-waste burden—are broadly discussed for steel, aluminum, and polyethylene. The environmental profiles are then applied to assess the use of alternative materials in terms of the LCA of an automotive component. Given the possibility of a substantial variation in results, one must be careful with the scoping and assessment of LCA. Despite the limitations, it provides a useful map for improving environmental compatibility and performance.     

Deposition welding of hot forging dies using nanoparticle reinforced weld metal

In the application field of forging, the form-giving tool components are subject to process-related severe environmental conditions, such as high mechanical loads acting simultaneously with high tribological and thermal charges. Due to high machine hour rates as well as increasing environmental requirements in terms of energy consumption, wear protection methods and suitable repair measures for forging tools become more and more important. Laser deposition welding represents an established process for the repair of complex shaped surfaces. A new approach is the addition of nano-sized ceramic particles to improve the mechanical properties. The main idea is to reduce the grain size of the cladded layers by adding nano-sized nuclei. A fine grained microstructure will improve strength as well as ductility and fatigue resistance. Furthermore small hard particles can improve the wear resistance without affecting the friction of the surface. After the cladding process the surface has to be finished usually by turning, milling and grinding operations. Within the presented paper the potential of nanoparticle-reinforced deposition welding with regard to increasing the wear resistance of forging dies will be examined. First, the process of nanoparticle-reinforced deposition welding will be presented. Afterwards it will be shown that yttrium oxide, titanium carbide and tungsten carbide nanoparticles in an AISI H10 matrix material will influence the friction coefficient between forging tool and material as well as the wear properties.     

Research and development of Chinese LCA database and LCA software

This paper detailed introduces the related work for building Chinese National Database, Sinocenter, of materials life cycle assessment (MLCA) and developing the environmental burden dataset of materials.The MLCA database was built in 2004, and the basic framework mainly includes LCA methodology, materials environmental dataset about energy consumption, resource input and environmental emissions.Nowadays, the database contains about fifty-thousand records of the main materials industries, such as cement, iron and steel, nonferrous metal, etc., and also includes the primary LCI data of fossil fuels and electricity grid in China.At the same time, the LCA method localization work is going on, for instance, calculated the resource characterization factors of 42 kinds of metal and 58 sorts of nonmetal, and also obtained some heavy metal impact factors in water.Based on the database, the iron and steel dataset has been developed with the data quality analysis, and some environmental burden data could be queried in our website, www.cnmlca.com, in the future.Lastly, according to the framework of the ISO14040 series standards, the antitype of Chinese LCA evaluation system was developed to support materials and products LCA evaluation in China.