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The development of a cost-effective and accurate model for predicting the fatigue life of materials is essential for designing thermal power plants and assessing their structural reliability under operational conditions. This paper reports a novel energy-based approach for developing unified models that predict the fatigue life of boiler tube materials in ultra-supercritical (USC) power plants. The proposed method combines the Masing behavior with a cyclic stress–strain relationship and existing stress-based or strain-based fatigue life prediction models. Notably, the developed models conform to the structure of the modified Morrow model, which incorporates material toughness (a temperature compensation parameter) into the Morrow model to account for the effects of temperature. A significant advantage of this approach is that it eliminates the need for tensile tests, which are otherwise essential for assessing material toughness in the modified Morrow model. Instead, all material constants in our models are derived solely from fatigue test results. We validate our models using fatigue data from three promising USC boiler tube materials—Super304H, TP310HCbN, and TP347H—and their welded joints at operating temperatures of 500, 600, and 700 °C. The results demonstrate that approximately 91% of the fatigue data for all six materials fall within a 2.5× scatter band of the model's predictions, indicating a high level of accuracy and broad applicability across various USC boiler tube materials and their welded joints, which is equivalent to the performance of the modified Morrow model. [ABSTRACT FROM AUTHOR]

Thermal power plant slag is a waste that is presently obtained from many power stations all over the world. A possible method for its utilization is using it to produce concrete. This paper analyses the effect of thermal power plant slag on the technological properties of concrete mixtures and the mechanical properties of concrete subjected to heat–moisture processing. Quantitative estimates of the investigated factors' influence on the concrete mixture's water demand and the strength of steamed concrete were obtained. The influences of TPP slag content and its water demand on concrete composition features as well as concrete strength are shown. The novelty of the work lies in the use of an experimental–statistical model to optimize the composition of steamed concrete using slag from the viewpoint of maximum strength per kilogram of cement. It has been demonstrated that the optimal part of slag in aggregate, which provides maximum strength at 4 h and 28 days after steaming, is 0.5–0.55 and 0.45–0.55, respectively. A method for the design of concrete composition using slag from thermal power plants is proposed. [ABSTRACT FROM AUTHOR]

Kaplan turbines, as one of the well-known hydraulic turbines, are generally utilized worldwide for low-head and high-flow conditions. Any failure in each of the turbine components can result in long-term downtime and high repair costs. In a particular case, if other parts are damaged due to the impact of the broken blades (e.g., the main shaft of the turbine), the whole power plant may be shut down. On the other hand, further research on the primary causes of failures in turbines can help improve the present failure evaluation methodologies in power plants. Hence, the main objective of this paper is to present the major causes of Kaplan turbine failures to prevent excessive damage to the equipment and provide practical solutions for them. In general, turbines are mainly subjected to both Internal Object Damage (IOD) and Foreign Object Damage (FOD). Accordingly, this paper presents a state-of-the-art review of Kaplan turbine failures related to material and physical defects, deficiencies in design, deficits in manufacturing and assembly processes, corrosion failures, fatigue failure, cavitation wear, types of cavitation in hydro turbines, hydro-abrasive problems, and hydro-erosion problems. Eventually, the authors have attempted to discuss practical hints (e.g., nanostructured coatings) to prevent damages and improve the performance of Kaplan turbines. [ABSTRACT FROM AUTHOR]

An important method that coal-fired power plants use to realise low-cost zero discharge of desulfurisation wastewater (FGD wastewater) is to utilise wet slag removal systems. However, the high Cl− content of FGD wastewater in wet slag removal systems causes environmental damage. In this study, the corrosion behaviour of the inner guide wheel material, 20CrMnTi, was studied using dynamic weight loss and electrochemical methods. X-ray diffraction, scanning electron microscopy, and energy spectroscopy were used to analyse the organisational and phase changes on the surfaces and cross sections of the samples at different Cl− concentrations. The corrosion rate increased with the Cl− concentration up to 20 g/L, but it decreased slightly when the Cl− concentration exceeded 20 g/L. In all the cases, the corrosion rate exceeded 0.8 mm/a. The corrosion product film density initially increased and then decreased as the Cl− concentration increased. The corrosion products comprised mainly α-FeOOH, γ-FeOOH, β-FeOOH, Fe3O4, and γ-Fe2O3. [ABSTRACT FROM AUTHOR]

The purpose of this research was to analyze the change in residual stresses in the surface layer of steel samples taking into account the technological heredity effect on the value and sign of residual stresses. An installation of combined processing was developed. Combined processing consists of sequentially performing electromechanical processing and diamond smoothing. All areas of the samples were studied—after machining (i.e., in the initial state), after electromechanical processing, and after diamond smoothing. The research shows that the sign and value of residual stresses are significantly affected by the combined processing modes. The main parameters of the surface layer are formed at the final stage of the combined processing–diamond smoothing. This paper gives recommendations on the use of combined processing for power plant parts. [ABSTRACT FROM AUTHOR]

An effective strategy for achieving cost-effective and environmentally friendly desulfurization wastewater in coal-fired power plants involves the incorporation of desulfurization wastewater into the slag water system. The objective of this study was to analyze the corrosion behavior of Q235-A slag-picker shell material upon the introduction of FGD wastewater into the slag water system. The dynamic weight loss method, electrochemical testing method and microscopic phase characterization were employed to investigate the impact of varying chloride ion concentrations (ranging from 1000 mg/L to 30,000 mg/L) of flue gas desulfurization wastewater (FGD wastewater) on the corrosion of Q235-A slag-picker shell material. The test results indicate that as the concentration of chloride ions increases, the corrosion rate increases from 1.1487 mm/a to 1.5590 mm/a when the concentration is less than 10,000 mg/L. However, when the concentration exceeds 10,000 mg/L, the corrosion rate decreases from 1.559 mm/a to 1.0393 mm/a. The corrosion rate is above 1 mm/a at all concentrations. As the Cl− concentration, the quality of the corrosion product film initially increases and then decreases. The primary components of the corrosion product are α- FeOOH, γ-FeOOH, β-FeOOH, Fe3O4 and γ-Fe2O3. [ABSTRACT FROM AUTHOR]

The results of the processing of ash from the combustion of fuel oil after roasting with the addition of Na2CO3 followed by aluminothermic melting are presented. As a result, metallic nickel and vanadium slag were obtained. Studies of slag, metal, and deposits on the electrode were carried out. The resulting metal contains about 90 wt% Ni. The main phases of scurf on the electrode are a solid solution based on periclase (Mg1–x–y–zNixFeyVzO), sodium-magnesium vanadate (NaMg4(VO4)3), and substituted forsterite (Mg2–x–yFexNiySiO4). The processing of ash made it possible to significantly increase the concentration of vanadium and convert it into more soluble compounds. Vanadium amount increased from 16.2 in ash to 41.4–48.1 V2O5 wt% in slag. The solubility of vanadium was studied during aqueous leaching and in solutions of H2SO4 and Na2CO3. The highest solubility of vanadium was seen in H2SO4 solutions. The degree of extraction of vanadium into the solution during sulfuric acid leaching of ash was 18.9%. In slag, this figure increased to 72.3–96.2%. In the ash sample, vanadium was found in the form of V5+, V4+ compounds, vanadium oxides VO2 (V4+), V2O5 (V5+), and V6O13, and nickel orthovanadate Ni3(VO4)2 (V5+) was found in it. In the slag sample, vanadium was in the form of compounds V5+, V4+, V3+, and V(0÷3)+; V5+ was presented in the form of compounds vanadate NaMg4(VO4)3, NaVO3, and CaxMgyNaz(VO4)6; V3+ was present in spinel (FeV2O4) and substituted karelianite (V2–x–y–zFexAlyCrzO3). In the obtained slag samples, soluble forms of vanadium are due to the presence of sodium metavanadate (NaVO3), a phase with the structure of granate CaxMgyNaz(VO4)6 and (possibly) substituted karelianite (V2–x–y–zFexAlyCrzO3). In addition, spinel phases of the MgAl2O4 type beta-alumina (NaAl11O17), nepheline (Na4–xKxAl4Si4O16), and lepidocrocite (FeOOH) were found in the slag samples. [ABSTRACT FROM AUTHOR]

A new type of cemented paste backfill (CPB) was prepared by using the bottom ash (BA) from a thermal power plant as an aggregate, alkali-activated slag as a binder, and an air-entraining agent as an admixture. Based on the central composite design (CCD) response surface method, the mix ratio was optimized, and scanning electron microscopy-energy dispersive spectroscopy (SEM-EDS) was performed on the optimal mix ratio. ImageJ software was utilized to determine the porosity of the experimental samples at various curing ages. The results indicate that the optimal mix ratio of the aggregate-binder ratio is 3.28, the alkali dosage is 3%, the solid content is 67.44%, and the air-entraining agent dosage is 0.1%. As the curing age increases, the porosity of CPB gradually decreases. A calcium aluminosilicate hydrate (C-A-S-H) gel is the main hydration product of alkali-activated slag. At the beginning of the hydration reaction, the slag gradually dissolves, and the C-A-S-H product binds the BA together. At 14 d, complete calcium hydroxide (CH) crystals appeared in the hydration product. Finally, the degree of C-A-S-H crystallization increased further to form a dense structure. [ABSTRACT FROM AUTHOR]

Lignite is an important natural resource with the application potential covering present and future energy systems, including conventional power plants and gasification systems. Lignite is also a valuable precursor for the production of porous materials of tailored properties for various environmental applications, including the removal of contaminants from gaseous or liquid media. Although the lignite-based activated carbons are commercially available, various approaches to produce carbon materials of desired properties are still being reported, covering temperature, partial oxidation and chemical activation effects on surface and structural properties of these materials. Limited data is, however, available on the effects of pressure as the activation parameter in shaping the porous structure of carbonaceous materials, in particularly lignite-derived. In the study presented the combined effect of carbon dioxide activation and pressure in the range of 1–3 MPa at the temperature of 800 °C on the development of porous structure of lignite chars was reported. The study was also focused on poor-quality resources valorization by using a relatively low calorific value, low volatiles and high ash content lignite as a carbon material precursor. The results showed that the application of pressure in carbon dioxide-activation process at 800 °C results in generation of chars of comparable or higher specific surface area than the carbon materials previously received with demineralization and carbon dioxide activation of lignite. They also proved that the combined pressure and carbon dioxide activation may be effectively applied in conversion of low quality lignite into valuable porous materials. [ABSTRACT FROM AUTHOR]

Advanced power plant alloys must endure high temperatures and pressures for durations at which creep data are often not available, necessitating the extrapolation of creep life. A recently developed creep life extrapolation method is the Wilshire equations, with which multiple approaches can be used to increase the goodness of fit of available experimental data and improve the confidence level of calculating long-term creep strength at times well beyond the available experimental data. In this article, the Wilshire equation is used to extrapolate the creep life of Inconel 617 and Nimonic 105 to 100,000 h. The use of (a) different methods to determine creep activation energy, (b) region splitting, (c) heat- and processing-specific tensile strength data, and (d) short-duration test data were investigated to determine their effects on correlation and extrapolation. For Inconel 617, using the activation energy of lattice self-diffusion as Q C * resulted in a poor fit with the experimental data. Additionally, the error of calculated rupture times worsened when splitting regions. For Nimonic 105, the error was reduced when heat- and processing-specific tensile strengths were used. Extrapolating Inconel 617 creep strength to 100,000 h life gave conservative results when compared to values calculated by the European Creep Collaborative Committee. [ABSTRACT FROM AUTHOR]