Materials Technologies for the Process Industries of the Future Management Strategies and Research Opportunities (2000) / Chapter Skim
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Research and Development Opportunities
Research and Development Opportunities
Pages 41-58
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From page 41... ...
In keeping with the crosscutting theme of this report, the committee focused on materials technologies that would enable or improve the understanding and processing of existing and new products used by more than one lOF industry rather than on the development of industry-specific products. ALUMINUM INDUSTRY Identified Needs Oxidation-Resistant and Corrosion-Resistant Materials In the Bayer process (used to convert bauxite to alumina)
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From page 42... ...
The industry needs improved aluminum joining technologies, such as resistance spot welcling, and improved materials to extend electrode tip life. Modeling Better modeling is a common need of the lOF industnes and has crosscutting potential, although models are likely to have specific applications.
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From page 43... ...
The production of aluminum is extremely energy intensive, and the use of consumable carbon anodes gives rise to emissions of greenhouse gases. Inert anode and cathode technology for electrowinning of aluminum in primary electrolysis cells is the subject of extensive ongoing research.
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From page 44... ...
The aluminum industry could use more durable refractory materials for melting, holding, and handling molten aluminum. Melting furnaces use salts to help break down the surface oxide during melting and chlorine for fluxing and magnesium control.
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From page 45... ...
Opportunities The committee identified several research opportunities to meet the needs of the chemical industry. The industry would benefit from improved materials capable of withstanding aggressive process environments (e.g., improved thermal spray coatings resistant to corrosive liquid environments; more cost-effective, reliable techniques of cladding exotic materials over a steel substrate; materials with improved resistance to high-temperature, high-dew point, and liquid halogencontaining environments; and materials resistant to metal dusting)
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From page 46... ...
A multi-institutional team, including ORNE, the Institute of Paper Science and Technology, the Pulp and Paper Research Institute of Canada, and a large number of pulp and paper companies and suppliers is involved in this project. Computer modeling and experimentation has shown that the washing process of the recovery boiler is a significant source of corrosion and the subsequent failure of composite tubes (Adams, 19971.
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From page 47... ...
Problems with conventional recovery boilers include: corrosion at air ports, the lack of on-line monitoring to detect impending failures, and water-side corrosion cracking. Recycled Paper One of the pressing issues for the pulp and paper industry is sticky polymer residues in the recycled paper stream.
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From page 48... ...
Modifications of surface materials would help prevent the adhesives used in "engineered lumber" from disturbing processing operations. Research Opportunities The forest products industry offers several high-priority R&D opportunities.
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From page 49... ...
Fourth, the industry needs ways to increase the corrosion resistance and wear resistance of existing materials in the changing chemical and physical environment. Fifth, the inclustr~r would benefit Tom surface modification to prevent detrimental interactions with adhesives, improve wear resistance, and .
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From page 50... ...
Improvements might include smaller, more efficient glass tanks, faster flow through (more "pull" from) furnaces, better refractories, more efficient burners, cheaper oxygen technologies, better sensors, more useful modeling, better energy recovery from melting operations, faster product forming, lower cost raw materials, and better glass compositions.
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From page 51... ...
The first mining industry road map on crosscutting technology deliberately excluded nonferrous metals in favor of technologies that would benefit both coal and hardrock mining ANNA, 1998~. The next road map will address processing technologies for coal and extractive metallurgy.
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From page 52... ...
Conserving some of the heat in a slab by hot charging minimizes the chances of cracking a scale and also saves energy but requires careful scheduling when several different grades of steel are made in consecutive heats. Oxidation also occurs when hot gases are contained (e.g., in the off-take from a basic oxygen furnace)
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From page 53... ...
The combination of wear with chemical attack at high temperatures and thermal cracking makes testing new materials difficult. Refractories The industry uses enormous quantities of refractory materials as structural containers, protective coatings, and fluxes, especially in continuous casting.
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Research Opportunities R&D opportunities include new equipment and hardware, such as design devices to ensure temperature uniformity and magnitude and to control heat losses and quenching devices to ensure uniform treatment of large volumes of material, reduce costs. improve disposal methods.
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From page 55... ...
~ general terms, the glass industry road map has need for improved refractories for melting systems that use oxygen refractories identified a ~ ~ ~ combustion. In fact, improved refractories for the crown and breast walls is one of the highest priorities in the glass technology roadmap (Energetics, ~ 997a)
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From page 56... ...
Neither the forging nor the heat-treating industry identified a need for improved refractories. Research Opportunities Although the committee identified many opportunities for crossscutting research from the lOF industry road maps, the one need common to all of the road maps is for a database on high-temperature materials.
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From page 57... ...
The steed industry road map indicated that refractories between the steel ladle and the continuous caster mold would yield major cost reductions. The industry greatly needs to reduce the cost of refractories for all equipment, from the well block and slicle gate system at the ladle to the submersible entry nozzles to the tundish lining, the tundish slide plates, and the shrouds.
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From page 58... ...
Funding by industry, universities, and the national laboratones for the development of improved refractories has been reduced although most of the members of Industries of the Future have identified a need for them. The Office of Industrial Technologies should consider starting a refractories initiative to encourage cooperative research and development agreements and other mechanisms that would promote cooperation between industry and government agencies.
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