A risk approach to the management of boiler tube thinning

A large set of industrial thickness inspection data covering four boiler units of a power station over a period of five years was made available to the authors. The measurements were made in regions of the boiler where corrosion/erosion was the major cause of failure of the boiler tubes. There were over 40,000 separately measured data points in the data and all were collected with some care and expense.In the development of maintenance strategies for equipment, this type of data is typical of the data that must be collected and assessed. This data thus represents an opportunity to evaluate the ability to generate a useful risk approach to the management of the tubing.An important example of a risk-based approach is the American Petroleum Institute (API) Risk Based Inspection (“RBI”), API 581. A variety of problems were encountered applying this to boiler tubes. The problems include irrelevant API 581 corrosion rate tables, lack of information on how to analyse inspection data, difficulty of dealing with multiple inspection categories and lack of suitable direction for programming inspection intervals.     

Modeling the tensile properties in β-processed α/β Ti alloys

The development of a set of computational tools that permit microstructurally based predictions for the tensile properties of commercially important titanium alloys, such as Ti-6Al-4V, is a valuable step toward the accelerated maturation of materials. This paper will discuss the development of neural network models based on a Bayesian framework to predict the yield and ultimate tensile strengths of Ti-6Al-4V at room temperature. The development of such rules-based model requires the population of extensive databases, which in the present case are microstructurally based. The steps involved in database development include producing controlled variations of the microstructure using novel approaches to heat treatments, the use of standardized stereology protocols to characterize and quantify microstructural features rapidly, and mechanical testing of the heat-treated specimens. These databases have been used to train and test neural network models for prediction of tensile properties. In addition, these models have been used to identify the influence of individual microstructural features on the tensile properties, consequently guiding the efforts toward development of more robust mechanistically based models. Based on the neural network model, it is possible to investigate the influence of individual microstructural features on the tensile properties, and in certain cases these dependencies can point toward unrecognized phenomena. For example, the apparently unexpected trend of increase in tensile strength with increasing prior β-grain size has led to the determination of the pronounced role of the basketweave microstructure in strengthening these alloys, especially in case of larger prior β grains. This article is based on a presentation made in the symposium “Computational Aspects of Mechanical Properties of Materials,” which occurred at the 2005 TMS Annual Meeting, February 13–17, 2005, in San Francisco, CA, under the auspices of the MPMD-Computational Materials Science & Engineering (Jt. ASM-MSCTS) Committee.     

Poly-functional Catalyst Development for Benzene Production from Alkyl-aromatic Mixture via Hydrodealkylation

Development of a poly-functional catalyst that has higher hydrodealkylation activity based on 15% Cr/γ- Al₂ O₃ was researched for benzene production from an alkyl-aromatic mixture via hydrodealkylation. For this goal, the effects of the promoters like Fe, Co, or Ni and their concentrations on the activity of a Cr/Al₂ O₃ catalyst were investigated. Toluene + n-heptane + tetrahydrotiophene (89:10:1 w%) model mixture, which has the same content as industrial aromatics, was used as feedstock. The activities of catalysis in reactions of hydrodealkylation, hydrocracking, and hydrogenolize with respect to conversions of toluene, heptane, and tetrahydrotiophene were tested, respectively. As to the obtained results, the catalyst including 5% Fe has a higher hydrodealkylation activity, compared to the catalyst including Co, and especially to the alumocrom catalyst not including a promoter, while it has a lower coke formation and reduced activity to the catalyst including Ni.     

Modeling of the AC Arc Discharge on Snow-covered Insulators

A mathematical model for predicting the ac flashover voltage of snow-covered insulators is presented. The arc constant parameters in air gaps and inside snow, as well as the arc reignition condition are determined using a cylindrical model. The effects of the arc length on the arc constants parameters are also investigated. The model is then applied to an EPDM insulator artificially covered with natural snow. There is good concordance between the flashover results determined from the mathematical model and those obtained experimentally.     

Multistage Zeolite Drying for Energy-Efficient Drying

This work discusses the potential of three multistage zeolite drying systems (counter-, co-, and cross-current) with a varying number of stages. The evaluation showed that for 2-4 stages with heat recovery the efficiency of the systems ranges between 80 and 90%. Additionally, by introducing a compressor, the latent heat in the exhaust air from the regenerator is recovered and used to heat the inlet air for an additional drying stage. As a result, for the counter-current drying system and compressor pressure 1.5-2 bar, a maximum energy efficiency of 120% is achieved, which results in halving the energy consumption compared to conventional drying systems.     

Modified determination of 2-thiobarbituric acid value in fats and oils

Several methods for the determination of TBA-value were compared with a new direct modification (omitting the previous distillation), using 1-butanol as the sole solvent. The absorbance is measured at 530 nm after heating to 95 degrees C for 120 min, and cooling. The effect of variables was tested by the Youdens ruggedness test (reaction time, temperature, cooling, concentration of sample, thiobarbituric acid, water, heavy metals, antioxidants, chelating agents, bubbling with oxygen or nitrogen). The Lambert-Beers law is valid in the absorbance range between 0.05 and 0.8. The repeatability is better than that of the Dzikowskis procedure and comparable with those of more complicated distillation methods. The standard deviation is in a linear relation with the absorbance (range 0.1-1.0). The method was found satisfactory for evaluating lard, cooking fat, soybean, sunflower, and rapeseed oils in the stage of beginning rancidity.     

Considerations on ex-vessel corium behavior: Scenarios, MCCI and coolability

The aim of this editorial article is to provide some structuring of the subject addressed in this part of the issue, which, in the view of the present authors, has not that clearly been reached by the specific contributions. Ex-vessel corium behavior is a wide field. Therefore, classification of the goals of investigations within a safety philosophy is especially required to get not lost in detailed aspects. The overall goals here are the coolability and retention options under ex-vessel conditions. Based on scenario considerations generally addressing risks and options, general principles of cooling and retention devices are outlined. Since the concrete erosion by melt yields a major risk and has to be considered in the concepts and devices, and also since several contributions to this part are dealing with specific aspects of this molten core-concrete interaction (MCCI), a large part of this editorial paper concerns the status of knowledge and modeling and the lines of research in this area. The status and the perspectives of codes is especially addressed by own contributions of one of the authors with the GRS code WEX and with MEDICIS, both codes included in the European integral code ASTEC. Finally, the coolability questions are discussed with respect to the different concepts in general and those addressed specifically in the present contributions. In some considerations, gas production by erosion plays a role to produce porous or particulate debris and thus to enhance coolability. Water injection from bottom is a more direct and probably more effective measure to reach this, specifically designed in the COMET core catcher concept. Specific contributions in this part deal with this concept, which is most closely related to the general subject of the present issue.     

High-rate sulphidogenic fluidised-bed treatment of metal-containing wastewater at high temperature.

The applicability of fluidised-bed reactor (FBR) based sulphate reducing bioprocess was investigated for the treatment of iron containing (40-90 mg/L) acidic wastewater at 65 degrees C. The FBR was inoculated with sulphate-reducing bacteria (SRB) originally enriched from a hot mining environment. Ethanol or acetate was supplemented as carbon and electron source for the SRB. A rapid startup with 99.9, 46 and 29% ethanol, sulphate and acetate removals, in respective order, was observed even after 6 days. Iron was almost completely removed with a rate of 90 mg/L.d. The feed pH was decreased gradually from its initial value of 6 to around 3.7 during 100 days of operation. The wastewater pH of 4.3-4.4 was neutralised by the alkalinity produced in acetate oxidation and the average effluent pH was 7.8 +/- 0.8. Although ethanol removal was complete, acetate accumulated. Later the FBR was fed with acetate only. Although acetate was present in the reactor for 295 days, its oxidation rates did not improve, which may be due to low growth rate and poor attachment ability of acetate oxidising SRB. Hence, the oxidation of acetate is the rate limiting step in the sulphidogenic ethanol oxidation by the thermophilic SRB.