[PDF] Analysis Of Cracking Of Co Extruded Recovery Boiler Floor Tubes eBook

Author :
Publisher :
Page : 17 pages
File Size : 39,95 MB
Release : 1997
Category :
ISBN :

GET BOOK

Cracking of the stainless steel layer in co-extruded 304L/SA210 tubing used in black liquor recovery boilers is being found in an ever-increasing number of North American pulp and paper mills. Because of the possibility of a tube failure, this is a significant safety issue, and, because of the extra time required for tube inspection and repair, this can become an economic issue as well. In a project funded by the U.S. Department of Energy and given wide support among paper companies, boiler manufacturers, and tube fabricators, studies are being conducted to determine the cause of the cracking and to identify alternate materials and/or operating procedures to prevent tube cracking. Examination of cracked tubes has permitted characterization of crack features, and transmission electron microscopy is providing information about the thermal history, particularly cyclic thermal exposures, that tubes have experienced. Neutron and x-ray diffraction techniques are being used to determine the residual stresses in as-fabricated tube panels and exposed tubes, and finite element modeling is providing information about the stresses the tubes experience during operation. Laboratory studies are being conducted to determine the susceptibility of the co-extruded 304L/SA210 tubes to stress corrosion cracking, thermal fatigue, and corrosion in molten smelt. This paper presents the current status of these studies. On the basis of all of these studies, recommendations for means to prevent tube cracking will be offered.

Author :
Publisher :
Page : 14 pages
File Size : 48,33 MB
Release : 1996
Category :
ISBN :

GET BOOK

Cracking of co-extruded (generally identified as composite) floor tubes in kraft black liquor recovery boilers was first observed in Scandinavia, but this problem has now been found in many North American boilers. In most cases, cracking in the outer 304L stainless steel has not progressed into the carbon steel, but the potential for such crack propagation is a cause of concern. A multidimensional study has been initiated to characterize the cracking seen in composite floor tubes, to measure the residual stresses resulting from composite tube fabrication, and to predict the stresses in tubes under operating conditions. The characterization studies include review of available reports and documents on composite tube cracking, metallographic examination of a substantial number of cracked tubes, and evaluation of the dislocation structure in cracked tubes. Neutron and X-ray diffraction are being used to determine the residual stresses in composite tubes from two major manufacturers, and finite element analysis is being used to predict the stresses in the tubes during normal operation and under conditions where thermal fluctuations occur.

Author :
Publisher :
Page : pages
File Size : 42,67 MB
Release : 2001
Category :
ISBN :

GET BOOK

Beginning in the mid-1960s, increasing energy costs in Finland and Sweden made energy recovery more critical to the cost-effective operation of a kraft pulp mill. Boiler designers responded to this need by raising the steam operating pressure, but almost immediately the wall tubes in these new boilers began to corrode rapidly. Test panels installed in the walls of the most severely corroding boiler identified austenitic stainless steel as sufficiently resistant to the new corrosive conditions, and discussions with Sandvik AB, a Swedish tube manufacturer, led to the suggestion that coextruded tubes be used for water wall service in kraft recovery boilers. Replacement of carbon steel by coextruded tubes has solved most of the corrosion problems experienced by carbon steel wall tubes, however, these tubes have not been problem-free. Beginning in early 1995, a multidisciplinary research program funded by the US Department of Energy was established to investigate the cause of cracking in coextruded tubes and to develop improved materials for use in water walls and floors of kraft recovery boilers. One portion of that program, a state-of-the-art review of public- and private-domain documents related to coextruded tube cracking in kraft recovery boilers is reported here. Sources of information that were consulted for this review include the following: tube manufacturers, boiler manufacturers, public-domain literature, companies operating kraft recovery boilers, consultants and failure analysis laboratories, and failure analyses conducted specifically for this project. Much of the information contained in this report involves cracking problems experienced in recovery boiler floors and those aspects of spout and air-port-opening cracking not readily attributable to thermal fatigue. 61 refs.

Author :
Publisher :
Page : 5 pages
File Size : 38,38 MB
Release : 2001
Category :
ISBN :

GET BOOK

Cracks were first reported in 1992 in co-extruded 304L stainless steel/SA210 Gd Al carbon steel floor tubes of North American black liquor recovery boilers. Since then, a considerable amount of information has been collected on the tube environment, crack characteristics, the stress state of the tubes, and the crack initiation and propagation mechanisms. These studies have identified both operating procedures that apparently can greatly lessen the likelihood of crack formation in the stainless steel layer and alternate materials that appear to be much more resistant to cracking than is 304L stainless.

Author :
Publisher :
Page : 18 pages
File Size : 43,89 MB
Release : 1998
Category :
ISBN :

GET BOOK

Cracking of the stainless steel layer of coextruded 304L/SA210 recovery boiler floor tubes has been observed in an increasing number of black liquor recovery boilers. Because failure of such tubes is a serious safety concern as well as an economic issue, this project was initiated with the objective of identifying alternate materials or process changes that would prevent tube cracking. Tensile stresses are essential for the most likely failure mechanisms, i.e., fatigue or stress corrosion cracking, therefore stresses were measured at room temperature and modeling was used to predict stresses under operating conditions. Laboratory studies have identified conditions under which composite tubes crack due to thermal fatigue and stress corrosion. Floor tube temperature measurements have defined the magnitude and frequency of temperature fluctuations experienced by such tubes, and smelt corrosion studies have measured the degradation rate when molten smelt comes in contact with tubes. Based on these observations, certain materials appear more likely to resist cracking and certain process changes should help avoid conditions that cause composite tube cracking.

Author :
Publisher :
Page : 9 pages
File Size : 28,56 MB
Release : 1999
Category :
ISBN :

GET BOOK

Cracking of the stainless steel layer of co-extruded 304L stainless steel/SA210 Gd A 1 carbon steel black liquor recovery boiler floor tubes has been identified as one of the most serious material problems in the pulp and paper industry. A DOE-funded study was initiated in 1995 with the goal of determining the cause of and possible solutions to this cracking problem. These studies have characterized tube cracking as well as the chemical and thermal environment and stress state of floor tubes. Investigations of possible cracking mechanisms indicate that stress corrosion cracking rather than thermal fatigue is a more likely cause of crack initiation. The cracking mechanism appears to require the presence of hydrated sodium sulfide and is most likely active during shut-downs and/or start-ups. Based on these results and operating experience, certain alloys appear to be more resistant than others to cracking in the floor environment, and certain operating practices appear to significantly lessen the likelihood of cracking. This report is the latest in a series of progress reports presented on this project.

Author :
Publisher :
Page : 10 pages
File Size : 19,23 MB
Release : 1998
Category :
ISBN :

GET BOOK

Cracking of coextruded, black liquor recovery boiler floor tubes is both a safety and an economic issue to mill operators. In an effort to determine the cause of the cracking and to identify a solution, extensive studies, described in this and three accompanying papers, are being conducted. In this paper, results of studies to characterize both the cracking and the chemical and thermal environment are reported. Based on the results described in this series of papers, a possible mechanism is presented and means to lessen the likelihood of cracking or to totally avoid cracking of floor tubes are offered.

Author : George Y. Lai
Publisher : ASM International
Page : 469 pages
File Size : 34,7 MB
Release : 2007-01-01
Category : Technology & Engineering
ISBN : 1615030557

GET BOOK

George Lai's 1990 book, High-Temperature Corrosion of Engineering Alloys, is recognized as authoritative and is frequently consulted and often cited by those in the industry. His new book, almost double in size with seven more chapters, addresses the new concerns, new technologies, and new materials available for those engaged in high-temperature applications. As we strive for energy efficiency, the realm of high-temperature environments is expanding and the need for information on high temperature materials applications was never greater. In addition to extensive expansion on most of the content of the original book, new topics include erosion and erosion-corrosion, low NOx combustion in coal-fired boilers, fluidized bed combustion, and the special demands of waste-to-energy boilers, waste incinerators, and black liquor recovery boilers in the pulp and paper industry. The corrosion induced by liquid metals is discussed and protection options are presented.

Author :
Publisher :
Page : 23 pages
File Size : 10,99 MB
Release : 1997
Category :
ISBN :

GET BOOK

Black liquor recovery boilers are essential components of kraft pulp and paper mills because they are a critical element of the system used to recover the pulping chemicals required in the kraft pulping process. In addition, the steam produced in these boilers is used to generate a significant portion of the electrical power used in the mill. Recovery boilers require the largest capital investment of any individual component of a paper mill, and these boilers are a major source of material problems in a mill. The walls and floors of these boilers are constructed of tube panels that circulate high pressure water. Molten salts (smelt) accumulate on the floor of recovery boilers, and leakage of water into the boiler can result in a violent explosion when the leaked water instantly vaporizes upon contacting the molten smelt. Because corrosion of the conventionally-used carbon steel tubing was found to be excessive in the lower section of recovery boilers, use of stainless steel/carbon steel co-extruded tubing was adopted for boiler walls to lessen corrosion and reduce the likelihood of smelt/water explosions. Eventually, this co-extruded or composite (as it is known in the industry) tubing was selected for use as a portion or all of the floor of recovery boilers, particularly those operating at pressures> 6.2 MPa (900 psi), because of the corrosion problems encountered in carbon steel floor tubes. Since neither the cause of the cracking nor an effective solution has been identified, this program was established to develop a thorough understanding of the degradation that occurs in the composite tubing used for walls and floors. This is being accomplished through a program that includes collection and review of technical reports, examination of unexposed and cracked tubes from boiler floors, computer modeling to predict residual stresses under operating conditions, and operation of laboratory tests to study corrosion, stress corrosion cracking, and thermal fatigue.