Meeting the challenges related to material issues in chemical industries

Reliable performance and profitability are two important requirements for any chemical industry. In order to achieve high level of reliability and excellent performance, several issues related to design, materials selection, fabrication, quality assurance, transport, storage, inputs from condition monitoring, failure analysis etc. have to be adequately addressed and implemented. Technology related to nondestructive testing and monitoring of the plant is also essential for precise identification of defect sites and to take appropriate remedial decision regarding repair, replacement or modification of process conditions. The interdisciplinary holistic approach enhances the life of critical engineering components in chemical plants. Further, understanding the failure modes of the components through the analysis of failed components throws light on the choice of appropriate preventive measures to be taken well in advance, to have a control over the overall health of the plant. The failure analysis also leads to better design modification and condition monitoring methodologies, for the next generation components and plants. At the Indira Gandhi Centre for Atomic Research (IGCAR), Kalpakkam, a unique combination of the expertise in design, materials selection, fabrication, NDT development, condition monitoring, life prediction and failure analysis exists to obtain desired results for achieving high levels of reliability and performance assessment of critical engineering components in chemical industries. Case studies related to design, materials selection and fabrication aspects of critical components in nuclear fuel reprocessing plants, NDT development and condition monitoring of various components of nuclear power plants, and important failure investigations on critical engineering components in chemical and allied industries are discussed in this paper. Future directions are identified and planned approaches are briefly described

Solvent Extraction Studies of Gadolinium in Tri-Butyl Phosphate

AbstractFast reactor spent fuel reprocessing plants should be designed for inherent criticality safety due to high plutonium content. Addition of soluble neutron poison is one way to do that. Gadolinium is the best choice based on neutron absorption cross section and chemical compatibility. In this work, using classical thermodynamic approach, the distribution coefficient of gadolinium in tributyl phosphate has been calculated and compared with the experimental data. The influence of acidity and uranium at equilibrium on gadolinium distribution in tributyl phosphate has been investigated. The result establishes the feasibility of employing gadolinium as soluble neutron poison in fast fuel reprocessing

Microstructure and interfacial reactions during active metal brazing of stainless steel to titanium

Microstructural evolution and interfacial reactions during active metal vacuum brazing of Ti (grade-2) and stainless steel (SS 304L) using a Ag-based alloy containing Cu, Ti, and Al was investigated. A Ni-depleted solid solution layer and a discontinuous layer of (Ni,Fe)2TiAl intermetallic compound formed on the SS surface and adjacent to the SS-braze alloy interface, respectively. Three parallel contiguous layers of intermetallic compounds, CuTi, AgTi, and (Ag,Cu)Ti2, formed at the Ti-braze alloy interface. The diffusion path for the reaction at this interface was established. Transmission electron microscopy revealed formation of nanocrystals of Ag-Cu alloy of size ranging between 20 and 30 nm in the unreacted braze alloy layer. The interdiffusion zone of β-Ti(Ag,Cu) solid solution, formed on the Ti side of the joint, showed eutectoid decomposition to lamellar colonies of α-Ti and internally twinned (Cu,Ag)Ti2 inter- metallic phase, with an orientation relationship between the two. Bend tests indicated that the failure in the joints occurred by formation and propagation of the crack mostly along the Ti- braze alloy interface, through the (Ag,Cu)Ti2 phase layer

Preparation and characterization of biocompatible carbon electrodes

Electron transfer in microbial fuel cell and biosensors could be facilitated through high conductive materials with enhanced active surface area and appropriate redox potential suited to microbial metabolism. In the first strategy based on bulk doping, graphite/epoxy composite electrode (GECE) bulk was modified with six types of metal ion which were prepared through a wet impregnation procedure. In the second strategy, immobilization of redox dye on carbon cloth and graphite sheet was carried out using N,N′-dicyclohexylcarbodiimide for surface modification. Crystallinity, morphology, surface chemistry and electrochemical properties of all modified electrodes were investigated. Influence of redox behavior of electrodes suited to microbial metabolism and conducive to biofilm formation have been examined. It was observed that the Fe³⁺ doped GECE surfaces exhibited significantly high biofilm formation of 1.10(±0.18) × 10⁷ CFU/cm² as compared to other dopants. The microbial growth on the carbon cloth electrode and carbon fiber reinforced plate were found to be less (2.6(±0.97) × 10⁴, 4.8(±1.8) × 10³ CFU/cm² respectively) compared to GECEs

Corrosion-resistant Ti-xNb-xZr alloys for nitric acid applications in spent nuclear fuel reprocessing plants

This article reports the development, microstructure, and corrosion behavior of two new alloys such as Ti-4Nb-4Zr and Ti-2Nb-2Zr in boiling nitric acid environment. The corrosion test was carried out in the liquid, vapor, and condensate phases of 11.5 M nitric acid, and the potentiodynamic anodic polarization studies were performed at room temperature for both alloys. The samples subjected to three-phase corrosion testing were characterized using scanning electron microscopy (SEM) and energy-dispersive X-ray microanalysis (EDAX). As Ti-2Nb-2Zr alloy exhibited inferior corrosion behavior in comparison to Ti-4Nb-4Zr in all three phases, weldability and heat treatment studies were carried out only on Ti-4Nb-4Zr alloy. The weldability of the new alloy was evaluated using tungsten inert gas (TIG) welding processes, and the welded specimen was thereafter tested for its corrosion behavior in all three phases. The results of the present investigation revealed that the newly developed near alpha Ti-4Nb-4Zr alloy possessed superior corrosion resistance in all three phases and excellent weldability compared to conventional alloys used for nitric acid application in spent nuclear reprocessing plants. Further, the corrosion resistance of the beta heat-treated Ti-4Nb-4Zr alloy was superior when compared to the sample heat treated in the alpha + beta phase

Electrochemical noise technique for corrosion assessment - a review

This review details the electrochemical noise technique as applicable to corrosion assessment with emphasis on the fundamental principles, theoretical aspects, data analysis and applications. The use of this technique in understanding the mechanistic aspects of corrosion and corrosion monitoring has been discussed. The important applications of this technique in corrosion processes like uniform corrosion, localized corrosion (pitting, crevice corrosion and stress corrosion cracking), and evaluation of coatings are highligted. Miscellaneous applications are also explained