Keynote: Materials Manufacturing for Extreme Conditions in Metallurgical Processing Industry

Pearson, Murray

Abstract

The development of more energy intensive metallurgical processes, with more extreme operating conditions, since the early 1990’s has driven the selection and application of unconventional materials and continues to support the commercialization and use of new hybrid materials and additive manufacturing processes. This presentation describes some of the unusual service conditions in metallurgical applications such as pressurized reactors with highly acidic environments (pH < 0) and elevated temperatures (T > 150°C), regeneration of HCl from ferric/ferrous chloride solutions by pyrohydrolysis, the development of erosion resistant valves, coatings and pressure-letdown systems for high pressure/temperature applications, supersonic diffusers for high pressure venting applications, re-design of gas cyclones for removal of entrained solids/slurry droplets from flashed steam, and corrosion-resistant spargers for oxygen injection applications. Each of these applications involved testing of an alloy or non-metallic material that had not been previously used in such application, or the use of multiple materials in concert, or the development of a new material not commercially available at the time. The presentation concludes with a discussion of evolving use of cold gas dynamic spray and wire-arc additive manufacturing processes for industrial-scale production of protective coatings and components for each of these novel applications.

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Keynote: Materials Manufacturing for Extreme Conditions in Metallurgical Processing Industry

Abstract