Results Of Industrial Testing Research Articles

TECHNOLOGICAL BASIS OF THE PROCESS OF ZIRCONIUM AND HAFNIUM SEPARATION

The paper presents the results of industrial testing of the process and equipment for the extraction separation of zirconium and hafnium in a single technological cycle with the production of high-purity nitrate compounds and pure nitric acid solutions as raw materials for the production of sodium nitrate. It is shown that the efficiency of the extraction process is determined primarily by the purity of the nitric acid solution by the content of a critical impurity – silicic acid, which causes an undesirable emulsification process and disrupts the stability of the process. Optimal conditions have been determined under which the formation of non-extractable forms of zirconium and hafnium is excluded. The replacement of pulsating columns with centrifugal extractors reduced operating costs by reducing the volume of a one-time load of a flammable extractant and its losses as a result of hydrolysis. This increased the degree of separation of zirconium and hafnium. Centrifugal extractors provided high process kinetics, reduced production areas, and increased labor productivity and product quality.

PHYSICAL AND CHEMICAL FOUNDATIONS OF THE TECHNOLOGY FOR OBTAINING URANIUM OXIDES

The article presents the results of industrial testing of processes for obtaining high-purity uranium compounds, including extraction, concentration, and purification of uranium from a mixture of nitric and phosphoric acids, solid-phase stripping, and reduction of U(VI) to U(IV). It is shown that the combination of three different extraction lines for the concentration and purification of uranium from accompanying valuable elements and radioactive isotopes makes it possible to obtain a natural uranium concentrate with a low content of impurities, which determine the economics of uranium hexafluoride production. The processes of drying and roasting of crystals of ammonium uranyl tricarbonate after solid-phase re-extraction in an atmosphere of reducing gases of ammonia and hydrogen make it possible to obtain uranium dioxide suitable for fluorination to obtain tetra and uranium hexafluoride.

Results of industrial testing of oil emulsion drilling mud in the Ustyurt urban area

Geological and physical conditions and peculiarities of the development of deposits of high-viscosity oils are given. To study the causes of flooding production of wells, dependencies have been made on the development period, the utilization factor of reserves and the recovery factor of oil. It is established that the rate of watering the production of wells depends on the activity of the water-pressure system.

PUNCHING CUPS WITH BOTTOM FLANGE BY DIRECT EXTRUSION WITH COUNTER-PUNCH. INDUSTRIAL TESTING AND ITS RESULTS

The results of industrial testing of a new method of manufacturing glasses with a flange in the bottom part by direct extrusion with a counter-punch are presented. The characteristics of the tools used, the geometrical parameters of the stamping, and also the lubrication are described in detail. A method for eliminating the meniscus of the end face of the extruded glass wall is described. The results of practical studies of the strength properties and hardness of billets and obtained products are presented. Additionally, the high accuracy of the obtained calculation formulas is confirmed.

Method of Speed Mode Correction of Rolling Pipes in the Reduction Mill

The article develops one of the main directions of improving the technology of pipe rolling on a reduction-stretching mill, in order to reduce the end crop. The article describes a speed adjustment technique of the reduction mill, when rolling the front end and back end of pipes, the length of which corresponds to the length of the thickness of ends of the finished pipe. A distinctive feature of the technique is the calculation of volume of the thickness end, which must be reduced by an adjusted value, when rolling the end area in the head stands. The sequence of technological calculations and the results of industrial testing of pipe reduction by standard rolling modes, and modes calculated by the proposed technique, are given. An analysis of the results of industrial testing showed the possibility of reducing the mass of the thickness ends by no less than 7%.

Research and development of broaching methods on mandrel of large-sized pipe forgings

In modern day industry of heavy engineering, parts made from billets comprising large-sized pipe forgings are widely used. The paper presents results of the study of various methods of broaching on mandrel of large-sized pipe forgings and presents the results of industrial testing of the developed methods of broaching and designs of mandrels.

Research of Recrystallization Processes in Low-Carbon Low-Alloy Steel in Modeling High-Temperature Rolling

Abstract—The processes of dynamic and static recrystallization occurring under various types of plastic deformation (compression pattern, deformation temperature) of low-carbon low-alloy steel are studied. Modeling of thermomechanical processing followed by a comprehensive analysis of the microstructure was performed on a Gleeble 3800. The studies performed revealed the thermal deformation conditions for the formation of a finely dispersed homogeneous steel structure. The results of industrial testing of the developed modes of hot rolling of sheet metal are given.

Processing of the Silver–Zinc Crust of the Product of Refining of Raw Lead in a Copper-Smelting Converter

We present the results of industrial testing of the technology of processing of silver–zinc crust obtained in the process of refining of raw lead from silver in a copper-smelting converter. We perform the tests for two versions of charging of dried crust into the converter: either into the empty converter prior to pouring matte from the smelting of secondary copper-containing raw materials in a shaft furnace or during the period of conversion after obtaining white mat. In the case of charging over the white mat, we get the slags that are poorer in all analyzed metals, whereas the yield of silver and gold into copper blister is higher. According to data of balance smelting, the direct yields of silver and gold from all types of processed raw materials into blister copper are 96.72% and 97.76%, respectively.

Plasticity and deformation resistance of the alloyed rail steels in rolling temperature interval

On the basis of conducted experimental studies, regularities of the influence of temperature-speed rolling conditions on the plasticity and deformation resistance in the zones of continuously cast billets of alloy rail steels of E76KhF, E76KhSF grades are determined and scientifically substantiated. The results indicate the complex nature of dependence of rail steel E76KhF plasticity on deformation temperature. In particular, for near-surface layers of continuously cast billets, a noticeable decrease in plasticity in the temperature range of 1025 – 1075 °Cwas recorded, which is absent for the layers located in central zone of that billets. Generalization of the results of plasticity studies of various layers of continuously cast rail E76KhF steel billets has shown that absolute values of the plasticity criterion are significantly reduced with the distance from the surface to the central zone. This fact can be explained by a coarse-grained structure and increased concentration of non-metallic inclusions in the central zone of continuously cast billets relative to their surface layers; it was confirmed by the results of metallographic studies. In particular, it was found that the average grains diameter in the surface layer of deformed continuously cast billets is in 1.3 – 2.1 times less compared to the central zone. There was confirmed the presence of significant concentrations of non-deformable inclusions of the silicate type (Al2O3· SiO2; FeO·SiO2; MnO·SiO2), which have most negative influence on steel plasticity while in the surface area such inclusions are absent. On the basis of conducted researches it was established that with increase in deformation temperature of rail steel E76KhSF there is a decrease in resistance to plastic deformation according to the exponential law. In this case, absolute values of the steel deformation resistance are reduced with the distance from the surface to the central zone of continuously cast billets, which is associated with the above illustrated increase in grain size and localization of non-metallic inclusions. The revealed tendency to reduce the deformation resistance from the surface layers to the center of continuously cast billets is maintained regardless to deformation rate, while the absolute values of the deformation resistance increase significantly with the growth of deformation rate from 1 to 10 s–1. Mathematical processing of the obtained experimental data allowed to obtain regression equations that help to predict plastic and deformation properties of alloyed rail steels of E76KhF and E76KhSF grades with a sufficient degree of reliability under the specified rolling conditions and are complex theoretical basis for the development and improvement of new heating modes of billets for rolling and rail rolling schemes. Adequacy of the obtained experimental dependences is confirmed by results of pilot industrial testing of the new mode of railway rails production on the universal rail mill of “EVRAZ ZSMK”.

ИЗЫСКАНИЕ ЭФФЕКТИВНЫХ РЕЖИМОВ И ТЕХНОЛОГИИ ДЕЗИНФЕКЦИИ ВЕТСАНОБЪЕКТОВ НАПРАВЛЕННЫМИ АЭРОЗОЛЯМИ АНОЛИТА «АЛОКС» В ПРОИЗВОДСТВЕННЫХ УСЛОВИЯХ

The article presents the results of industrial testing of the modes and technology of disinfection of industrial premises and equipment at poultry farms with directed aerosols of the new preparation anolyte «Alox». It has been established that the developed technology is efficient and can be recommended for veterinary practice. According to the results of the research for veterinary practice has been developed «The technology of application of the new disinfectant «ALOX» for disinfection of objects of veterinary supervision».

Study of the Performance Characteristics of Erbium-Containing Laser Glasses

The present state of laser glasses production for optoelectronic systems and devices is considered. The limitations of existing laser glasses and the necessity to create new ones have been viewed. The urgency of the development and introduction of new types of laser glass for its use in both civilian and defense equipment sectors is shown. The technological complexity of the phosphate erbium glasses production is substantiated. The purpose of the work is to create laser glasses and make a laser element, will be operating wavelength of 1.54 μm. Optimum concentration of rare earth oxides in laser glasses has been determined. The quality control methodology and technology of laser glasses were developed. The production of a new laser glass makes it possible to use it in modern optoelectronic systems. The laser elements were fabricated and their generation characteristics were investigated. The results of the laser elements industrial testing are presented.

Need to Identify Parameters of Concrete in the Weakest Zone of the Industrial Floor

The ways in which industrial floors are exploited leads to the requirement for the highest strength of their upper zone. Physical phenomena occurring during the compaction and hardening of the concrete cause different strength distributions. In the top zone of industrial floors, the strength is significantly lower (over a dozen MPa) than the strength in the bottom zone (several dozen MPa). Standard tests of control samples do not detect this fact. Processes for the application and finishing of embedded mineral-aggregate hardeners (dry shakes) can be regarded as uncontrolled. The effects of the use of dry shakes are not evaluated. In combination with the phenomenon of bleeding, they often fail by delamination. This paper presents the results of industrial floor testing. The ultrasonic pulse velocity method with dry point contact transducers was used. The results show how upper layer strength was reduced, and how dry shakes application affected the strength of the floor. The strength distribution in hardened concrete, which delaminated from the rest of the floor was presented as well. The extension of compulsory control tests of concrete samples was proposed. In the authors’ opinion, particular attention should be paid to 3 centimetres of the upper layer.

Structure, Properties, and Use of Protective Cermet Coatings Prepared By Electric-Spark Alloying and Electric-Arc Hardfacing

Research results are given for study and use of cermet electrode materials, intermetallics, materials based on MAX-phase and ceramic materials with a nanosize structure for application of protective coatings by electric-spark alloying and electric-arc hardfacing on a metal substrate. The microstructure and properties of the alloy and hardfacing layers formed, and the nature of substrate material interaction with SHS-electrodes are studied, and comparative tribological tests are performed for coating strength. Some results of industrial testing of the materials developed are provided.

Alloying principles and requirements for production technologies of new generation high-strength vessel steels

Alloying principles for new high-strength cold-resistant steels for marine equipment with a yield strength of 500–800 MPa are developed. The technology is based on a lower amount of expensive alloying elements. The production technologies for that are shown. Optimum structure requirements on high-strength steels used for marine engineering are discussed. Hot plastic working schemes for industry with immediate quenching and posttempering that provide the formation of nanosized structural elements are described. The results of industrial testing of new high-strength steels and their comparison with the properties of the known hardened and tempered steels are represented.

Basic laws of the processes and the principle of minimum energy consumption during pneumatic transport and distribution of pulverized fuel in direct pulverized fuel preparation systems

The paper presents analysis of the basic laws and a calculation-based investigation of processes related to the low-concentration pneumatic transport and the distribution of finely dispersed pulverized fuel in direct pulverized fuel preparation systems of boiler units. Based on the principle of the minimum energy consumption, it is shown that, at high (standard) velocities of the turbulent gas flow—of 25–30 m/s, which is by 1.5–2 times higher than the critical speeds—the finely dispersed pulverized fuel can be transported simultaneously in the form of a low-concentration flow in pipelines and a concentrated, to 30% of the flow rate, thin layer on the pipeline walls with the height of the layer equal to 0.02–0.04 of the pipe radius. Consideration of this phenomenon is of great significance in terms of securing the efficient operation of pulverized fuel distribution units. The basic characteristics of the process have been determined and validated by test bench investigations using both model systems and pulverized fuel distribution systems of a number of power-generating units. The obtained results underlie a methodological approach to developing high-efficiency adjustable pulverized fuel distribution units. Also, results of industrial testing are presented that confirm the results of the analysis and of experimental studies.

Cold Treatment of Parts of ESh-20.90S Dragline for Mining Applications at the Uralmashzavod Plant

Results of laboratory and industrial testing of the effect of cold treatment on the structure, hardness and size stability of parts such as spools and sleeves entering the hydraulic drive of an ESh-20.90S dragline (bucket volume 20 m3, boom length 90 m) for mining applications under the conditions of the Far North are presented.

Preparation and Research of the High-Strength Lightweight Concrete Based on Hollow Microspheres

The paper presents the results of research aimed at development of nanomodified high-strength lightweight concrete for construction. The developed concretes are of low average density and high ultimate compressive strength. It is shown that to produce this type of concrete one need to use hollow glass and aluminosilicate microspheres. To increase the durability of adhesion between cement stone and fine filler the authors offer to use complex nanodimensional modifier based on iron hydroxide sol and silica sol as a surface nanomodifier for hollow microspheres. It is hypothesized that the proposed modifier has complex effect on the activity of the cement hydration and, at the same time increases bond strength between filler and cement-mineral matrix. The compositions for energy-efficient nanomodified high-strength lightweight concrete which density is 1300...1500 kg/m3 and compressive strength is 40...70 MPa have been developed. The approaches to the design of high-strength lightweight concrete with density of less than 2000 kg/m3are formulated. It is noted that the proposed concretes possess dense homogeneous structure and moderate mobility. Thus, they allow processing by vibration during production. The economic and practical implications for realization of high-strength lightweight concrete in industrial production (in particular, for construction of high-rise buildings) have been justified. The results of industrial testing of new compositions in precast concrete technology are shown.

3D Inspection of Fuel Assembly Components

Safety increasing of nuclear reactors is urgent problem for atomic industry. It takes 100% noncontact dimensional inspection of nuclear reactor components. Optoelectronic methods and systems for 3D inspection of fuel assembly elements, including spacer grids and fuel elements, are presented. The universal structured light method for 3D inspection of Russian and western grid spacers using diffraction elements is developed. For fuel elements inspection one considers the shadow method which allows one to implement full inspection of articles under transported along the automatic production line. TDI SIE has developed the commercial version of systems for integral inspection of spacer grids and fuel elements. The experimental results of industrial testing are given.

Use of an electromagnetic-acoustic technique in the practice of testing tubes of main gas pipelines

The results of development, design, and industrial testing of an electromagnetic-acoustic (EMA) technique are considered. An ultrasonic EMA pig flaw detector has higher sensitivity to cracks and can work in gas pipelines as well as a magnetic pig flaw detector does. The EMA pig flaw detector reliably detects cracks with a 10-μm opening, which are almost invisible for a magnetic pig flaw detector.

Hardening technology in integrated deformational-thermal production of sheet steels of the martensite class

Hardening technologies have been developed for medium-carbon alloyed steels in the system of integrated deformation-thermal production. The results of industrial testing using the equipment complex on a reversing mill 2000 are given.