Creep damage in small punch creep specimens of Type 304 stainless steel

Small punch creep tests on Type 304 stainless steel have been performed at 650 °C. Based on these tests, a finite element model, with modified Kachanov–Rabotnov creep damage constitutive equations, was established. The variation of central deflection and creep strain with time and the evolution of creep damage under constant loads were analysed by using the finite element model. The central creep deflection curves in the specimens were obtained at different loads in both tests and simulations and have three different stages, similar to conventional creep tests. There is good agreement between experimental results and simulation data. The creep damage at the central part is high, and localization of damage is obvious. Initial failure occurs at the bottom surface, about 0.8 mm away from the centre which agrees well with the finite element mode observation.     

Crack initiation and crack growth assessment of a high pressure steam chest

Extensive cracking had occurred in a number of high pressure steam chests. An assessment was undertaken based on the R5 British Energy methodology to assess the components for both creep–fatigue damage initiation and crack growth analysis to determine fitness for purpose. The analysis determined that the remaining base rupture endurance life of the component was greater then 1 million hours, however, due to the start-up and shutdown ramp rates, creep–fatigue damage greater then unity has occurred leading to crack initiation in a number of locations. These cracks were confirmed during internal inspection of the steam chest. A subsequent crack growth analysis determined that the component could safely be returned to service for the expected future life of the station.     

Can high temperature steam electrolysis function with geothermal heat?

It is possible to improve the performance of electrolysis processes by operating at a high temperature. This leads to a reduction in electricity consumption but requires a part of the energy necessary for the dissociation of water to be in the form of thermal energy.     

Creep behaviour and lifetime of large welds in X 20 CrMOV 12 1—results based on simulation and inspection

Weld creep performance in steam lines of X 20 CrMoV 12 1 (X20) has been studied by simulation and plant inspection. By finite-element simulations, the influences of (i) the heat affected zone creep rate, (ii) the material constant α, related to the multiaxial rupture criterion, and (iii) axial system stresses on creep life, have been studied. The results show that an increase of each factor (i)-(iii) reduces the creep life, especially when two of them act at the same time. The inspection study covers over two decades of replica inspection of steam line welds in Danish power plants with service times up to 190.000 h. Analysis of the results shows that large butt joints and T-butt joints in X20 perform exceptionally well. They are unlikely to develop detectable creep damage within service times up to 200.000 h. One of the reasons for this good performance of the steel is its high time safety margin.     

Creep crack growth data and prediction for a P91 weld at 650 °C

Creep crack growth tests have been carried out on compact tension (CT) specimens machined from a P91 weldment. Four of these specimens were cut from the parent material side of the weld and another seven specimens were cut across the weld. For the cross-weld specimens, starter cracks were positioned into (or close to) the Type IV region. The creep tests were carried out under constant loads, at 650 °C. The results obtained showed that, the creep crack growth rates for parent material specimens are about ten times lower than those for the cross-weld specimens and that the scatter in the data is relatively high. In this respect, the accuracy of the crack tip location, in the cross-weld CT specimens, plays an important role. Finite Element (FE) analyses were carried out, on notched bar and CT models, using damage mechanics material behaviour models. These analyses were used to estimate the triaxial stress factor, α, for the parent material (PM), the weld metal (WM) and the heat affected zone (HAZ). FE analyses were then used to predict the creep crack growth in the CT specimens. Results from the FE analyses for both the PM and the cross-weld CT specimens were in good agreement with the corresponding experimental results. The effect of the potential drop versus crack length calibration on the calculated C* values was also investigated.     

Low temperature steam gasification to produce hydrogen rich gas from kitchen food waste: Influence of steam flow rate and temperature

Large amount of food waste is generated from Indian kitchens and disposing off such a large amount possesses a great challenge in terms of environmental degradation and viable food waste processing technology. In this work, steam gasification was tested as an alternative viable technology to process the kitchen food waste. Preliminary study was carried out at low temperature on steam gasification in a fixed bed reactor to study the influence of steam flow rate (SFR) and temperature on the syngas yield, syngas composition, hydrogen yield. Performance parameters such as carbon conversion efficiency (CCE), and apparent thermal efficiency (ATE) are also calculated. Steam flow rates are varied from 0.125 mL/min to 0.75 mL/min and the temperatures are varied from 700 °C to 800 °C. The highest hydrogen yield is obtained at 0.5 mL/min SFR and 800 °C temperature and its highest value is 1.2 m³/kg. The highest value of performance parameters, CCE and ATE are found to be 63% and 1.8.     

Status and research of highly efficient hydrogen production through high temperature steam electrolysis at INET

Hydrogen generation through high temperature steam electrolysis (HTSE) using solid oxide electrolysis cells (SOEC) has recently received increasingly international interest in the large-scale, highly efficient nuclear hydrogen production field. The research and development of HTSE technology was initiated in INET of Tsinghua University from 2005 as one of the approaches in National Key Special Projects for HTGR which aims at promoting highly efficient and sustainable application of nuclear process heat in the future. In the past three years, the research team mainly focused on preliminary investigation, feasibility study, equipment development and fundamental research. Currently, two bench-scale equipments for the study of HTSE process and SOEC components have been designed and constructed. In addition, the research group made rapid progress in the development of novel anode materials, effective microstructure control of cathodes and theoretically quantitative analysis of hydrogen production efficiency through HTSE coupled with HTGR.     

Dry reforming of methane has no future for hydrogen production: Comparison with steam reforming at high pressure in standard and membrane reactors

The methane dry-reforming and steam reforming reactions were studied as a function of pressure (1–20 atm) at 973 K in conventional packed-bed reactors and a membrane reactors. For the dry-reforming reaction in a conventional reactor the production yield of hydrogen rose and then decreased with increasing pressure as a result of the reverse water-gas shift reaction in which the hydrogen reacted with the reactant CO₂ to produce water. For the steam reforming reaction the production yield of hydrogen kept increasing with pressure because the forward water-gas shift reaction produced additional hydrogen by the reaction of CO with water. In the membrane reactors the methane conversion and the hydrogen production yields were higher for both the dry-reforming and steam reforming reactions, but for the dry reforming at high pressure half of the hydrogen was transformed into water. Thus, the dry-reforming reaction is not practical for producing hydrogen.     

Numerical investigation on the creep damage induced by void growth in heat affected zone of weldments

In structural welded joints after long-term service at high temperature, fracture occurs mainly in the fine-grained heat affected zone (HAZ). Recently, the nucleation and growth of creep voids in the fine-grained HAZ of weldments, recognized as Type IV fracture, have become an important problem for low alloy ferritic heat resisting steels. In this paper, a new constitutive model was introduced to analyze the creep damage development in HAZ induced by void growth. This model is based on the equations of continuum damage mechanics (CDM) and combines a micromechanism-based method to account for the void growth process, which is different from the previous studies of creep damage. By coding a user-defined material subroutine (UMAT) in the FEA software ABAQUS, the proposed model was used to investigate the creep damage development in HAZ of a multi-material cross-weld specimen and a medium bore welded branched pipe where four different material properties: base material, coarse-grained HAZ, fine-grained HAZ, and weld material, were taken into account.     

Failure pressure analysis of hydrogen storage pipeline under low temperature and high pressure

Low temperature and high pressure line pipes are widely used in hydrogen storage, air separation plant, liquefied natural gas (LNG) transportation etc. The material properties of pipes at low temperature are different from those at room temperature. If the medium in the pipe is corrosive, it will cause the pipe wall thickness to decrease. However, the failure pressure of the corroded hydrogen storage pipeline at extremely low temperature is lacking of adequate understanding. In this paper, we provided a novel failure pressure equation of the mild steel line pipe with corrosion defects at extremely low temperature. Firstly, a mechanical model of the line pipe with corrosion defects is established. And then, an analytical solution of the mechanical model is obtained based on elastic theory. Next, a failure pressure equation of the corroded hydrogen storage pipeline at extremely low temperature is developed. In the end, the accuracy of the failure pressure equation is verified by comparing with finite element method (FEM). The results suggest that the calculated value of the failure pressure equation is consistent with that of FEM. This paper provides a theoretical basis for the safety assessment of low temperature hydrogen storage pipeline. The new equation presented in this paper can provide useful guidance for the design of low temperature and high pressure pipelines.     

Creep and damage analysis of a serviced tee intersection in a boiler header: Comparison between numerical and experimental results

In the last few years modelling of damage phenomena under creep condition has been developed in order to take into account the microstructural material evolution in life predictions of high temperature components. The new analytical methods based on “Continuum Damage mechanics” and experimental creep and creep-rupture data aim at describing both stress-strain and damage field in structures in order to predict crack initiation. These models are implemented in computer finite element programs and should be subjected to rigorous experimental verification for a practical use in power plant assessment activities.

In the present paper the numerical results obtained from some creep and damagement analyses of a header component (10 CrMo 910 steel) are shown and compared with the experimental ones. The creep analyses have been performed by the computer code ABAQUS and the damage evaluation has been carried out by means of proper in-house developed user's subroutine and post processor.     

A high temperature and pressure framework for supercritical water electrolysis

Water electrolysis technologies aim to provide a significant increase in green hydrogen production efficiency. In this work, a framework was developed to explore the use of supercritical water for alkaline electrolysis. This framework was used to perform Arrhenius analysis as a function of potential, and to explore activation energies for sub- and supercritical water electrolysis. An analysis of the conductivity of solution unveiled a discontinuity in the trends between sub- and supercritical potassium hydroxide solution conductivity. Unlike prior work on supercritical water electrolysis, this work investigates trends in electrochemical parameters, the sources of these trends, and how they change between the sub- and supercritical regimes.     

The CO removal performances of Cr-free Fe/Ni catalysts for high temperature WGSR under LNG reformate condition without additional steam

The goal of this study was to investigate Cr-free, Fe/Ni, metal oxide catalysts for the high temperature shift (HTS) reaction of a fuel processor using liquefied natural gas (LNG). As hexavalent chromium (Cr⁶⁺) in commercial HTS catalyst is a hazardous material, we selected Ni as a substitute for chromium in the Fe-based HTS catalyst and investigated the HTS activities of these Cr-free, metal oxide catalysts under the LNG reformate condition. Cr-free, Fe/Ni-based catalysts containing Ni instead of Cr were prepared by coprecipitation and their performance was evaluated under a gas mixture condition (56.7% H₂, 10% CO, 26.7% H₂O, and 6.7% CO₂) that simulated the gas composition from a steam methane reformer (SMR, at H₂O/CH₄ ratio = 3 with 100% CH₄ conversion). Under this condition, the Fe/Ni catalysts showed higher CO removal activities than Fe-only and Cr-containing catalysts, but the methanation was promoted when the Ni content in the catalyst exceeded 50 wt%. Brunner-Emmett-Teller (BET), X-ray diffraction (XRD), inductively coupled plasma (ICP) and X-ray photoelectron spectroscopy (XPS) analyses were performed to explain the HTS activity of the Fe/Ni catalysts based on the catalyst structure.     

Exergoeconomic assessment of a geothermal assisted high temperature steam electrolysis system

Exergoeconomic formulations and procedure including exergy flows and cost formation and allocation within a high temperature steam electrolysis (HTSE) system are developed, and applied at three environmental temperatures. The cost accounting procedure is based on the specific exergy costing (SPECO) methodology. Exergy based cost-balance equations are obtained by fuel and product approach. Cost allocations in the system are obtained and effect of the second-law efficiency on exergetic cost parameters is investigated. The capital investment cost, the operating and maintenance costs and the total cost of the system are determined to be 422.2, 2.04, and 424.3 €/kWh, respectively. The specific unit exergetic costs of the power input to the system are 0.0895, 0.0702, and 0.0645 €/kWh at the environmental temperatures of 25 °C, 11 °C, and −1 °C, respectively. The exergetic costs of steam are 0.000509, 0.000544, and 0.000574 €/kWh at the same environmental temperatures, respectively. The amount of energy consumption for the production of one kg hydrogen is obtained as 133 kWh (112.5 kWh power + 20.5 kWh steam), and this corresponds to a hydrogen cost of 1.6 €/kg H₂.     

An effective finite element model for the prediction of hydrogen induced cracking in steel pipelines

This paper presents a comprehensive finite element model for the numerical simulation of Hydrogen Induced Cracking (HIC) in steel pipelines exposed to sulphurous compounds, such as hydrogen sulphide (H₂S). The model is able to mimic the pressure build-up mechanism related to the recombination of atomic hydrogen into hydrogen gas within the crack cavity. In addition, the strong couplings between non-Fickian hydrogen diffusion, pressure build-up and crack extension are accounted for. In order to enhance the predictive capabilities of the proposed model, problem boundary conditions are based on actual in-field operating parameters, such as pH and partial pressure of H₂S. The computational results reported herein show that, during the extension phase, the propagating crack behaves like a trap attracting more hydrogen, and that the hydrostatic stress field at the crack tip speed-up HIC related crack initiation and growth. In addition, HIC is reduced when the pH increases and the partial pressure of H₂S decreases. Furthermore, the relation between the crack growth rate and (i) the initial crack radius and position, (ii) the pipe wall thickness and (iii) the fracture toughness, is also evaluated. Numerical results agree well with experimental data retrieved from the literature.     

Effects of prior damage on the creep failure behaviour of similar and dissimilar welded CrMoV main steam pipes incorporating a partial repair

Creep damage finite element analyses, with the inclusion of “prior damage”, were performed for partially-repaired circumferential welds in a thick-walled, main steam, CrMoV pipe. The repair consists of aged parent material, weld metal and one HAZ region being partially excavated and replaced by new weld metal. The pipe welds were subjected to realistic internal pressure and uniform axial loading, the magnitude of the latter being up to that allowed by design codes. The material properties used are related to those of a CrMoV weldment at 640 °C. It is assumed that a full post-weld heat treatment has been carried out and that the effects of welding induced residual stresses reduce to negligible levels. The results obtained are used to examine the subsequent performance for “similar” and “dissimilar” welds with a range of “repair times” (defined as prior damage levels), magnitudes of axial (system) load, etc. From these results, the failure behaviour of this particular partial repair case was evaluated and discussed.     

Effect of high temperature steam annealing for SiO2 passivation

We introduced high-temperature steam annealing (HSA) as a low-cost and effective post-annealing method for c-Si solar cell processing. The annealing effects were analyzed by measuring effective lifetime and C–V characteristics and were compared with the effects of forming gas annealing (FGA) and hydrogen-radical annealing (HRA). By using this method, effective lifetime of a SiO₂-coated wafer was increased in a very short annealing time compared to the conventional FGA. It was determined that the improvement of lifetime by HSA can be attributed to the decrease of interface state density.     

高温热管在小氮肥余热回收中的应用

将高温热管蒸汽发生器应用于小氮肥造气工艺，以取代原普通余热锅炉回收煤气工段的高温余热，解决了合成氨生产工艺中煤气降温的难题，取得了很好的经济效益和社会效益。     

Configuration design and performance optimum analysis of a solar-driven high temperature steam electrolysis system for hydrogen production

A new solar-driven high temperature steam electrolysis system for hydrogen production is presented, in which the main energy consumption processes such as steam electrolysis processes, heat transfer processes, and product compression processes are included. The detailed thermodynamic-electrochemical modeling of the solid oxide steam electrolysis (SOSE) is carried out, and consequently, the electrical and thermal energy required by every energy consumption process are determined. The efficiency of the system is derived, from which the effects of some of the important parameters such as the operating temperature, component thickness of the SOSE, leakage resistance, effectiveness of heat exchangers, and inlet rate of water on the performance of the system are discussed. It is found that the efficiency attains its maximum when a proper current density is chosen. The ratio of the required electric energy to the total energy input of the system is calculated, and consequently, the problem how to rationally operate the solar concentrating beam splitting device is investigated. The results obtained will be helpful for further understanding the optimal design and performance improvement of a practical solar-driven high temperature steam electrolysis system for hydrogen production.     

Development and operation of alternative oxygen electrode materials for hydrogen production by high temperature steam electrolysis

High temperature steam electrolysis (HTSE) is one of the most promising ways for hydrogen mass production. To make this technology suitable from an economical point of view, each component of the system has to be optimized, from the balance of plant to the single solid oxide electrolysis cell. At this level, the optimization of the oxygen electrode is of particular interest since it contributes to a large extent to the cell polarization resistance. The present paper is focused on alternative oxygen electrode materials with improved performances compared to the usual ones mainly based on perovskite structure. Two nickelates, with compositions La₂NiO_4+δ and Nd₂NiO_4+δ are investigated and evaluated in HTSE operation at the button cell level. The performances of the Ln₂NiO_4+δ - containing cells (Ln = La, Nd) is improved compared to a cell containing the classical Sr-doped LaMnO₃ (LSM) perovskite oxygen electrode showing that nickelates are promising candidates for HTSE oxygen electrodes, especially for operation below 800 °C. Indeed, current densities determined at 1.3 V are 1.1 times larger for the La₂NiO_4+δ - containing cell and 1.6 times larger for the Nd₂NiO_4+δ one compared to the LSM - containing cell at 850 °C, whereas at 750 °C they are 1.8 and 4.4 times larger, respectively. Thanks to the use of a reference electrode, by coupling impedance spectroscopy and polarization measurements, the overpotential of each working electrode is deconvoluted from the complete cell voltage under HTSE operating conditions.