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TO INVESTIGATE THE EROSIVE WEAR OF THERMAL SPRAYED CERAMIC COATING ON CAST IRON USED IN ASH SLURRY DISPOSAL PUMP

A THESIS SUBMITTED IN THE PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF DEGREE OF

MASTER OF TECHNOLOGY In Mechanical Engg. Machine Design SUBMITTED BY

Sunil Kumar
M80801161019

PUNJAB TECHNICAL UNIVERSITY JALANDHAR, PUNJAB, INDIA


July 2012

TO INVESTIGATE THE EROSIVE WEAR OF THERMAL SPRAYED CERAMIC COATING ON CAST IRON USED IN ASH SLURRY DISPOSAL PUMP
A THESIS SUBMITTED IN THE PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF DEGREE OF

MASTER OF TECHNOLOGY In Mechanical Engg. Machine Design

SUBMITTED BY

Sunil Kumar
M80801161019

PUNJAB TECHNICAL UNIVERSITY REGIONAL CENTER Baba Banda Singh Bahadur Engineering College Fatehgarh Sahib (Punjab)

July 2012

ACKNOWLEDGEMENTS
I express my sincere gratitude to the Punjab Technical University, Jalandhar for giving me the opportunity to work on the thesis during my final year of M.Tech. I would like to thank Dr. M.S. Grewal, Coordinator, PTU Regional Center, Baba Banda Singh Bahadur Engineering College, Fatehgarh Sahib for their kind support. I also owe my sincerest gratitude towards Prof. Jasbir Singh Ratol, Associate Professor & Workshop Superintendent, Department of Mechanical Engineering, Baba Banda Singh Bahadur Engineering College, for acting as supervisor and giving valuable guidance during the course of this investigation, for his ever encouraging and timely moral support. I would like to thank Dr. A.P.S. Sethi, Prof. & Head, Mechanical Evgineering Department, Baba Banda Singh Bahadur Engineering College, Fatehgarh Sahib for providing me the facilities in the department for the completion of my work. I would like to thank the Dean Academics and members of the Departmental Research Committee for their valuable suggestions and healthy criticism during my presentation of the work. I would also like to thank my parents for their blessings and my wife who helped me in my thesis. I would also like to thank everyone who has knowingly & unknowingly helped me throughout my thesis. Last but not least, a word of thanks for the authors of all those books and papers which I have consulted during my thesis work as well as for preparing the report. At the end thanks to the Almighty for all good deeds.

Sunil Kumar M80801161019

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ABSTRACT
Centrifugal pumps are used to transport the ash slurry from the thermal power plant to ash pond. Erosive wear occurs on the impeller of the pump due to the impingement of the ash particles, suspended in water, on the impeller with a high velocity. The service life of centrifugal pump, handling solid-liquid mixture can be increased by reducing the erosive wear. Due to erosion, pump life become very short and need to be replaced periodically. It affects both the initial cost and life of the component.

In the present work, three parameters were selected to investigate the erosive wear i. e., rotational speed, ash concentration and ash particle size. Detonation gun sprayed Al2O3 coating is provided on the surface to reduce the erosive wear and hence to improve the performance of centrifugal pump. The experimentation on high speed slurry erosion tester has been carried out to test the erosive wear of uncoated and coated material. The erosive wear behavior was investigated by Response surface methodology (RSM). Statistical analysis was performed in the form of the analysis of variance (ANOVA) to determine the interaction of experimental parameters. At the end, the graphs were compared for uncoated and coated material to get the final result. The result shows that the increase in each parameter contributes to erosive wear of pump impeller. The effect of rotational speed and ash concentration on erosive wear of the uncoated material is found to be significant as compared to ash particle size. For Al2O3 coated cast iron, the effect of rotational speed on erosive wear is found to be significant followed by ash concentration and ash particle size. Al2O3 coating on the surface of the pump impeller improves the performance of centrifugal pump.

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Contents
CANDIDATES DECLARATION ACKNOWLEDGMENTS ABSTRACT LIST OF TABLES LIST OF FIGURES i ii iii vi vii

1 INTRODUCTION
1.1 Ash Disposal System 1.1.1 1.1.2 1.1.3 1.1.4 Mechanical handling system Hydraulic system Pneumatic system Steam jet system

1
2 4 4 7 8 8 8 8 9 14

1.2 Principal Requirements of a Good Ash Handling Plant 1.3 Ash Disposal Using Centrifugal Pump 1.3.1 1.3.2 1.3.3 Working principle of centrifugal pump Main parts of a centrifugal pump Advantages of using centrifugal pumps for transportation of slurry 1.4 Wear 1.4.1 1.4.2 Types of wear Parameters affecting erosive wear

15 15 17 19 20 21 21

1.5 Methods for Testing Erosion in Slurry Pumps 1.5.1 1.5.2 1.5.3 Jet erosion test Slurry pot test Coriolis erosion test

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1.6 Survey of Thermal Power Plant, Yamunanagar 1.7 Thermal Spraying 1.8 Motivation of the Work

22 23 25

2 LITERATURE REVIEW 3 SLURRY EROSION TESTING


3.1 Hydraulic Ash Handling System 3.2 High Speed Slurry Erosion Tester 3.3 Erosion Testing of High Chrome Cast Iron 3.3.1 3.3.2 3.3.3 Experimental design (Response Surface Methodology) Analysis of variance (ANOVA) Modeled equation in terms of actual factors

27 37
37 39 41 45 46 48 49 49 52

3.4 Erosion Testing of Ceramic Coated Cast Iron 3.4.1 3.4.2 Experimentation and statistical analysis Modeled equation in terms of actual factors

4 RESULTS AND DISCUSSIONS


4.1 Results 4.1.1 4.1.2 Uncoated cast iron Ceramic coated cast iron

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54 54 57 59

4.2 Discussions

5 CONCLUSIONS AND SCOPE FOR FUTURE WORK REFERENCES A APPENDIX - Weight of each uncoated and coated specimen before and
after experimentation

62 64 68

B APPENDIX - Physical and chemical properties of fly ash C PUBLICATIONS

70 71

LIST OF TABLES
Table No. 1.1 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 Caption Technical data used for slurry disposal pumps Sieve analysis chart Factors affecting erosion with levels Box-Behnken design matrix ANOVA for response surface linear model Regresion analysis for response surface linear model Experimental and modeled values for the response (uncoated material) ANOVA for response surface reduced quadratic model Regresion analysis for response surface reduced quadratic model Experimental and modeled values for the response (Coated Material) Page No. 22 44 45 46 47 47 48 51 52 53

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LIST OF FIGURES
Figure No. 1.1 1.2 1.3 1.4 1.5 1.6 1.7(a) 1.7(b) 1.8(a) 1.8(b) 1.9 1.10 1.11 1.12 1.13 1.14 3.1 3.2 3.3 3.4 3.5(a) 3.5(b) 3.6 3.7 3.8 3.9 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 Caption Schematic diagram of a coal-fired thermal power station General outline of generation of ash Mechanical handling system Low pressure handling system High pressure handling system Pneumatic system Fluid flow in a centrifugal pump Model of a centrifugal pump Front view of impeller 3D model of impeller Open impeller Semi-open impeller Enclosed impeller Methods to test erosion Schematic of thermal spray process Schematic of the detonation thermal spray process Clean water for making slurry Slurry before entering the impeller Hydraulic ash handling system Slurry pumps in series Monitoring panel of high speed slurry erosion tester Experimental set-up of high speed slurry erosion tester Test specimen holder for holding maximum of 12 specimens Test specimens Ash percentage versus particle size Al2O3 coated specimens affected by erosive wear Weight loss vs. rotational speed Weight loss vs. ash concentration Weight loss vs. ash particle size Contributions of selected parameters for erosive wear of high chrome cast iron Weight loss vs. rotational speed Weight loss vs. ash concentration Weight loss vs. ash particle size Contributions of selected parameters for erosive wear of Al2O3 coated cast iron Comparison of erosion for coated and uncoated material Page No. 1 3 4 5 6 7 9 9 10 10 12 12 12 20 23 25 37 38 38 39 40 40 42 42 44 50 54 55 56 56 57 57 58 59 60

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Chapter 1

INTRODUCTION
A thermal power station is a power plant in which the prime mover is steam driven. A huge quantity of ash is produced in central stations, hundreds of tons of ash may have to be handled every day in large power stations and mechanical devices become indispensable. Figure 1.1 shows a schematic diagram of a Coal-Fired Thermal Power Station.

Fig. 1.1 Schematic diagram of a Coal-Fired Thermal Power Station (Source: en.wikipedia.org)
1. Cooling tower 2. Cooling water pump 3. Three-phase transmission line 4. Step-up transformer 5. Electrical generator 6. Low pressure steam turbine 7. Boiler feed water pump 8. Surface condenser 9. Intermediate pressure steam turbine 10. Steam control valve 11.High pressure steam turbine 12. Deaerator 13. Feed water heater 14. Coal conveyor 15. Coal hopper 16. Coal pulverizer 17. Boiler steam drum 18. Bottom ash hopper 19. Super heater 20.Forced draught fan 21. Reheater 22.Combustion air intake 23. Economizer 24. Air preheater 25. Precipitator 26.Induced draught fan 27. Flue gas stack

1.1 ASH DISPOSAL SYSTEM


All the available coals have some percentage of ash. The percentage of ash content (by weight) in anthracite coal, bituminous coal and lignite Coal ranges from 9.7 to 20.2 %, 3.3 to 11.7% and 4.2 to 5.3 % respectively. In the modern large steam power plants where huge amounts of coal are used, the amount of ash may be go up to many thousands tones of ash per year. Theoretically whole of the ash from the furnace should get deposited in the ash hoppers, but actually from 5 to 40% of it leaves with the flue gases. Figure 1.2 shows a general outline of generation of ash.

Ash handling comprises the following operations: 1. Removing the ash from the furnace ash hoppers. 2. Conveying this ash to a fill or storage by means of conveyors. 3. Disposal of the stored ash. To handle huge amounts of ash per day, mechanical means are employed. The ash handling and disposal system can work continuously or intermittently.

The following are some of the places where the ash can disposed off: 1. Where seaborne coal is used, barges may take the ash to sea for disposal into a watery grave. 2. Disused queries within reasonable distance of the power station may be used for dumping the ash into evacuated land. 3. Building contractors may use it to fill the low lying areas. 4. Wasteland sites may be reserved for the disposal of the ash. 5. Deep ponds may be constructed and the ash can be dumped into these ponds and when they are completely filled, they may be covered with soil and seeded with grass.

Ash handling is major and difficult problem due to the following difficulties encountered in its handling and disposal: 1. Ash is dusty and so irritating and annoying in handling. 2. It is hot when it comes out of the boiler furnace. 3. It is abrasive and wears out the containers. 4. Poisonous gases are produced. 5. Corrosive acids are produced in water. 6. It forms clinkers by fusing together in lumps.

The following points should be kept in view while handling and disposing ash: 1. Locate the ash plant on the leeward side of the power station to avoid blowing in and drawing into the buildings of the dry ash. 2. If the ash is cold and cannot be disintegrated, it may be better to crush it before passing it further or otherwise it might choke the sluiceway. 3. In case of pulverised fuel firing, 60 to 80% of ash is in the form of dust and fly ash; the plant should be designed accordingly.

Figure 1.2 General Outline of Generation of Ash (Source: en.wikipedia.org)

The modern ash handling systems are mainly classified into four groups:

1.1.1 Mechanical Handling System

This system is generally employed for low capacity power plants using coal as fuel. The hot ash released from the boiler furnaces is made to fall over the belt conveyor after cooling it through water seal. This cooled ash is transported to an ash bunker through the belt conveyor. From ash bunker the ash is removed to the dumping site through trucks. Figure 1.3 shows a mechanical ash handling system.

Figure 1.3 Mechanical Handling System (Source: en.wikipedia.org)

1.1.2 Hydraulic System

In this system ash is carried with the flow of water with high velocity through a channel and finally dumped in the sump. This system is subdivided as follows. (a) Low pressure system. (b) High Pressure system.

(a) Low Pressure System In this system a trough or drain is provided below the boilers and water is made to flow through the trough. The ash directly falls into the troughs and is carried by water to sumps. In the sump the ash and water are made to pass through a screen so that water is separated from ash; this water is pumped back to the trough for reuse and ash is removed to the dumping yard. The ash carrying capacity of this system is 50 tons/hour and distance covered is 500 meters. Figure 1.4 shows a low pressure hydraulic ash handling system.

Figure 1.4 Low Pressure Handling System (Source: en.wikipedia.org)

(b) High Pressure System.

The hoppers below the boilers are fitted with water nozzles at the top and on the sides. The top nozzles quench the ash while the side one provides the driving force for the ash. The cooled ash is carried to the sump through the trough. The water is again separated from ash and recalculated. The ash carrying capacity of this system is as large is 120 tons per hour and the distance covered is as large as 5000 meters. Figure 1.5 shows a high pressure hydraulic ash handling system.

Figure 1.5 High Pressure Handling System (Source: en.wikipedia.org)

Advantages of Hydraulic System: 1. The system is clean and healthy. 2. It can also be used to handle stream of molten ash. 3. Working parts do not come into contact with the ash. 4. It is dustless and totally closed. 5. It can discharge the ash at a considerable distance (8000 m) from the power plant. 6. The unhealthy aspects or ordinary ash basement work is eliminated. 7. Its ash carrying capacity is considerably large, hence suitable for large thermal power plants.

1.1.3 Pneumatic System

This system can handle abrasive ash as well as fine dusty materials such as fly ash and soot. It is referable for the boiler plants from which ash and soot must be transported some far off distance for final disposal. The exhauster provided at the discharge end creates a high velocity stream which picks up ash and dust from all discharge points and then these are carried in the conveyor pipe to the point of delivery. Large ash particles are generally crushed to small sizes through mobile crushing units which are fed from the furnace ash hopper and discharge into the conveyor pipe which terminates into a separator at the delivery end.

The separator working on the cyclone principle removes dust and ash which pass out into the ash hopper at the bottom while clean air is discharged from the top. The exhauster may be mechanical or it may use steam jet or water jet for its operation. When a mechanical exhauster is used it is usually essential to use a filter or washer to ensure that the requirements are less. Steam exhauster may be used in small and medium size stations. Where large quantities of water are easily and cheaply available water exhauster is preferred. The ash carrying capacity of this system varies from 25 to 15 tons per hour. A Pneumatic ash handling System is shown in figure 1.6.

Figure 1.6 Pneumatic System (Source: en.wikipedia.org)

1.1.4 Steam Jet System In this case steam at sufficiently high velocity is passed through a pipe and dry solid materials of considerable size are carried along with it. In a high pressure steam jet system a jet of high pressure steam is passed in the direction of ash travel through a conveying pipe in which the ash from the boiler ash hopper is fed. The ash is deposited in the ash hopper. The system can remove economically the ash through a horizontal distance of 200 m and through a vertical distance of 30 m.

1.2 PRINCIPAL REQUIREMENTS OF A GOOD ASH HANDLING PLANT


1. The plant should be able to operate with minimum personal attention and should be able to handle large clinkers as well as dust and soot. 2. Precautions should be taken against abrasiveness of ash. 3. It should be able to handle both wet and dry ash and operate with little noise and keep the dust menace to minimum. 4. Disposal of ash from the plant site should be speedy. 5. The plant should have adequate capacity to deal with the ultimate station capacity.

1.3 ASH DISPOSAL USING CENTRIFUGAL PUMP


The selection of a pumping system for any slurry transportation system is governed more by the practical considerations rather than purely on economical considerations of maximum efficiency. However, discharge pressure and the abrasivity are the two key factors for the selection of a pump. 1.3.1 Working Principle of Centrifugal Pump The centrifugal pump works on the principle of forced vortex flow, which means that when a certain mass of liquid is rotated by an external flow, the rise in pressure

head of the rotating liquid takes place. The rise in pressure head at any point of the rotating liquid is proportional to the square of tangential velocity of the liquid at that point. Thus at the outlet of the impeller where the radius is more, the rise in pressure head will be more and the liquid will be discharged at the outlet with high pressure head. Due to high-pressure head, the liquid can be lifted to a high level. Figure 1.7 (a, b) shows a flow of fluid and 3-D model of centrifugal pump.

Figure 1.7 (a) Fluid Flow in a Centrifugal Pump; (b) Model of a Centrifugal Pump (Source: en.wikipedia.org)

1.3.2 Main parts of a centrifugal pump The following are the main parts of centrifugal pumps 1) Impeller 2) Casing 3) Suction pipes with a foot valve and a strainer 4) Delivery pipe 1) IMPELLER The rotating part of centrifugal pump is called impeller. It consists of a series of backward curved vanes. The impeller is mounted on a shaft, which is connected to the shaft of an electric motor. An impeller is usually made of iron, steel, aluminium or 9

plastic, which transfers energy from the motor that drives the pump to the fluid being pumped by forcing the fluid outwards from the centre of rotation. Figure 1.8(a) shows the axial, radial and tangential component of flow and figure 1.8(b) shows a model of impeller [1].

Figure 1.8(a) Front view of impeller;

(b) 3D model of impeller

Components of impeller a) Blade Blades are the series of backward or forward curved vanes which transfers the power from shaft to the fluid. b) Hub and Shroud The hub is the surface of the machine closest to the axis of rotation. It defines the inner fluid flow surface. The shroud is the surface of the machine farthest from the axis of rotation. It defines the outer fluid flow surface. The hub and shroud can be

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defined only after the machine data has been defined, although all of these objects can be defined in one step. c) Leading and trailing edges The leading edge curve is the most upstream part of the blade. Any change to the leading edge changes the blade surfaces, which changes the periodic surfaces as well as the hub and shroud surfaces. The trailing edge curve is the most downstream part of the blade. Impellers are classified as: Open impeller Most totally open impellers are found on axial flow pumps. This type of impeller would be used in a somewhat conventional appearing pump to perform a chopping, grinding action on the liquid. The totally open axial flow impeller moves a lot of volume flow, but not a lot of head or pressure. With its open tolerances for moving and grinding solids, they are generally not high efficiency devices. Open impeller is shown in figure 1.9. Semi-open impeller A semi-open impeller has exposed blades, but with a support plate or shroud on one side. These types of impeller are generally used for liquids with a small percentage of solid particles from the bottom of a tank or river, or crystals mixed with the liquid. The efficiency of these impellers is governed by the limited free space or tolerance between the front leading edge of the blades and the internal pump housing wall. Semiopen impeller is shown in figure 1.10.

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Figure 1.9 Open Impeller Figure 1.10 Semi-Open Impeller (Source: Slurry System Handbook by Baha Abulnaga, 2002-McGraw Hill Companies Inc.)

Enclosed impeller Totally enclosed impellers are designed with the blades between two support shrouds or plates. These impellers are generally used clean liquids because tolerances are tight at the eye and the housing, and there is no room for suspended solids, crystals or sediment. Figure 1.10 shows a type of enclosed impeller.

Figure 1.11 Enclosed Impeller (Source: Slurry System Handbook by Baha Abulnaga, 2002-McGraw Hill Companies Inc.)

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2) CASING Casing of a pump is an airtight passage surrounding the impeller and is designed in such a way that the kinetic energy of the water discharged at outlet of the impeller is converted into the pressure energy before the water leaves the casing and enters the delivery pipe. Types of casing: a) Volute casing Volute casing is of spiral type in which area of flow increase gradually. The increase in the area of flow decreases the velocity of flow. The decrease in velocity increases the pressure of the water flowing through the casing. In case of volute casing the efficiency of the pump increase slightly as a large amount of energy is lost due to formation of eddies in this type of casing. b) Vortex casing If a circular chamber is introduced between the casing and the impeller, the casing is known as vortex casing. By introducing the circular chamber, the loss of energy due to formation of eddies is reduced considerably. Thus, the efficiency of the pump is more than the pump with volute casing. c) Casing with guide blades In this type of casing, the impeller is surrounded by series of guide blades mounted on ring, which is known as diffuser. The guide vanes are designed in such a way that water from the impeller enters the guide vanes without stock. Also as the area of guide vanes increase, thus reducing the velocity of flow through guide vanes and consequently increasing the pressure of water. The water from the guide vanes then passes through the surrounding casing, which is concentric with the impeller

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3) SUCTION PIPE WITH A FOOT VALVE AND A STRAINER A pipe whose one end is connected to the inlet of the pump and the other end dips into water in a sump is known as a suction pipe. A foot valve, which is non-return valve or one-way type of valve, is fitted at the lower end of suction pipe. The foot valve opens only in the upward direction. A strainer is also fitted at the lower end of suction pipe. 4) DELIVERY PIPE A pipe whose one end is connected to the outlet of the pump and the other delivers the water at the required height is known as delivery pipe. 1.3.3 Advantages of using Centrifugal Pumps for Transportation of Slurry 1) Simplicity of design 2) Easier installation 3) Low maintenance 4) Lower weight 5) Handles suspensions and slurry easily Centrifugal pumps are best suited for short distances and for in-plant slurry pipe line systems. Though the discharge pressure of centrifugal pumps is relatively low, they can also be used for moderate pressure requirements when used in series. The centrifugal pumps are used for over 97% of all short distance slurry pipelines. The design of a centrifugal pump for slurry handling system needs special consideration to ensure that the flow passage are such as to offer no restriction to the passage of solids. The abrasivity of solids cause wears in the pumps. A vertical split casing design is necessary to provide ready access to the wearing parts for replacement. For a given duty, centrifugal pumps are usually cheaper, occupy less space and have lower maintenance costs than positive displacement types, and can handle much larger solids.

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1.4 WEAR
Wear is defined as progressive volume loss of material from a solid surface due to corrosion, abrasion and erosion. Wear is one of the most common problems encountered in industrial applications. It is defined as the erosion of material from a solid surface by the action of another solid. In the domain of wear, particularly the wear encountered in handling abrasive solid particles, much work has been done in the past half century with regard to dry abrasivity, but only in more recent years has interest grown in wet abrasivity, namely slurries [24]. 1.4.1 Types of wear 1) Adhesive wear Adhesive wear is the only universal form of wear; it arises from the fact that, during sliding, regions of adhesive bonding, called junctions, form between the sliding surfaces. If one of these junctions does not break along its original interface, then a chunk from one of the sliding surfaces will have been transferred to the other surface. In this way, an adhesive wear particle will have been formed. Initially adhering to the other surface, adhesive particles soon become loose and can disappear from the sliding system. One of the significant things about adhesive wear is that at the interface, or the point where it touches another metal surface, it must be very hot in order for the micro welding to take place at all. That is what adhesive wear is microscopic welding. The heat produced at the contact interface is very high near the melting point of the two metals touching each other. This heat mostly comes from the stress of contact and not from the temperature of the environment [29]. 2) Abrasive wear Abrasive wear is produced by a hard, sharp surface sliding against a softer one and digging out a groove. The abrasive agent may be one of the surfaces or it may be a

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third component (such as sand particles) Abrasive wear coefficients are large compared to adhesive ones. Thus, the introduction of abrasive particles into a sliding system can greatly increase the wear rate; automobiles, for example, have air and oil filters to catch abrasive particles before they can produce damage. On the abrasive specimen, the surface shows a scratched appearance from hard particles digging into it as they were moved across the surface [29].

3) Corrosive wear Corrosive wear arises when a sliding surface is in a corrosive environment, and the sliding action continuously removes the protective corrosion layer, thus exposing fresh surface to further corrosive attack. Corrosive wear occurs as a result of chemical reaction on a wearing surface. The most common type of corrosion is mainly due to reaction between metal and oxygen. These oxides are wiped away with the flow and cause pitting of the surfaces. Corrosion is accelerated as impacted surfaces are exposed to slurry chemistry [35].

4) Erosive wear Erosive wear is the dominant process and can be defined as the removal of material from a solid surface due to mechanical interaction between the surface and the impinging particles in a liquid stream. Erosion involves the transfer of kinetic energy to the surface. This means that in erosion material removal is a function of particle velocity squared to higher power. Erosive wear depends on the predominant impact angle of particle impingement with the material surface. Impact angle will vary from zero degree to 90 degrees and depend on both fluid particle and particle- particle interaction [19]. This type of wear can be found on impellers and volute casing in slurry pumps, angled pipe bends, turbines, pipes and pipe fitting, nozzles, burners etc. The material loss due to erosion increases with the increase in kinetic energy of the particles impacting at the target surface.

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The volume loss due to erosion is a troublesome problem foe slurry transportation systems e.g. mineral transport systems, ash disposal systems. The erosion wear due to the air borne particles in some devices such as jet planes and turbines is also significant due to very high impact velocity. It is thus a challenging task to control the erosion wear in many engineering applications. The material removal due to erosion is caused by two dominant mechanisms namely brittle fractures and platelet deformations. In brittle type material, the solid particles impacting on the target surface forms cracks in longitudinal and lateral directions. These cracks propagate due to impact of succeeding particles and broken materials pieces will be carried out by flowing fluid.The material removal rate due to brittle fracture increases with increase in normal component if the particle velocity and thus the brittle type material show maximum wear near normal impact angles. In Platelet mechanism, the impact of solid particles deforms the target surface to forms hills and valleys. The repeated impacts of particles remove the material and forms crater at the surface. This mechanism along with micro-cutting and chipping dominates in ductile type materials, which show the maximum wear in the impact angle range of 20-40 degree. Apart from the target surface characteristics like brittle or ductile type, many other parameters such as solid particles, carrier fluid, flow conditions etc. affect the erosion wear. It is, therefore, difficult to estimate wear for a given operating conditions [19]. 1.4.2 Parameters Affecting Erosion Wear 1) Impact angle Impact angle is defined as the angle between the target surface and the direction striking velocity of the solid particle. The variation of erosion wear with the impact angle depends on the characteristics of the target surface material namely brittle or ductile type.

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2) Velocity of solid particles Velocity of solid particle strongly affects the erosion wear. As particle velocity increases there is significant increase in erosion rate [25]. The erosion rate is generally related to the particle velocity using power law relationship in which the power index for velocity varies in the range of 2-4. 3) Hardness Hardness is the characteristic of a solid material expressing its resistance to permanent deformation. Surface hardness as well as hardness of solid particles has profound effect on the erosion wear mechanism. Hardness ratio has been defined as the ratio of hardness of target material to the hardness of solid particles. 4) Particle size and shape Particle size and shape is also one of the prominent parameter, which affect erosion wear. Many investigators have considered solid particle size important to erosion. The erosive wear increases with increase in particle size according to power law relationship. The effect of particle shape on the erosion is not very well established due to difficulties in defining the different shape features. Generally roundness factor is taken into consideration. If roundness factor is one then the particles are perfectly spheres and a lower values show the particle angularity [4]. Sizing of the ash particles by sieve analysis: A sieve analysis is a procedure used to assess the particle size distribution of a granular material. Being such a simple technique of particle sizing, it is probably the most common. A mechanical shaker is used for sieve analysis in which sieves are used for gradation test. A gradation test is performed on a sample of aggregate. A sieve analysis involves a column of sieves with wire mesh cloth (screen). A weighed sample is poured into the top sieve which has the largest screen openings. Each lower sieve in the column has smaller openings than the one above. At the base is a round pan, called the receiver. The column is placed in a mechanical shaker. The shaker shakes the column for some fixed amount of time. After

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the shaking is complete the material on each sieve is weighed. The weight of the sample of each sieve is then divided by the total weight to give a percentage retained on each sieve [11].

%Retained =

100%

Where WSieve is the weight of aggregate in the sieve and WTotal is the total weight of the aggregate. 5) Solid concentration Concentration is amount of solid particles by weight or by volume in the fluid. As concentration of particle increases more particles strike the surface of impeller which increase the erosion rate, the concentration of slurries can vary from 2% to 50% depending upon the type of slurry. However, at very high concentrations particleparticle interaction increases and this decreases the striking velocity of particle on the surface.

1.5 METHODS FOR TESTING EROSION IN SLURRY PUMPS


The erosion wear has been estimated by different ways such as field tests, pilot plant tests, bench scale tests or numerical analysis. Field tests give the actual wear but required a long time and the results are particular to a specified condition. It is therefore preferable to conduct pilot plant test where the field conditions are to be simulated in a scaled test loop to generate data for different operating conditions with relatively less efforts. However, such tests are laborious, time consuming and require large materials. Hence, most of the wear test data have been generated using bench scale test rigs. These rigs are suitable to small laboratory being small in size and some of the rigs can generate the data at an accelerated rate. The large data available for different

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operating conditions have been generally used to develop empirical correlations for estimating erosion wear. In some of the numerical analysis, the correlations obtained through bench scale rigs have been used to estimate the erosion wear based on local values of the effecting parameters. Erosion in slurry pumps can be tested by following methods: 1.5.1 Jet erosion test In jet erosion, testing a high velocity jet strikes a flat specimen at some adjustable angle. In jet erosion tests, the amount of material removed is determined by the weight loss. The material which accumulates on the specimen surface interferes with the incoming particle. The weight loss of the specimen corresponds to the average erosion over the surface. Figure 1.12 (a, b, c) shows a principle of Jet erosion test, Slurry pot test and Coriolis erosion test. Jet erosion tester has been developed to investigate the effect of different parameters particularly the impact angle under controlled environment. In jet erosion tester, a circular jet of solidliquid mixture strikes at the wear specimen fixed in a fixture, which can be oriented at any angle with respect to the former. Generally a pump is used to drive water at high pressure and the solid particles are being sucked through an injector. The mixing of the solidliquid is formed in the mixing chamber before the jet comes out through a nozzle.

Figure 1.12 (a) Jet erosion test; (b) Slurry pot test; (c) Coriolis erosion test (Source: Slurry System Handbook by Baha Abulnaga, 2002-McGraw Hill Companies Inc.)

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1.5.2 Slurry pot test In slurry pots, a specimen rod of circular cross-section, fixed to the end of an arm, is rotated in a circular container filled with the slurry assuming homogeneous suspension of the solid particles. In slurry pot tests, also the amount of material removed is determined by the weight loss. The samples are weighted before and after the tests [13]. Slurry pot tester is simple in design, easy to fabricate and operate. In a slurry pot tester, generally two cylinder wear specimens have been rotated in solid liquid mixture. The rotational movement of the wear specimens and sometimes an impeller attached at the end of 6th shaft keep the solid particles suspended in the liquid. The rotating test specimen moves at a velocity relative to the solid-liquid suspension, which is assumed stationary and homogeneous inside the pot. In a slurry pot tester the rotational velocity of the specimen has been taken as the relative velocity between the particles and wear specimens assuming suspension as stationary. However, due to rotation of the wear specimen and propeller the mixture inside the pot are highly turbulent conditions. Baffles are used to break the vortex produced, which also develops some amount of non-homogeneity in the suspension. These phenomena result in some error in evaluating the independent/isolated effect of various parameters such as velocity, concentration, and impact angle etc on erosion wear. 1.5.3 Coriolis erosion test The Coriolis tester is used to simulate the motion of dense slurries and their interaction with surfaces such as slurry pumps or pipelines. In this type of tester slurry passes rapidly through a revolving rotor containing a wear specimen. In the Coriolis testing slurry is introduced into the centre of gravity of a rotor and exists through two radial channels. The specimen is mounted into the walls of a radial channel facing the

21

direction of rotation and is eroded by slurry particles, which are pressed against the specimen face by the Coriolis acceleration. The erosion groove is transversed using a profilometer and the local erosion depth is determined to within a few microns. In the Coriolis erosion tester, a relatively small batch of slurry, from an over-head tank passes through the rotor in one pass. At rotor speeds of 6000 rpm, a measurable groove is worn into the specimen within a few minutes [14].

1.6 SURVEY OF THERMAL POWER PLANT YAMUNANAGAR


Visit Report Fly Ash was collected directly for thermal power plant having physical and chemical properties shown in Annexure 2. There are two stages where twelve slurry pumps are used to dispose the ash at a distance of 8 Km. away from the power plant. For each pipeline, three slurry pumps are used in series. Table 1 shows the technical detail used for slurry disposal pumps.
Table 1.1: Technical data used for slurry disposal pumps

No. of Stages

No. of pumps in series

Speed

Flow Rate

Lift (kgf/cm2)

Power Input (KW)

Pipe Length (Km)

Impeller Dia. (mm)

(RPM)

(m3/hr)

3 1st

600-1600

600

6-7

125

545

545 3 600-1600 600 6 125 8 545 3 2nd 545 3 600-1600 600 6 125 8 600-1600 600 6 125 8

22

1.7 THERMAL SPRAYING


Thermal spraying techniques are coating processes in which melted (or heated) materials are sprayed onto a surface. The "feedstock" is heated by electrical (plasma or arc) or chemical means (combustion flame). Thermal spraying can provide thick coatings (approx. thickness range is 20 microns to several mm, depending on the process and feedstock), over a large area at high deposition rate. Figure 1.13 shows a schematic of thermal spray process [15].

Figure 1.13 Schematic of thermal spray process (Source: Thermal spray coatings-ASM Handbook, Surface Engineering, Vol. 5)

Coating materials available for thermal spraying include metals, alloys, ceramics, plastics and composites. They are fed in powder or wire form, heated to a molten or

23

semi-molten state and accelerated towards substrates in the form of micron-size particles. Combustion or electrical arc discharge is usually used as the source of energy for thermal spraying. Resulting coatings are made by the accumulation of numerous sprayed particles. The surface may not heat up significantly, allowing the coating of flammable substances. Coating quality is usually assessed by measuring its porosity, oxide content, hardness, bond strength and surface roughness. Generally, the coating quality increases with increasing particle velocities [16]. Types of thermal spraying processes 1. Plasma spraying 2. Detonation spraying 3. Wire arc spraying 4. Flame spraying 5. High velocity oxy-fuel coating spraying (HVOF) 6. Cold spraying Detonation Gun Thermal Spraying Process The Detonation gun basically consists of a long water cooled barrel with inlet valves for gases and powder. Oxygen and fuel (acetylene most common) is fed into the barrel along with a charge of powder. A spark is used to ignite the gas mixture and the resulting detonation heats and accelerates the powder to supersonic velocity down the barrel. A pulse of nitrogen is used to purge the barrel after each detonation. This process is repeated many times a second. The high kinetic energy of the hot powder particles on impact with the substrate result in a build up of a very dense and strong coating [28]. Figure 1.14 shows a schematic of the Detonation Thermal Spray Process.

24

Figure 1.14 Schematic of the Detonation Thermal Spray Process (Source: Thermal spray coatings-ASM Handbook, Surface Engineering, Vol. 5)

1.8

MOTIVATION OF THE WORK


Power generation in India is primarily coal based in the present scenario. The

coal used in our thermal power plants produce a large amount of ash, which is around 100 million tons per year, at present. Out of this, around 80 million tons will be fly ash and the remainder will be bed ash. It is expected that at the best 30% of the total ash produced will be utilized which will still leave the remaining 70% for safe disposal. The visit of the ash handling unit of the Deen Bandhu Chhotu Ram Thermal Power Plant Yamuna Nagar has motivated me to undertake the thesis work currently, both the type of ash are being mixed together and transported hydraulically from thermal power plant to ash ponds through pipelines at the solid concentration of around 10-20% by weight. The operation of ash disposal is highly uneconomical due to requirement of large quantity of water and increase in power consumption for pumping 80-90% of clear water. The other problems associated in the slurry pump are excessive wear due to high velocity of the ash water mixture which reduces their working life. 25

Following are the objectives of the present work: 1. To decrease the wear rate of pump. 2. To study the effect of thermally sprayed ceramic coating on cast iron. 3. To get the increased ash disposal rate. 4. To assess the damage to the impeller and casing of ash slurry disposal pump. 5. To improve the performance of ash slurry disposal pump. 6. To reduce the maintenance cost. 7. To save the amount of water used to dispose large amount of ash into the ash ponds by increasing the ash concentration in the slurry. 8. To suggest the coating materials for the impellers to protect them from erosive wear at high ash concentration in the slurry. 9. To reduce the down time.

26

Chapter 2

LITERATURE REVIEW
Gupta et al. [1995] studied the effect of velocity, concentration, and particle size on erosive wear. The experiment was performed by pot tester for two pipe materials namely, brass and mild steel. They evaluated that for a given concentration, erosive wear increases with increase in velocity and for a given velocity, erosion wear also increases with increase in concentration but this increase is comparatively much smaller. They also concluded that erosive wear decreases with decrease in particle size.

Dasgupta et al. [1998] evaluated the effect of sand slurry concentration on steel using DUCOM made TR-41 erosion tester. They also varied the rotational speed and transverse distance during the test. They concluded that increase in the concentration of sand reduces the erosion rate. They also concluded that the erosion rate deteriorates with rotational speed.

Walker et al. [2000] conducted experimental work on different slurry pump impeller and side-liner geometries to determine the effects of solid particle size, slurry concentration and pump speed on wear. Explanations are offered for the resultant wear patterns and empirical wear relationships are outlined for the key variables. The experimental work outlined has compared the wear performance of side-liners running with three different impeller designs. The major difference in location and quantity of wear occurs between the HE wear-ring style side-liner impeller and the STD and RE expelling vane style impeller and side-liner.

Walker [2001] compares the wear rate of the white cast-iron with rubber material. He found that both material show excellent similarities in wear rate trend with particle size

27

but rubber show lower wear rate than the metal for equivalent particle size < 700 m. This is because the rubber surface can absorb smaller particle impact energy without significant cutting tearing.

Clark et al. [2001] discussed the nature and signicance of the particle size effect on the rate of slurry erosion and the problem of its experimental evaluation. Experiments involving the change of erodent particle size in typical laboratory test equipment, while revealing a decrease in erosion rate with decreasing erodent particle size, also produce signicant changes in the slurry ow conditions and particle motion which, unless evaluated quantitatively, will mask the nature of the particle size effect. Wear results have been obtained using a slurry pot erosion tester, using 0.94 wt. % suspensions of SiC (varying in mean particle size from 14 to 780 m) in diesel oil for aluminium and Pyrex glass. For aluminium no damage threshold was observed and the experimental erosion rate varied as dp over the whole particle size range. A contribution to this of dp was found to be ascribable to uid ow changes in the experimental apparatus and the remaining contribution of dp between 100 and 780 m tentatively assigned to the decrease in surface energy of debris particles with increasing particle size. Below 100 m there is a transition from wear by particle impact to wear by wet abrasion by particles moving across the surface. Hawthorne [2002] has conducted Coriolis tests for the evaluation of slurry erosion on different materials. Slurries consisting of glass beads of size 90- 200- micron size with 10% slurry concentration were taken and tests were performed on 1020 steel and copper at different impingement angles of 90-20 degrees. It was also observed that in slurry jet testing, most particles impact the specimen above its critical velocity resulting severe plastic deformation. In contrast, in the Coriolis test most particle impacts result in only elastic deformation or mild plastic deformation. Hence, elastic as well as plastic properties of specimen materials affect their performance in a Coriolis slurry erosion evaluation, thus the results obtained from Coriolis tests were more accurate.
2

28

Clark [2002] has investigated the effect of Particle velocity and particle size in slurry erosion. A list of factors affecting slurry erosion such as concentration of particles, Slurry flow speed (particle impact speed), particle impact angle, particle size, particle density, hardness, friability, nature of suspending liquid, nature of slurry flow (esp. local turbulence),nature of target material were explained. It is emphasized that material loss must be measured by changes in surface profile rather than mass loss, and that the best specimen form for this analysis is a cylinder.

Tahsin Engin et al. [2003] have evaluated some existing correlations to predict head degradation of centrifugal slurry pumps. A new correlation has been developed in order to predict head reductions of centrifugal pumps when handling slurries. The proposed correlation takes into account the individual effects of particle. The proposed correlation is therefore recommended for the prediction of performance factors of small-sized slurry pumps having impeller diameters lower than 850 mm. size, particle size distribution, specific gravity and concentration of solids, and impeller exit diameter on the pump performance.

Goodrich et al. [2003] observed that the main mixing tanks are located under the ash silos. Fly ash slurry is conveyed into these tanks from the fly ash mix tanks which are located under the fly ash silos. Bed ash is then added to the fly ash slurry. Once the combined slurry density reaches target level, a centrifugal slurry pump conveys the slurry out of the plant.

Clark [2004] has studied the influence of the squeeze film in slurry erosion. A squeeze film may be taken as any liquid layer separating two approaching surfaces. The presence of a squeeze film generally leads to a significant retardation of any particle closely approaching a wearing surface at any speed and may even prevent direct impact altogether. The experiments were performed in slurry pot tester. In addition to this it is has also found that if the Reynolds number (i.e. velocity or mass) of the approaching

29

particles is low enough, penetration of the squeeze film on rebound or even approach may not be possible, resulting in particle entrapment at the target surface and a change in erosion mechanism. He observed that small particles (less then100 micron) and concentrated slurries were especially liable to behave in this way.

Gandhi et al. [2004] have developed a methodology to determine the nominal particle size of multi-sized particulate slurry for estimation of mass loss due to the erosion wear. The effect of presence of finer particles (less than 75 microns) in relatively coarse particulate slurry has also been studied. They have observed that addition of particles finer than 75 micron in narrow-size or multi-sized slurries reduce the erosion wear. In addition, the effective particle size for narrow-size particulate slurries can be taken as the mean size whereas the weighted mass particle size seems to be a better choice for multi-sized particulate slurries. The reductions in erosion wear due to addition of fine particles decreases with increase in the concentration of coarse size particles.

Rajesh et al. [2004] have carried out experiments on the effect of impinging velocity on the erosive wear behaviour of polyamides. The impact angles were 30 and 60 degrees at two impact velocities (80 and 140 m/s). Silica sand is used as an erodent. Surface blackening at the impact zone was observed for all the materials at normal impact and at both the impact velocities. At normal impact and at lower impinging velocity (i.e. 80 m/s), a mass gain in the initial period was observed for all the materials except amorphous. The extent of increase in wear, however, depended on the materials and the angle of impact. The velocity effect was more prominent at the oblique angle of impact.

Aino Helle et al. [2004] investigated that at impingement angle closer to 90 degree, the ceramic coating do not offer any advantages over uncoated metallic surface, while at an impingement angle closer to zero degree, the ceramic coatings seems to offer wear

30

protection. Harder erodent particles cause more wear on ceramic coatings than do softer particles.

Neville et al. [2005] studied the erosion-corrosion behavior of WC-Metal Matrix composites (EFM, EFW, EGC, EGG). The materials were eroded by two sizes of silica sand with stream velocities of 10 and 17 m/s at 65oC. Test was conducted by varying the concentration. They evaluated that WC grain size fractions has very little effect on wear. They also concluded that the erosion-corrosion rate is strongly dependent upon erodent size, impinging velocity and solid loading.

Tian et al. [2005] have observed the erosive wear of some metallic materials such as high chromium white iron and aluminium alloy using Coriolis wear testing approach. In the present study, the correlation between wear rate and particle size on the tested materials is discussed. Factors, which should be considered in wear modeling and prediction, have also been addressed. It can be seen that larger solids particles resulted in higher mass loss in all test materials. Although the wear rates at smaller particle sizes were relatively close within each material group, the wear rate difference was significantly widened with larger particle sizes. The tested high-Cr white irons showed a wear resistance some 27140 times higher than that of the aluminium alloys in the Coriolis test conditions Both flow rate and solids concentration of slurry affected the wear results of the test materials. The higher the flow rate, the higher the wear rate of test materials.

Tian et al. [2005] have experimented on Coriolis wear testing. Wear coefficients (or specific energy coefficients) have been determined for different slurry conditions over a large range of particle sizes. Among the test materials, the harder CrMo white iron alloy demonstrated the best wear resistance under slurry testing conditions. It is also observed that Coriolis wear testing is an excellent approach to simulate the erosive wear condition within a slurry pump. Beside particle sizes, other particle properties such

31

as particle shape and size distribution also exhibited significant effect on the values of wear coefficients. Silica sand and copper ore slurries were used as examples. The relationship between linear wear rate and solid particles was also shown.

Mann et al. [2006] compared erosive wear of WC-10Co-4Cr, Armcore M, Stellite 6 and 12 HVOF coatings, Ti-Al-N PVD coatings. Impact angle of 60o and velocity of 20 m/s was kept constant for all experiments. Mineral sand was used as solid particle of slurry. They concluded that WC-10Co-4Cr HVOF coatings show best performance against slurry erosion. They also evaluated the corrosion performance and found that WC-10Co-4Cr HVOF coating corroded significantly. WC-10Co-4Cr HVOF coatings have very good erosion resistance but not corrosion resistance.

Desale et al. [2006] shows the effect of erodent properties on slurry erosion. Experiments have been performed in a pot tester to evaluate the wear of two ductile materials namely, AA6063 and AISI 304L steel. Solidliquid mixtures of similar particle sizes of three different natural erodents namely, quartz, alumina and silicon carbide have been used to evaluate the mass loss of the two target materials at different orientation angles. The result shows that the maximum angle for erosion wear is a function of target material properties and does not depend on the erodent. The erosion rate of ductile materials varies with the erodent properties other than its size and hardness. The effect of erodent properties namely, shape and density is more dominant at shallow impact angles compared to higher impact angles.

Desale et al. [2007] have conducted experiments to visualize the effect of slurry erosion on ductile materials under normal impact condition. These tests were being done in slurry pot tester. It is being observed that wear depends upon hardness of target material and hardness of solid particles. The various ductile materials tested were copper, mild steel brass etc. The erodent materials used were quartz, alumina, and silicon carbide. Experiments were performed at 3m/s velocity and 10 percent by weight

32

concentration of 550 micron size particles for combination of different erodent and target materials at normal impact condition.

Santa et al. [2007] studied the slurry erosion of two coatings applied by oxy fuel powder (OFP) and wire arc spraying (WAS) processes onto sand-blasted AISI 304 steel and the results were compared to those obtained with AISI 431 and ASTM A743 grade CA6NM stainless steels, which are commonly used for hydraulic turbines and accessories. Slurry erosion tests were carried out in a modied centrifugal pump, in which the samples were placed conveniently to ensure grazing incidence of the particles. The slurry was composed of distilled water and quartz sand particles with an average diameter between 212 and 300 m and the solids content was 10 wt % in all the tests. The mean impact velocity of the slurry was 5.5 m/s and the erosion resistance was determined from the volume loss results. The coated surfaces showed higher erosion resistance than the uncoated stainless steels, with the lower volume losses measured for the E-C 29123 deposit.

Vasile Hotea et al. [2008] shows that variety of mechanical and chemical cleaning and pre-treatment techniques are used prior to coating. The thermal spray techniques to deposit coatings consist of atomization and deposition of molten or semi-molten droplets of the coating material on substrates. The feed material is melted by using energy from fuel combustion, electric arc or plasma.

Desalea et al. [2009] studied the effect of particle size on erosive wear of aluminium alloy (AA 6063) using slurry pot tester. Quartz particles were used as slurry of eight different sizes varying between 37.5 and 655 m. Keeping the concentration of 20% by weight and velocity as 3 m/s experiment was conducted. They found that the erosive wear increases with increase in mean particle size.

33

Santa et al. [2009] compared the erosion and corrosion resistance of various thermal spray coatings on martensitic stainless steel. Nickel, chromium oxide and tungsten carbide coating were applied by oxy fuel powder whereas chromium and tungsten carbide coatings were applied by HVOF. A modified centrifugal pump was used to evaluate the performance. They found that thermal spray coating has more erosion resistance as compared to bare steel. They also found that coatings do not help in protecting cavitations, in fact shows poorer performance than bare steel.

Mishra et al. [2009] studied all the parameters affecting the erosive wear using jet erosion tester on fly ash-quartz coating. By varying different parameters they evaluate that impact angle is the most significant factor influencing the erosive wear of fly-ashquartz coating. They also evaluated that maximum erosion takes place at impact angle of 90o.

Mishra et al. [2009] studied the erosion wear behavior of fly ashillmenite coating using dry silica sand as an erodent. The Taguchi technique was used to acquire the data in a controlled way. An orthogonal array and signal-to-noise ratio was employed to investigate the influence of the impact angle, the velocity, the size of the erodent, and the standoff distance (SOD) on erosion wear. The objective was to investigate which design parameter significantly affects the erosion wear. It was found that the impact angle is the most powerful factor influencing the erosion wear rate of the coating. Further, when erosive wear behavior of fly ashillmenite coating was investigated at three impact angles (i.e., at 30, 60, 90), it was revealed that the impact angle is the prime factor and maximum erosion takes place at = 90.

Nagarajan et al. [2009] studied through experimental investigation the effects of ash particle physical properties and transport dynamics on the erosive wear of three different grades of low alloy steel, using three different power-station ash types. The study used a Taguchi fractional-factorial L27 DOE. The experimental data were used to derive

34

a model for the prediction of erosion rates. The model incorporates the properties of the ash particles and the target metal surface, as well as the characteristics of ash particle motion in the form of the impingement velocity and the impingement angle. It became possible to predict the relationship between erosion loss and the factors inuencing the rate of room-temperature erosion. Fly-ash particulate size and concentration, moisture and titania content, impact velocity and angle, duration of impact, and alloy surface roughness were determined to be rst-order effects. The results show that the rate of erosion increases with increasing impact velocity of y-ash on metal and also increases with increasing concentration of y-ash.

Khuri et al. [2010] provide a survey of the various stages in the development of response surface methodology (RSM). This includes a review of basic experimental designs for fitting linear response surface models, in addition to a description of methods for the determination of optimum operating conditions. Discussion was made on more recent modeling techniques in RSM, in addition to coverage of Taguchis robust parameter design and its response surface alternative approach. The prediction capability of any response surface design does not remain constant throughout the experimental region.

Yassine et al. [2010] experimentally investigated the performance characteristics of a centrifugal pump using different sand concentrations ranging from 0 to 15 wt % of sand. The flow behavior of different sand/water mixtures has been inspected using a test rig with 50 mm diameter PVC pipes with various fittings and valves. It was observed that the head and the efficiency of a centrifugal pump with slurries are, in general, lower for traditional designs in comparison to water due to the presence of suspended solids. The head and efficiency of the pump decrease with increase in sand concentration (by weight). Power consumption on the other hand increases with increase in sand concentration at a rate that is higher than the rate of increase of the mixture specific gravity (S). The study has also shown that the head ratio, efficiency ratio, and power

35

ratio do not vary significantly with flow rate and the variation is within 9 % at any sand concentration tested.

Chawla et al. [2011] concluded that hot corrosion and erosion are recognized as serious problems in coal based power generation plants in India. The coal used in Indian power stations has large amounts of ash (about 50%) which contain abrasive mineral species such as hard quartz (up to 15%) which increase the erosion propensity of coal. An understanding of these problems and thus to develop suitable protective system is essential for maximizing the utilization of such components. These problems can be prevented by either changing the material or altering the environment or by separating the component surface from the environment. Corrosion prevention by the use of coatings for separating material from the environment is gaining importance in surface engineering.

Telfer et al. [2012] investigated the effect of particle and target material on the erosioncorrosion mechanisms. The performance of Fe as the target material has been modeled when considering particle concentration and size. A comparison was made between the erosion-corrosion mechanisms of Fe, Ni, Al and Cu under different conditions of particle size and concentration. By producing several maps, the regimes and wastage rates predicted as functions of velocity and applied potential.

Singh et al. [2012] studied that detonation gun spraying is one of the thermal spraying techniques known for providing hard, wear resistant and dense micro structured coatings. Process parameters of detonation spraying influence the microstructure, mechanical and other properties of the coatings. Research is needed in optimization of the process parameters of detonation spraying process. Detonation gun separation device designed by researchers resulted in good performance of the detonation gun spraying in high performance requirement.

36

Chapter 3

SLURRY EROSION TESTING


3.1 HYDRAULIC ASH HANDLING SYSTEM
The handling and disposal of ash is a major problem because due to its dusty, irritating and abrasive nature. When it comes out of boiler furnace, it is very hot. In the thermal power plant, 60 % to 80 % of ash is in the form of fly ash and remaining is the bottom ash. Ash handling systems are mechanical, hydraulic and pneumatic. In Hydraulic System ash is carried with flow of water with high velocity through a pipeline and finally dumped in the sump. This system is preferred because it is clean and healthy. It is dustless and completely closed. It can discharge large amount of ash at large distance from the power plant, therefore is suitable for large thermal power plants. Clean water is collected in a tank as shown in figure 3.1. A high pressure pump (90 KW, 6 to 8 kgf/cm2) is used to draw the clean water from water tank to the collector tank where the ash is mixed with it. Ash is collected from the ash hoppers and mixed with clean water.

Figure 3.1 Clean water for making slurry

37

The ash-water mixture before entering the impeller is shown in figure 3.2. Slurry pumps are used to draw the ash slurry from collector tank and dispose it at a large distance (1000 meters to 8000 meters) away from power plant. The hydraulic ash handling and disposal system is shown in figure 3.3. Slurry pumps are used in series to increase the pressure head as shown in figure 3.4.

Figure 3.2 Slurry before entering the impeller

Figure 3.3 Hydraulic ash handling system

38

Figure 3.4 Slurry pumps in series

3.2 HIGH SPEED SLURRY EROSION TESTER


In slurry erosion tester, a specimen, fixed to the specimen holder, is rotated in a circular container (slurry pot) filled with the slurry which is made homogeneous. In slurry erosion test, the amount of material removed from the specimen is determined by the weight loss. The samples are weighed before and after the tests. Slurry pot tester is simple in design and easy to operate. In a slurry pot tester, generally two specimens have been rotated in solid-liquid mixture. The rotational movement of specimens keeps the solid (ash) particles suspended in the liquid (water). The rotating test specimens move at a velocity relative to the solid-liquid suspension. The monitoring penal and experimental set-up of high speed slurry erosion tester is shown in Figure 3.5a and Figure 3.5b. 39

Figure 3.5a - Monitoring Panel of High Speed Slurry Erosion Tester

Figure 3.5b - Experimental Set-up of High Speed Slurry Erosion Tester

40

3.3 EROSION TESTING OF HIGH CHROME CAST IRON


The fly ash which was collected from directly thermal power plant was used as the erodent and the particle size varied from 10 to 100 m. Sizing of the ash particles was done by sieve analysis and the average particle size was 75 m. Three levels were selected for ash particle size in micron as 50, 75 and 90. The test specimens of impeller material (High Chromium Cast Iron) were prepared and cut into the cylindrical pieces of 12 mm OD 6 mm ID 10 mm long and polished using emery paper (200 m grit size). The hardness of the specimen was measured to be 500 BHN. The rotation per minute (r/min) maintained as 1200, 1400 and 1600 whereas the ash concentration taken as 100,000 ppm, 200,000 ppm and 300,000 ppm. Specimens were cleaned with acetone and weighed before and after the experimentation. The weight of the specimen material was reduced due to erosion.

Rotations of specimen, ash concentration in slurry and particle size were considered to be significant factors. Three levels were taken for each factor as shown in table 3.2. Two test specimens were tightened opposite to each other. The test specimens were tightened properly to the specimen holder with the help of the screws. There was a drum of water carrying capacity of 30 liters was properly cleaned and slurry is prepared and drawn into the drum. The specimens were rotated in the slurry for 30 minutes.

The slurry was made homogeneous in the drum by rotating it continuously during the experimentation. The test specimen holder is shown in Figure 3.6 having the capacity to hold maximum of 12 specimens and the prepared test specimens (before experimentation) are shown in figure 3.7.

41

Figure 3.6 Test specimen holder for holding maximum of 12 specimens

Figure 3.7 Test Specimens

The total number of tests and the values of variables for each test were determined with the help of Response Surface Methodology (RSM). Table 3.4 shows the analysis of variance for response surface linear model. The modeled values for the response were calculated and tabulated in Table 3.5.

42

Apparatus used: No. of Specimens: No. of factors: No. of levels: Material of specimen: Time Taken: Ash used: Software used:

High Speed Slurry Erosion Tester 34 (02 for each test) 03 03 Chromium alloy cast iron 30 minutes for each test Fly ash Design-Expert 8.0.7.1

The chemical composition of the material used was checked with the help of spectrometer. The detail is as under:

Material High Chrome Cast Iron

C 3.01

Mn 1.12

Si 0.39

S 0.006

P 0.02

Cr 14.64

Ni 0.42

A sieve analysis was used to assess the particle size distribution of fly ash (table 3.1). The results were presented in a graph of percent retained in each sieve versus the sieve size range (figure 3.8) by using the following equation:

%age Retained =

100%

where WSieve: weight of fly ash in the sieve WTotal: total weight of the fly ash

43

Table: 3.1 Sieve Analysis Chart

Particle size range (Up to 35m) (35-45 m) (45-50 m) (50-75 m) (75-90 m) (90-105 m) (105-125 m) (125-150 m)

%age retained in sieves 15/500*100=3 % 30/500*100=6 % 72/500*100=14.4 % 235/500*100=47 % 105/500*100=21 % 23/500*100=4.6 % 12/500*100=2.4 % 8/500*100=1.6 %

Particle Size Distribution


50 40 A sh % age 30 20 10 0 0 20 40 60 80 100 120 140 160 Ash Particle Size (micron) 35, 3 50, 14.4 45, 6 90, 21 105, 4.6 125, 2.4 150, 1.6

75, 47

Figure 3.8: Ash percentage versus particle size

44

Table 3.2: Factors affecting Erosion with levels

Sr. No. Factors Rotation of specimen 1 (rpm) Ash concentration 2 (ppm) Particle size 3 (m) 50 75 90 100x103 200 x103 300 x103 1200 1400 1600 Level 1 Level 2 Level 3

3.3.1 Experimental Design (Response Surface Methodology)

Experimental design is the design of any information-gathering exercises where variation is present, whether under the full control of the experimenter or not. DesignExpert 8.0.7.1 software was used in current investigation for statistical analysis i.e. Response Surface Methodology (RSM) and analysis of variance (ANOVA). In statistics, RSM explores the relationships between several explanatory variables and one or more response variables. The main idea of RSM is to use a sequence of designed experiments to obtain an optimal response. It is sufficient to determine which explanatory variables have an impact on the response variable(s) of interest. An estimated optimum point need not be optimum in reality, because of the errors of the estimates and of the inadequacies of the model [17]. In Box-Behnken design for RSM, each numeric factor is varied over 3 levels hence used in current experimentation. This model is only an approximation, but uses it because such a model is easy to estimate and apply, even when little is known about the process. Box-Behnken design model has given 17 numbers of tests for randomized values of variables as shown in Table 3.3.

45

Table 3.3 Box-Behnken design matrix

Run

Rotational Speed (rpm)

Ash Concenteration (ppm) 200000 300000 200000 100000 200000 100000 200000 200000 200000 300000 100000 200000 200000 300000 100000 200000 300000

Particle Size (microns) 75 75 90 50 75 75 90 50 75 75 90 50 75 50 75 75 90

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

1400 1200 1600 1400 1400 1200 1200 1600 1400 1600 1400 1200 1400 1400 1600 1400 1400

3.3.2 Analysis Of Variance (ANOVA) In statistics, analysis of variance (ANOVA) is a collection of statistical models, and their associated procedures, in which the observed variance in a particular variable is partitioned into components attributable to different sources of variation. ANOVA provides a statistical test of whether or not the means of several groups are all equal, and therefore generalizes t-test to more than two groups. Doing multiple two-sample t-

46

tests would result in an increased chance of committing a type I error. For this reason, ANOVA is useful in comparing two, three, or more means. The analysis of variance has been studied from several approaches, the most common of which use a linear model that relates the response to the treatments and blocks. Even when the statistical model is nonlinear, it can be approximated by a linear model for which an analysis of variance may be appropriate.
Table 3.4 ANOVA for Response Surface Linear Model

Sum of Source Squares

df

Mean Square

F Value

p-value Prob > F

Model A-rotation B-ash concen. C-particle size Residual Lack of Fit Pure Error Cor Total

0.083 0.040 0.041 1.243E-003 0.021 0.017 3.621E-003 0.10

3 1 1 1 13 9 4 16

0.028 0.040 0.041 1.243E-003 1.610E-003 1.923E-003 9.052E-004

17.10 24.96 25.58 0.77

< 0.0001 0.0002 0.0002 0.3956

significant

2.12

0.2434

Non-significant

The Model F-value of 17.10 implies the model is significant. Values of "Prob > F" less than 0.0500 indicate model terms are significant. In this case A, B are significant model terms. The "Lack of Fit F-value" of 2.12 implies the Lack of Fit is not significant relative to the pure error. Non significant lack of fit is good.
Table 3.5 Regression Analysis for Response Surface Linear Model

Std. Dev. Mean C.V. % PRESS

0.040 0.28 14.47 0.038

R-Squared Adj R-Squared Pred R-Squared Adeq Precision

0.7979 0.7512 0.6293 14.656

47

The "Pred R-Squared" of 0.6293 is in reasonable agreement with the "Adj RSquared" of 0.7512. "Adeq Precision" measures the signal to noise ratio. A ratio greater than 4 is desirable. The ratio of 14.656 indicates an adequate signal. This response surfece linear model can be used to navigate the design space.

3.3.3 Modeled equation in terms of actual factors Weight Loss = (-0.40687) + (3.54375x10-4) x Rotational Speed + (7.17500x10-7) x Ash Concenteration + (6.13078x10-4) x Particle Size

Table 3.6: Experimental and modeled values for the response (Uncoated Material)

Run 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Rotation (rpm) 1600 1400 1200 1400 1600 1200 1200 1200 1400 1600 1400 1400 1600 1400 1400 1400 1400

Ash conc. (ppm) 300000 200000 200000 200000 200000 100000 200000 300000 200000 200000 100000 100000 100000 300000 200000 200000 300000

Particle size (microns) 75 75 90 75 90 75 50 75 75 50 50 90 75 90 75 75 50

Experi. Values (gms.) 0.497 0.281 0.248 0.282 0.365 0.175 0.186 0.288 0.208 0.308 0.239 0.163 0.294 0.353 0.262 0.258 0.307

Modeled Values (gms.) 0.421 0.279 0.217 0.279 0.359 0.136 0.193 0.280 0.279 0.334 0.192 0.216 0.278 0.360 0.279 0.279 0.335

Weight reduction due to erosion for each uncoated and coated specimen is shown in appendix 1.

48

3.4 EROSION TESTING OF CERAMIC COATED CAST IRON


Ceramic coating can be applied to increase the performance of a slurry pump by reducing the erosive wear. Before applying coating, specimens should be cleaned by acetone and abrasive shot blast. The detonation gun thermal spray technique may be used for applying coating. The extreme hardness and high density of Al2O3 is expected to have a superior erosion and corrosion resistance. The detonation gun thermal spray technique provides the dense microstructure with less porosity. Alumina ceramic coated impellers are particularly resistant to the ripping and tearing damage caused by sharp objects often found in slurries. Alumina ceramic impellers are chemically inert and suitable for use in hazardous and hostile environment. The superior wear characteristics of alumina ceramics prevent wear in critical areas and this enables the impeller to function for far longer at a constant rpm. 3.4.1 Experimentation and Statistical Analysis The problem was the high wear rate of the pump impeller during its continuous use. The suggested solution to this problem is applying alumina ceramic coating on the surface of the impeller so as to reduce the wear rate on the surface by keeping the mechanical properties of the impeller material unchanged. Rotation of specimen, ash concentration in slurry, and particle size were considered to be significant factors. Same levels are taken for each factor as discussed in case of uncoated material. The values of rotational speed of specimens and ash concentration in slurry were estimated with the help of technical data obtained from thermal power station. The particle size range was selected by sieve analysis. Experiments were performed on the high speed slurry erosion tester (DUCOM Bangalore make, Model TR 401). Total number of experiments was decided by the Response surface technique. After performing experiments, ANOVA was used to calculate the modeled equation of the response. Response was the weight loss of the

49

material due to erosive wear. Weight of the specimens was taken before and after the experimentation to get the weight reduction of the material. Total number of runs was given by RSM. Box-Behnken design matrix for ceramic coated material in terms of actual values is same as shown in Table 3.3. ANOVA for Response Surface Reduced Quadratic Model is shown in Table 3.7. Experiments were performed on the Al2O3 coated specimens having the coating thickness of 250 m. Test Specimens affected by erosive wear as shown in figure 3.9.

Figure 3.9: Al2O3 coated specimens affected by erosive wear

50

Table 3.7: ANOVA for Response Surface Reduced Quadratic Model

Sum of Source Model A-rotation B-ash concent. C-particle size AC A2 C2 Residual Lack of Fit Squares 1.889E-003 7.313E-004 6.301E-004 2.101E-004 5.455E-007 1.540E-004 1.765E-004 2.906E-004 2.694E-004

df

Mean Square

F Value 10.84 25.17 21.69 7.23 0.019 5.30 6.07

p-value Prob > F 0.0007 0.0005 0.0009 0.0227 0.8937 0.0441 0.0334 significant

6 1 1 1 1 1 1 10 6

3.149E-004 7.313E-004 6.301E-004 2.101E-004 5.455E-007 1.540E-004 1.765E-004 2.906E-005 4.490E-005

3.47

0.1289

nonsignificant

Pure Error Cor Total

2.120E-005 2.180E-003

4 16

5.300E-006

The Model F-value of 10.84 implies the model is significant. There is only a

0.07

chance that a "Model F-Value" this large could occur due to noise. Values of "Prob > F" less than 0.05 indicate model terms are significant. In this case A, B, C, A2, C2 are significant model terms. The "Lack of Fit F-value" of 3.47 implies the Lack of Fit is not significant. There is only a 12.89% chance that a "Lack of Fit F-value" this large could occur due to noise. Non-significant lack of fit is considered as good. Regresion analysis for response surface reduced quadratic model is shown in table 3.8.

51

Table 3.8: Regresion Analysis for Response Surface Reduced Quadratic Model

Std. Dev. Mean C.V. % PRESS

5.39E-03 0.024 22.8 1.38E-03

R-Squared Adj R-Squared Pred R-Squared Adeq Precision

0.8667 0.7267 0.6665 11.319

The "Pred R-Squared" of 0.6665 is close to the "Adj R-Squared" of 0.7267 as one might normally expect. "Adeq Precision" measures the signal to noise ratio. A ratio greater than 4 is desirable. Ratio of 11.319 indicates an adequate signal. This model can be used to navigate the design space. Experimental and modeled values for the response are shown in Table 3.9.

3.4.2 Modeled Equation in Terms of Actual Factors:

Weight reduction = 0.30368 - 3.80604 x10-4 x (rotational speed) + 8.87500 x 10-8 x (ash concentration) - 2.32409 x 10-3 x (particle size) + 9.09091 x 10-8 x (rotational speed) x (particle size) + 1.50987 x 10-7 x (rotational speed2) + 1.75219 x 10-5 x (particle size2).

52

Table 3.9: Experimental and modeled values for the response (Coated Material)

Run

Rotation

Ash concent. (ppm)

Particle size (microns)

Experimental Values (Wt. reduction) (gms.)

Modeled Values (Wt. reduction) (gms.)

(rpm)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

1600 1400 1200 1400 1600 1200 1200 1200 1400 1600 1400 1400 1600 1400 1400 1400 1400

300000 200000 200000 200000 200000 100000 200000 300000 200000 200000 100000 100000 100000 300000 200000 200000 300000

75 75 90 75 90 75 50 75 75 50 50 90 75 90 75 75 50

0.053 0.02 0.027 0.014 0.041 0.006 0.013 0.023 0.017 0.028 0.013 0.026 0.025 0.033 0.015 0.016 0.032

0.043 0.018 0.025 0.018 0.045 0.006 0.015 0.023 0.018 0.034 0.010 0.020 0.025 0.038 0.018 0.018 0.027

53

Chapter 4

RESULTS AND DISCUSSIONS


4.1 RESULTS
Graphs were plotted between the factors affecting erosive wear and the weight reduction of specimen for uncoated high chrome cast iron and ceramic coated cast iron. The effect of each variable on the weight loss due to erosion was undertaken by considering other variables at lower, middle and higher level. 4.1.1 UNCOATED CAST IRON It has been found form these graphs that all the three parameters behave linearly with the weight loss.

Figure 4.1 Weight Loss vs. rotational speed

54

As the rotational speed of the impeller increases, the force with which slurry strikes the impeller increases which in turn increases the erosion rate (Figure 4.1). It shows that at 1200 rpm rotational speed, 100000 ppm ash concentration and 50 m particle size, the weight loss of the material due to erosive wear is very less. For 12001600 rpm, the erosive wear is increased linearly.

Figure 4.2 Weight Loss vs. Ash Concentration

The weight loss of the material increases linearly with the increase of ash concentration as shown in figure 4.2. It shows that at 100000 ppm ash concentration, 1200 rpm rotational speed and 50 m particle size, the weight loss of the material due to erosive wear is very less. For 100000-300000 ppm, the erosive wear is increased linearly.

55

Figure 4.3 Weight Loss vs. Ash Particle Size

The effect of particle size on the weight loss due to erosion is shown in figure 4.3. The behavior of particle size with erosive wear is linear. The particle size has low effect on erosive wear when other values are taken at lower level, but increase in wear is more by taking other parameter level at middle and higher. Reduction in weight is primarily depends upon the ash concentration in the slurry followed by the rotational speed of the pump impeller and ash particle size as shown in figure 4.4.

Lack of Fit 14% Particle Size 2%

Error 3%

Rotational Speed 40%

As h Concent. 41%

Figure 4.4 Contributions of selected parameters for erosive wear of high chrome cast iron

56

4.1.2 CERAMIC COATED CAST IRON

Figure 4.5 Weight loss vs. Rotational Speed

For Al2O3 Coated High Chrome Cast Iron, the effect of rotational speed on the weight loss due to erosion is shown in figure 4.5. As the rotational speed of the impeller increases, the force with which slurry strikes the impeller increases which in turn increases the erosive rate. It shows that from 1200 to 1400 rpm the increment in wear is comparatively less than for 1400 to 1600 rpm. In the range of1400-1600 rpm, the wear increases exponentially.

Figure 4.6 Weight loss vs. Ash Concentration

57

The effect of ash concentration in slurry on the weight loss due to erosion is shown in figure 4.6. Increase in ash concentration increases the viscosity of the slurry which in turn increases the wear rate. The behavior of ash concentration with erosive wear is linear.

Figure 4.7 Weight loss vs. Ash Particle Size

Erosive wear occurs on the impeller of slurry pump when the impact of ash particles flows in water is at very high velocity. The kinetic energy of the moving particles and ash particle size are responsible for the loss of material due to erosion. The weight loss of the material increases with the increase of particle size in the range of 75 90 m as shown in Figure 4.7. From 50- 75 m, there is no effect of particle size on the erosion.

Reduction in weight is primarily depends upon the rotational speed of the pump impeller followed by ash concentration and ash particle size as shown in figure 4.8.

58

Lack of Fit 12% Particle Size 18%

Error 1% Rotational Speed 41%

Ash Concent. 28%

Figure 4.8 Contributions of selected parameters for erosive wear of Al2O3 Coated cast iron

4.2 DISCUSSIONS
Erosion is a complex process in which three co-existing phases, namely conveying fluid (water), solid particles (ash) and the surface (pump impeller) interact in many ways. The kinetic energy of the moving particles and amount of ash

concentration in slurry are mainly responsible for the loss of material. The impingement attack is either by solid or by liquid. A high erosive wear is observed at high rotation speed. The ash particles at high velocity were associated with more kinetic energy, causing severe impingement on the specimen surface.

The effect of the rotational speed, ash concentration and particle size on the erosive wear for Al2O3 coated high chrome cast iron was compared with uncoated high chrome cast iron and shown in figure 4.9. The effect of these parameters was studied at the middle level.

59

Figure 4.9 Comparison of erosion for coated and uncoated material

60

By comparing the results of uncoated and Al2O3 coated high chrome cast iron, it is clear that up to 1400 rpm the effect of erosion is not much but after 1400 rpm there is an exponential growth in wear rate for coated material. Hence the speed must be kept near 1400 rpm for the maximum slurry transport at low wear rate. The graphs for ash concentration vs. wear rate are linear for both metallic and ceramic coated surface but the wear rate is less in the later case due to the high wear resistance of Al2O3 coating. It is shown that if the particles are finer than 75 microns, there will be no any significant effect on the wear rate but from 75 microns to 90 microns the increase in wear rate is significant, hence can not be ignored. When the particle size is very small, it is not having the sufficient internal energy to penetrate or erode the high wear resistant material.

61

CHAPTER 5

CONCLUSIONS AND SCOPE FOR FUTURE WORK


If the slurry pumps has to work the range where the erosive wear is less; the performance of the slurry disposal pump may be improved. Erosive wear of the pump impeller would decreases with decreasing ash concentration, rotation speed and particle size. Wear takes place by cutting and removal of material from the specimen surface. Ceramic coating is very helpful to protect the pump due to slurry erosion. Instead of applying coating to whole impeller, the coating can be applied only to blades to cut manufacturing cost. In the present case, erodent directly hit the cylindrical surface. Specimens can be fitted to the specimen holder at different angles with respect to the slurry rotation inside the slurry pot. They can hit by the ash particles at different angles as rotating at a particular speed. There is no provision to hold the specimen at a particular angle in the current set-up on which the experimentation is done. This is the limitation of present experimental work. A special attachment can be provided to avoid this problem.

Ash particles may only tend to slide over the specimen surface at a lower angle without effectively impinging on it. For Brittle materials such as cast irons and ceramics, at a lower impingement angle, the tendency of erosive particles towards deflection from the surface becomes prominent, resulting in a low erosive wear. As the specimen angle increases up to 90o, the impact of impingement increases and the material is removed due to the high impact pressure. To investigate the effect of impingement angle, the test specimen should be flat. On cylindrical specimen, the impact angle can not be measured accurately.

62

Instead of applying coating on the metallic surface, it is suggested that if whole impeller is made by alumina ceramic, the pump life and performance increases very much. There are advanced materials available such as nano composites and cermets whose wear resistance is very high. Advanced Wear-Resistant Nano-composites are a new class of super-hard materials having the potential for obtaining a high-wearresistance. A cermet is a composite material composed of ceramic and metallic materials having the combined properties of both a ceramic and a metal. The experimentation can be performed with such kind of advanced materials. Various coating materials such as zirconia, chrome carbide, silicon carbide, tungsten carbide, titanium carbide etc. are available for experimentation on the different machines. Experiments are changed as the working condition changes therefore for a new working condition the same modeling technique can not be applied. Different experimental design techniques can be used for different set of parameter.

63

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APPENDIX-A
Weight Difference Due To Erosion for Each Uncoated Specimen: Material High Chrome Cast Iron Experimentation on Slurry Erosion Tester Specimen Initial Weight Final Weight No. (grams) (grams) 1 6.921 6.882 2 6.764 6.731 3 6.674 6.618 4 7.156 7.148 5 6.897 6.876 6 6.987 6.833 7 6.729 6.675 8 6.959 6.935 9 6.912 6.857 10 6.906 6.895 11 6.959 6.728 12 6.957 6.702 13 4.936 4.921 14 6.778 6.613 15 6.985 6.959 16 6.654 6.461 17 6.618 6.339 18 7.046 6.822 19 7.547 7.318 20 7.128 6.899 21 7.151 6.793 22 6.915 6.908 23 7.321 7.112 24 7.159 6.875 25 6.281 6.247 26 6.595 6.471 27 7.024 6.715 28 6.559 6.427 29 6.519 6.351 30 5.684 5.545 31 7.119 6.963 32 7.071 6.828 33 7.049 6.897 34 7.079 6.981 68

Wt. Difference (grams) 0.039 0.033 0.056 0.008 0.021 0.154 0.054 0.024 0.055 0.011 0.231 0.255 0.015 0.165 0.026 0.193 0.279 0.224 0.229 0.229 0.358 0.007 0.209 0.284 0.034 0.124 0.309 0.132 0.168 0.139 0.156 0.243 0.152 0.098

Weight Difference Due To Erosion for Each Coated Specimen: Material - Ceramic Coated Cast Iron Experimentation on Slurry Erosion Tester Specimen Initial Weight Final Weight No. (grams) (grams) 1 6.825 6.813 2 7.055 7.053 3 6.902 6.899 4 6.899 6.897 5 6.724 6.699 6 6.426 6.423 7 6.925 6.921 8 6.847 6.835 9 7.093 7.069 10 6.636 6.623 11 7.209 7.198 12 7.221 7.199 13 6.854 6.851 14 6.268 6.265 15 7.063 7.042 16 6.955 6.952 17 6.998 6.994 18 6.736 6.733 19 6.437 6.433 20 6.889 6.868 21 6.768 6.756 22 6.438 6.427 23 6.815 6.794 24 7.129 7.118 25 6.925 6.919 26 6.827 6.811 27 6.599 6.593 28 6.422 6.417 29 6.899 6.868 30 7.046 7.044 31 7.378 7.374 32 7.212 7.208 33 7.339 7.337 34 6.951 6.945

Wt. Difference (grams) 0.012 0.002 0.003 0.002 0.025 0.003 0.004 0.012 0.024 0.013 0.011 0.022 0.003 0.003 0.021 0.003 0.004 0.003 0.004 0.021 0.012 0.011 0.021 0.011 0.006 0.016 0.006 0.005 0.031 0.002 0.004 0.004 0.002 0.006

69

APPENDIX-B
Physical Properties of Fly Ash

Particle Size Distribution (% Finer by Weight) Size (m) % Finer 100 98 90 85 70 64 61 55 43 28 16 8 3 300 200 100 75 64 50 41 36 25 17 13 10 4

Specific gravity of fly ash (unsieved) =1.992 Weighted mean diameter = 65 m

Chemical Properties of Fly Ash

Chemical Composition of Fly Ash SiO2 54.77 Al2O3 33.83 Fe2O3 2.79 CaO 0.80 K2O 1.97 TiO2 2.76 Na2O 0.72 MgO 2.35

(Source: DBCRTPP, Yamunanagar)

70

APPENDIX-C
PUBLICATIONS 1. Kumar, S. and Ratol, J. S., 2012. Investigation of Erosive Wear on Al2O3 Coated Cast Iron Using Response Surface Technique, International Journal of Advances in Engineering & Technology, Vol. 3, No. 2, pp. 403-410. 2. Kumar, S. and Ratol, J. S., 2012. Experimental Investigation of Erosive Wear on the High Chrome Cast Iron Impeller of Slurry Disposal Pump Using Response Surface Methodology, Materials Engineering- Materilov ininierstvo, Vol. 19, No. 3, pp. 110-116.

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