Multifunctional Metallic and Refractory Materials for Energy Efficient Handling of Molten Metals
The goal of the project was to extend the lifetime of hardware submerged in molten metal by an order of magnitude and to improve energy efficiency of molten metal handling process. Assuming broad implementation of project results, energy savings in 2020 were projected to be 10 trillion BTU/year, with cost savings of approximately $100 million/year. The project team was comprised of materials research groups from West Virginia University and the Missouri University of Science and Technology formerly University of Missouri – Rolla, Oak Ridge National Laboratory, International Lead and Zinc Research Organization, Secat and Energy Industries of Ohio. Industry partners included six suppliers to the hot dip galvanizing industry, four end-user steel companies with hot-dip Galvanize and/or Galvalume lines, eight refractory suppliers, and seven refractory end-user companies. The results of the project included the development of: (1) New families of materials more resistant to degradation in hot-dip galvanizing bath conditions were developed; (2) Alloy 2020 weld overlay material and process were developed and applied to GI rolls; (3) New Alloys and dross-cleaning procedures were developed for Galvalume processes; (4) Two new refractory compositions, including new anti-wetting agents, were identified for use with liquid aluminum alloys; (5) A new thermal conductivity measurement technique was developed and validated at ORNL; (6) The Galvanizing Energy Profiler Decision Support System (GEPDSS)at WVU; Newly Developed CCW Laser Cladding Shows Better Resistance to Dross Buildup than 316L Stainless Steel; and (7) A novel method of measuring the corrosion behavior of bath hardware materials. Project in-line trials were conducted at Southwire Kentucky Rod and Cable Mill, Nucor-Crawfordsville, Nucor-Arkansas, Nucor-South Carolina, Wheeling Nisshin, California Steel, Energy Industries of Ohio, and Pennex Aluminum. Cost, energy, and environmental benefits resulting from the project are due to: i) a reduced number of process shutdowns to change hardware or lining material, ii) reduced need to produce new hardware or lining material, iii) improved product quality leads to reduced need to remake product or manufacturing of new product, iv) reduction in contamination of melt from degradation of refractory and metallic components, v) elimination of worn hardware will increase efficiency of process, vi) reduced refractory lining deterioration or formation of a less insulating phase, would result in decreased heat loss through the walls. Projected 2015 benefits for the U.S. aluminum industry, assuming 21% market penetration of improved refractory materials, are energy savings of approximately 0.2 trillion BTU/year, cost savings of $2.3 billion/year and carbon reductions of approximately 1.4 billion tons/year. The carbon reduction benefit of the project for the hot-dip galvanize and aluminum industries combined is projected to be approximately 2.2 billion tons/year in 2015. Pathways from research to commercialization were based on structure of the project’s industrial partnerships. These partnerships included suppliers, industrial associations, and end users. All parties were involved in conducting the project including planning and critiquing the trials. Supplier companies such as Pyrotech Metaullics, Stoody, and Duraloy have commercialized products and processes developed on the project.
- Research Organization:
- West Virginia Univ., Morgantown, WV (United States)
- Sponsoring Organization:
- USDOE Office of the Secretary of Energy Advisory Board (AB); USDOE Office of Industrial Technology Program (EE-2F)
- DOE Contract Number:
- FC36-04GO14038
- OSTI ID:
- 947111
- Report Number(s):
- DE/GO14038-1; TRN: US200905%%66
- Country of Publication:
- United States
- Language:
- English
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Related Subjects
01 COAL, LIGNITE, AND PEAT
ALLOYS
ALUMINIUM
BUILDUP
CABLES
CARBON
COMMERCIALIZATION
CONTAMINATION
CORROSION
EFFICIENCY
ENERGY EFFICIENCY
GEOGRAPHIC INFORMATION SYSTEMS
IMPLEMENTATION
LINERS
STAINLESS STEELS
STEELS
STELLITE 6
THERMAL CONDUCTIVITY
ZINC
Continuous hot-dipping
aluminum melting
hardware
refractories
liquid metal corrosion
wear