High-temperature nickel superalloy to improve efficiency of coal-fired power plants
February 14, 2019
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The U.S. Department of Energy’s National Energy Technology Laboratory, in partnership with Energy Industries of Ohio Inc., is set to scale up the fabrication of components made from advanced nickel superalloys that will help bring advanced ultrasupercritical (AUSC) power plant technology to the level of readiness for commercial-scale demonstration.
Conventional coal-fired power plants, which generate steam to drive a power generation turbine, operate with efficiencies varying from 32 to 42 percent, depending upon the age and design of the plant. AUSC power plants can potentially operate at temperatures and pressures higher than current state-of the-art coal-fired power plants—about 25 percent more efficient than the average U.S. coal-fired power plant fleet, and 10 percent more efficient than state-of-the-art coal-fired power plants. AUSC power plants would require less coal per megawatt-hour, resulting in lower emissions and lower fuel costs per megawatt.
Successful widespread use of AUSC technology requires fabrication of advanced nickel superalloys into large plant components; development of installation and repair methods for the nickel superalloy components; and sufficient testing and metallurgical analysis to support the final design of a commercial-scale AUSC demonstration plant.
Since the early 2000s, NETL has been working with a partnership to conduct AUSC research. This partnership consists of the Energy Industries of Ohio, the Electric Power Research Institute, and industry partners known as the AUSC Consortium. Together, they have done research to the point that the fabrication of AUSC nickel components is ready to be built at full commercial scale—the last stage of research and development before a commercial-scale demonstration of AUSC power plant technology can be implemented.
Private-sector partners involved in the current phase of the AUSC project include Energy Industries of Ohio, Electric Power Research Institute, ALSTOM Power Division of General Electric, Riley Power, MetalTek, Special Metals, and AECOM
www.netl.doe.gov
The U.S. Department of Energy’s National Energy Technology Laboratory (NETL), in partnership with Energy Industries of Ohio Inc., is set to scale up the fabrication of components made from advanced nickel superalloys that will help bring advanced ultrasupercritical (AUSC) power plant technology to the level of readiness for commercial-scale demonstration.
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U.S. Steel to restart pipe mill in Texas and EAF construction in Alabama
Source: ASM International
United States Steel Corp., Pittsburgh, announces plans to restart the No. 1 Electric-Weld Pipe Mill at Lone Star Tubular Operations in Lone Star, Texas, and also to restart construction on a technologically advanced electric arc furnace steelmaking facility at its Tubular Operations in Fairfield, Ala.
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Seco Warwick vacuum heat treating/brazing system includes high-pressure gas quench
February 5, 2019
Source: ASM International
Seco Warwick, Meadville, Pa., announces that is has provided a vacuum heat treatment and brazing system equipped with high-pressure gas quench to Grupo TTT for its facility in Bergara, Spain.
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Department of Energy to award $38 million for projects to advance coal-fired power plants
January 29, 2019
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The U.S. Department of Energy, Washington, announces up to $38 million in federal funding for cost-shared R&D projects enhancing technologies that improve the overall performance, reliability, and flexibility of the nation’s existing coal-fired power plant fleet.
Coal is vital to the Nation’s energy security and provides around 30 percent of U.S. electricity. DOE is funding research to modernize the grid and improve the existing coal-fired power plant fleet under the Office of Fossil Energy’s (FE) funding opportunity announcement Improving Efficiency, Reliability, and Flexibility of Existing Coal-Based Power Plants.
“Utilizing all of our energy resources to ensure the reliability and resiliency of our nation’s electricity is a top priority for the Department of Energy,†said Under Secretary of Energy Mark Menezes. “Modernizing and advancing the existing coal fleet is imperative to this mission. By improving the efficiency of our baseload generation, we are strengthening the reliability of all our electricity generation.â€
“Along with the Department’s Coal FIRST initiative, modernizing the existing coal-fired fleet is critical to our effort to allow existing coal plants to load, follow and operate more efficiently. This research and development will lower emissions and foster new technologies beneficial to our electric grid,†said Assistant Secretary for Fossil Energy Steven Winberg.
This FOA will develop advanced technologies that improve the overall performance, reliability, and flexibility of the nation’s existing coal-fired power plant fleet. Projects will support DOE’s Transformative Power Generation Program and Crosscutting Research Program. R&D funded under this FOA will also benefit FE’s efforts to advance the coal-fired plant of the future as part of the Coal FIRST initiative. The National Energy Technology Laboratory (NETL) will manage these projects. Read more details of the FOA here.
https://www.energy.gov/fe/office-fossil-energy
The U.S. Department of Energy, Washington, announces up to $38 million in federal funding for cost-shared R&D projects enhancing technologies that improve the overall performance, reliability, and flexibility of the nation’s existing coal-fired power plant fleet.
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Stack Metallurgical installs Quintus Mega HIP for heat treating aerospace, medical products
January 23, 2019
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Stack Metallurgical Group, Albany, Ore., announces that it has installed a Quintus Mega-HIP hot isostatic press for heat treating and processing of aerospace, power generation, medical implant, and other products. The model QIH 286 M URC is equipped with proprietary uniform rapid cooling and features a work zone of 63 in. dia. by 102 in. tall, allowing densification of large batches at 29,000 psi and a maximum operating temperature of 2280°F.
The URC design enables all casting areas to cool uniformly, minimizing thermal distortion and non-uniform grain growth. Heating and cooling the workload only once, in a single cycle, enhances efficiency and dramatically reduces per-unit processing costs. In addition, the press offers significant savings in space, energy, and infrastructure investment.
With its new HIP facility coming on-line in 2019, Stack will offer four Nadcap-accredited locations with a focus on the aerospace, power generation, medical implant, and high-end knife and cutlery markets. The company’s modern and extensive equipment line-up offers a comprehensive portfolio of services for demanding clients throughout North America. With a range of aerospace OEM approvals for heat treatment, Stack has built trusted relationships with aerospace titans Boeing, General Electric, Sikorsky, and PCC Aerostructures.
“As a new entrant into the HIP market, it was critical that we continue to have the ability to offer a premium combination of quality and delivery to our clients,†says Doug Puerta, CEO, Stack Metallurgical Group.
http://www.stackmet.com
Stack Metallurgical Group, Albany, Ore., announces that it has installed a Quintus Mega-HIP hot isostatic press for heat treating and processing of aerospace, power generation, medical implant, and other products.
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Powder coating conveyor oven preheats and coats steel couplings for oil and gas equipment
December 9, 2018
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Wisconsin Oven Corp., East Troy, Wis., has delivered a natural-gas-fired conveyor oven to a supplier of the oil and gas industry for the preheating and powder coating of steel couplings. It has sufficient capability to heat 1000 pounds per hour of steel parts from 70°F to 1000°F, provided that the workload is configured in a manner that is capable of absorbing the heat that is generated within the time available.
The powder coating conveyor oven has a maximum temp of 1000°F with guaranteed temperature uniformity of ±10°F at 1000°F. The work chamber dimensions are 2 x 10 x 1. 2 ft., and the chamber was designed with bottom-up airflow to maximize heating rates and temperature uniformity of the part load configuration. A roller chain conveyor system with cross flight attachments is utilized to transport the product through the system, and a variable frequency drive provides adjustable speed control. Fabric ribbon curtains are located at both ends of the conveyor to prevent heat spill-out.
“This conveyor oven will be used for both preheating and powder coating, so it was important to provide design features to handle both applications,†says Gene Vetter, Senior Applications Engineer. “One of those features is an Allen-Bradley variable frequency drive that allows the operator to adjust the conveyor speed based on the application or part being processed.â€
https://www.wisoven.com/products/conveyor-ovens
Wisconsin Oven Corp., East Troy, Wis., has delivered a natural-gas-fired conveyor oven to a supplier of the oil and gas industry for the preheating and powder coating of steel couplings.
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Steel Dynamics to invest $1.6 billion in new electric-arc furnace flat roll steel mill
November 28, 2018
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Steel Dynamics Inc., Fort Wayne, Ind., announces that its Board of Directors has authorized the company to construct a new state-of-the-art, electric-arc-furnace (EAF) flat roll steel mill with annual production capacity of approximately 3.0 million tons, including the capability to produce the latest generation of Advanced High Strength Steel products.
The project will include value-added finishing lines, including a galvanizing line with an annual capacity of 450,000 tons, and a paint line with an annual coating capacity of 250,000 tons. The product offering is anticipated to include various flat roll steel products, including hot roll, cold roll, galvanized, Galvalume and painted steel, primarily serving the energy, automotive, construction, and appliance sectors. The current estimated investment is $1.7 billion to $1.8 billion, with anticipated direct job creation of approximately 600 well-paying positions, and numerous opportunities for indirect job growth from other support service providers.
The company currently expects to locate the facility in the southwestern United States, to cost effectively serve not only the southern United States, but also the underserved Mexican flat roll steel market. Determination of the final site location is subject to state and local government infrastructure and incentive support. Upon final site selection and the receipt of required environmental and operating permits, the company would expect to begin construction in 2020, followed by the commencement of operations in the second half of 2021.
"We plan to utilize new technologies that will further reduce the gap between existing EAF and integrated steel mill production capabilities,†says Mark. D. Millett, President and Chief Executive Officer. “We are excited to announce this investment, which is a culmination of our intentional focus to cost effectively further serve the customers in this growing flat roll steel consuming region, while increasing our steelmaking capacity and value-added product capability.â€
www.steeldynamics.com
Steel Dynamics Inc., Fort Wayne, Ind., announces that its Board of Directors has authorized the company to construct a new state-of-the-art, electric-arc-furnace (EAF) flat roll steel mill with annual production capacity of approximately 3.0 million tons, including the capability to produce the latest generation of Advanced High Strength Steel products.
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Idaho National Lab develops heat treatment to extend life of superalloys in nuclear reactors
November 24, 2018
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Researchers at Idaho National Laboratory, Idaho Falls, announce that they have developed a heat treatment process that enables superalloys to withstand high heat more than six times longer than an untreated counterpart, extending useful life by thousands of hours in applications such as nuclear reactors.
"We came up with a way to make a superalloy that is much more resistant to heat-related failures. This could be useful in electricity generators and elsewhere," says Subhashish Meher, an INL materials scientist. He was lead author of a new Science Advances paper describing the research.
INL scientists have been studying nickel-base superalloys, which are useful for electricity-generating turbines and high-temperature nuclear reactor components. Previous research had shown that performance can be improved if the material structure of the superalloy repeats in some way from very small sizes to very large, like a box within a box within a box.
This is called a hierarchical microstructure. In a superalloy, it consists of a metallic matrix with precipitates, regions where the composition of the mixture differs from the rest of the metal. Embedded within the precipitates are still finer-scale particles that are the same composition as the matrix outside the precipitates — conceptually like nested boxes.
Dr. Meher and his coauthors found that with the right recipe of heating and cooling, they could make the precipitates two or more times larger than would be the case otherwise, thereby creating the heat-resistant microstructure.
These larger precipitates last longer when subjected to extreme heat. Moreover, computer simulation studies suggest that the superalloy can resist heat-induced failure for 20,000 hours, compared to about 3,000 hours normally.
One application could be electrical generators that last much longer because the superalloy structures would be tougher. What's more, INL scientists may now be able to come up with a procedure that can be applied to other superalloys. So, it may be possible to adjust a superalloy's strength, heat tolerance, or other properties to enhance its use in a particular application.
https://www.inl.gov/article/treated-superalloys-demonstrate-unprecedented-heat-resistance/
Researchers at Idaho National Laboratory, Idaho Falls, announce that they have developed a heat treatment method that enables superalloys to withstand high heat more than six times longer than an untreated counterpart, extending useful life by thousands of hours in applications such as nuclear reactors.
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Tenaris invests $7 million to re-activate its steel line pipe and OCTG mill in Texas
October 28, 2018
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Tenaris, Luxembourg, announces that it has re-activated its steel line pipe and OCTG plant in Conroe, Texas, following a three year suspension of operations. The Conroe mill is now heat treating and finishing pipe from the Tenaris mill in Bay City, Texas, to support the ramp-up of domestic production. Tenaris invested approximately $7 million to ready the plant for operations, including safety, training, equipment, and systems upgrades.
“I want to thank our employees, many of whom have returned to the plant and those who are new to Tenaris, for their dedication to completing a safe and successful, start-up,†said Luca Zanotti, President, Tenaris USA. “Our Conroe facility is playing an important role in the resurgence of U.S. manufacturing.â€
Production at Conroe was temporarily stopped in 2015 due to record levels of unfairly traded oil country tubular goods (OCTG) imports and the collapse of the oil and gas market. In June, Tenaris announced it would restart specific manufacturing processes at the Conroe mill as a result of improved market conditions and actions by the U.S. government in support of domestic manufacturing.
www.tenaris.com
Tenaris, Luxembourg, announces that it has re-activated its steel line pipe and OCTG plant in Conroe, Texas, following a three year suspension of operations.
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Japanese scientists develop molybdenum-base high-temperature high-strength alloy
October 1, 2018
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Tohoku University, Japan, reports that its researchers have developed a titanium carbide-reinforced, molybdenum-silicon-boron (Mo-Si-B)-based alloy, or MoSiBTiC, whose high-temperature strength was identified under constant forces in the temperature ranges of 2550 to 2900°F.
The study was published in Nature's open access journal Scientific Reports in July 2018. "Our experiments show that the MoSiBTiC alloy is extremely strong compared with cutting-edge nickel-base single crystal superalloys, which are commonly used in hot sections of heat engines such as jet engines and gas turbines for electric power generation," says lead author Prof. Kyosuke Yoshimi of Tohoku University's Graduate School of Engineering.
"This work suggests that the MoSiBTiC, as ultrahigh temperature materials beyond nickel-based superalloys, is one promising candidate for those applications," added Yoshimi.
Yoshimi and colleagues report several parameters that highlight the alloy's favorable ability to withstand disruptive forces under ultrahigh temperatures without deforming. They also observed the alloy's behavior when exposed to increasing forces and when cavities within MoSiBTiC formed and grew, resulting in to microcracks and final rupturing.
The researchers assessed the alloy's creep in a stress range of 100 to 300 MPa for 400 hours. All experiments were performed in a computer-controlled test rig under vacuum in order to prevent the material from oxidizing, or reacting with the any potential air moisture, which could ultimately result in rust formation.
Furthermore, the study reports that, contrary to previous studies, the alloy experiences larger elongation with decreasing forces. This behavior, they write, has so far only been observed with superplastic materials that are capable of withstanding against unexpected premature failure.
These findings are an important indicator for MoSiBTiC's applicability in systems that function at extremely high temperatures, such as energy conversion systems in automotive applications, power plants, and propulsion systems in aircraft engines and rockets. The researchers say that several additional microstructural analyses are needed in order to fully understand the alloy's mechanics and its ability to recover from exposure of high stresses such as large forces under high temperatures.
http://www.tohoku.ac.jp/en/press/metal_withstands_ultra_high_temperature.html
Tohoku University, Japan, reports that its researchers have developed a titanium carbide-reinforced, molybdenum-silicon-boron (Mo-Si-B)-based alloy, or MoSiBTiC, whose high-temperature strength was identified under constant forces in the temperature ranges of 2550 to 2900°F.
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