An optimization model for evaluating the economic impact of availability and maintenance notions during the synthesis and design of a power plant

In this paper, we introduce an optimization strategy in order to comprehensively quantify the impact of availability and maintenance notions during the early stages of synthesis and design of a new natural gas combined cycle power plant. A detailed state-space approach is thoroughly discussed, where influence of maintenance funds on each component's repair rate is directly assessed.In this context, analysis of the reliability characteristics of the system is centered at two designer-adopted parameters, which largely influence the obtained results: the number of components which may fail independently at the same time, and the number of simultaneous failure/repair events.Then, optimal solutions are evaluated as the availability-related parameters and the amount of resources assigned for maintenance actions are varied across a wide range of feasible values, which enable obtaining more accurate and detailed estimations of the expected economic performance for the project when compared with traditional economic evaluation approaches.     

Effect of copper additions in directly quenched titanium–boron steels

The present study concerns the effect of copper additions on the microstructural evolution and mechanical properties of directly quenched Ti–B steels. Ti and B are added as microalloying elements with an aim of achieving adequate austenite hardenability and Cu is added to retard the austenite (γ) → ferrite (α) transformation. Therefore, the microalloying and Cu additions together allow the transformation of austenite to occur at a lower temperature, resulting in a finer microstructure containing martensitic constituents. The direct-quenching route is adopted with an aim of facilitating the nucleation of the constituent phases from the deformed austenite. In order to circumvent the hot-shortness due to the Cu addition, 0.79 wt% Ni has been added to one of the 1.5 wt% Cu microalloyed steels. The present study has demonstrated that the Ni-containing 1.5Cu–Ti–B steel is capable of providing an attractive combination of strength and ductility comparable to the high strength varieties of HSLA steels in directly quenched condition.     

Production of hydrogen by thermal methane splitting in a nozzle-type laboratory-scale solar reactor

A high-temperature solar reactor has been developed for co-producing hydrogen-rich gas and high-grade carbon black (CB) from concentrated solar energy and methane. The approach is based on a single-step thermal decomposition (pyrolysis) of methane without catalysts and without emitting carbon dioxide since solid carbon is sequestered.In the tested reactor, a graphite nozzle absorbs concentrated solar radiation provided by a solar furnace. The heat is then transferred to the reactive flow. The experimental setup, first test results, and effect of operating conditions are described in this paper.The conversion of methane was strongly dependant on the solar furnace power input, on the geometry of the graphite nozzle, on gas flow rates, and on the ratio of inert gas-to-reactive gas. CB was recovered in the carbon trap, and maximum chemical conversion of methane-to-hydrogen and CB was 95%, but typical conversion was in the range 30–90%.     

Effect of Magnetic Interaction on Thermally Activated Reversal in a Magnet With a Distribution of Energy Barriers

The time dependence of magnetization is usually expressed as M(t)=M₀-SInt [see Proc. Phys. Soc. 62, 562 (1949)] for magnetic viscosity experiments. Considering magnetic interaction during the thermal activation process, a form as M(t)=M₀-SIn(t+t₀) is deduced. The dipolar interaction and exchange coupling in a magnet can lead to positive and nonpositive t₀, respectively. In the experiments of the magnetic viscosity for nanocrystalline Pr₂Fe₁₄B ribbons, the existence of positive t₀ is confirmed.     

Improvement in galvannealed coating of IF-HS steel strips by combined GDOES and colour-etching method

Galvannealed coating of high strength interstitial free (IF-HS) steel was characterised by Glow Discharge Optical Emission Spectroscopy (GDOES) and colour-etching techniques. Overalloyed galvannealed coatings with considerably high amount of Γ and Γ1 phases were detected in the first set of experiments. Necessary process modifications in galvannealing furnace were made to maximise the ä phase in the galvannealed coating, which was confirmed through GDOES and colour-etching techniques. As a result, an improvement in galvannealed product quality with a better powdering resistance property during forming has been achieved.     

Optimization of annealing cycle parameters of dual phase and interstitial free steels by multiobjective genetic algorithms

Data-driven models have been constructed for Dual Phase (DP) and Interstitials Free (IF) steels using an evolutionary approach. DP steel data are utilized from an existing database, while for the IF steels, data generated at an integrated steel plant have been used. The objective function for Ultimate Tensile Strength (UTS) and % elongation, created as data-driven models, is simultaneously optimized for an optimum strength-ductility balance and the results indicate the possibilities of developing steels with better mechanical properties than what are known to have been existing so far.     

Elimination of Surface Defects in High Tensile Steel for Wheel Rim Application

One of the important applications of high tensile steel grades is in wheel rims by the automotive industry. High tensile steel facilitates vehicle weight reduction under the ‘Go Green’ initiative. Along with weight reduction, in recent times, the surface quality requirement of steels for wheel rim applications has also gained a significant focus, and in many cases, it is becoming the cause of rejection at the customers’ processing line. It is known that owing to chemistry requirements such high strength steel grades generally show peritectic behavior during solidification and are prone to surface defects. Tata Steel India produces several wheel rim grades of varying strength levels. In one such high manganese and micro-alloyed peritectic steel grade, the rejection by the customer on account of surface defects was a major concern. The defects consisted of typical longitudinal cracks of varying dimensions along with the unique defects in transverse direction named tear marks on the surface of 100-mm-thick plates rolled from 215-mm-thick slab. In subsequent stages, these plates were processed into rim profiles through hot working by the wheel customer. The paper highlights how systematic study led to arrive at root causes and helped redesign steel chemistry to ensure zero rejection for surface quality without affecting mechanical property requirements.     

Catastrophic Failure of a Steel Chimney in a Lime Plant

Failure analysis of a steel chimney used in a lime plant was carried out. The chimney broke from two different locations during a storm. During the site visit, it was observed that the chimney was dislodged from weld joints. The chimney was made up of hot rolled mild steel plates. Investigations were carried out on the failed chimney plate and welding between plates. The investigation consists of visual observation, chemical analysis, characterization of macro- and microstructures, measurement of hardness, tensile property tests and energy-dispersive spectroscopy (EDS). Calculation of wind load at the location of breakage was also carried out. EDS analysis revealed entrapment of slag inside weld. Overall analysis suggested that the failure took place due to selection of improper reconditioning technique as well as poor workmanship in welding.     

The cut-groove technique to infer interfacial effects during hot rolling

This article presents a novel experimental technique to infer the coupled effects of friction and heat transfer during the hot rolling of steels. The technique, termed the “cut-groove” method, relates the behavior of the deforming grooves cut on the strip surface to the local effects of friction and heat transfer. Validation of the experimentally observed groove shapes involved developing two-dimensional (2-D) and three-dimensional (3-D) finite-element (FE) models that employed a probabilistic distribution diagram (PDD). The PDD framework modeled the roll-strip interface and accounted for the variations in the oxide scale as distinct states that affect both friction and heat transfer. The numerically predicted groove openings are in good agreement with the experimentally observed groove shapes, particularly for the 2-D case. For the 3-D model, deviations are observed at regions close to the strip edges that are affected by nonplanar strain arising from spread during laboratory rolling. S. DAS, formerly Student, Department of Engineering Materials, and later Research Associate, Institute of Microstructural and Mechanical Process Engineering, The University of Sheffield (IMMPETUS), Sheffield, SI 3JD, United Kingdom