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Tables of Contents for Industrial Materials for the Future R&d Strategies
Chapter/Section Title
Page #
Page Count
List of Figures
iii
List of Tables
iii
Abbreviations and Terms
iv
Acknowledgments
v
ES.0 Executive Summary
1
1
ES.1 The Problem and Its Impact
1
1
ES.2 The R&D Approach and Recommended Solutions
2
1
ES.3 Estimated Benefits
3
1
ES.4 The Government Role
4
1
ES.5 Lessons Learned: A Model to Follow
4
1
Introduction
5
2
The Pulp and Paper Industry
7
7
Industry Branches
7
1
Global Competition
7
6
Sustaining Global Competitiveness
13
1
Description of the Problem: The Kraft Chemical Pulping Process
14
7
Introduction to the Kraft Chemical Pulping Process
14
1
Wood Yard Operations: Timber Preparation
14
1
Digester
14
1
Recovery Boiler
14
1
Chemical Recovery
15
3
The Problem
18
3
Solving the Problem through R&D
21
11
Background of Boiler Materials
21
1
R&D Approach
22
1
Factors Influencing R&D Allocation
22
2
The Role of DOE
24
1
AIM/IMF-Funded R&D Activities and Results
25
7
Overview of R&D Activities
25
1
Task 1: Examination of Microscopic Characteristics of Cracked Tubes
26
1
Task 2: Measurement of the Forces (Stresses) on the Surface of the Tube
26
1
Task 3: Modeling of the Forces (Stresses) on the Surface of the Tube
27
2
Task 4: Determination of the Service Environment
29
1
Tasks 5 and 6: Identification of Cracking Mechanism and Identification of More Ideal Processes and Materials
30
2
Economic, Energy, and Environmental Impacts of the R&D Program
32
8
Introduction to Estimation of Benefits
32
1
Industry Boiler Maintenance and Replacement Experience
33
1
The Economics from the Industry Viewpoint
33
2
The Economics of Better Maintenance Practice
34
1
The Economics of New Materials Upon Normal Replacement
34
1
The Economics of Early Replacement
34
1
The Benefits of the IMF Kraft Recovery Boiler Materials Research Program
35
4
Unit Efficiency and Cost Impacts of the IMF Kraft Recovery Boiler R&D Program
39
1
Environmental Benefits of the IMF Kraft Recovery Boiler R&D Program
39
1
Appendix A: Detailed Description of R&D Activities
40
Microstructural Characterization
40
Residual Stress Measurements
41
Finite Element Modeling
42
Thermal Fluctuations (Thermal Spikes)
43
Thermal-Fatigue Cracking and Thermal Fluctuations
43
Outer-Layer Stress State and Thermal Fluctuations
44
Characterization of Service Environment -- Stress-Corrosion Cracking
44
Service Environment During Normal Operation
44
Service Environment During Start-up, Dry-out, Shutdown, and Water-wash
45
Summary and Solutions to Composite Floor Tube Cracking
45
Summary of Conclusions
45
Path I: Improving Recovery Boiler Operating Procedures
48
Path II: Improving Recovery Boiler Floor-Tube Materials
48