Thermal Fatigue Life Prediction of Ventilation Air Methane Oxidation Bed
Thermal flow-reversal oxidation is the main technology that can effectively reduce emissions of ventilation air methane. As the core component of coal mine ventilation oxidation devices, honeycomb ceramic oxidation beds play a decisive role in the functionality of these devices. The thermal fatigue...
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Інститут проблем міцності ім. Г.С. Писаренко НАН України
2016
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| Cite this: | Thermal Fatigue Life Prediction of Ventilation Air Methane Oxidation Bed / Y.Q. Liu, Q.H. Shang, D.H. Zhang, Y.X. Wang, T.T. Sun // Проблемы прочности. — 2016. — № 1. — С. 13-19. — Бібліогр.: 12 назв. — англ. |
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| author | Liu, Y.Q. Shang, Q.H. Zhang, D.H. Wang, Y.X. Sun, T.T. |
| author_facet | Liu, Y.Q. Shang, Q.H. Zhang, D.H. Wang, Y.X. Sun, T.T. |
| citation_txt | Thermal Fatigue Life Prediction of Ventilation Air Methane Oxidation Bed / Y.Q. Liu, Q.H. Shang, D.H. Zhang, Y.X. Wang, T.T. Sun // Проблемы прочности. — 2016. — № 1. — С. 13-19. — Бібліогр.: 12 назв. — англ. |
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| description | Thermal flow-reversal oxidation is the main technology that can effectively reduce emissions of ventilation air methane. As the core component of coal mine ventilation oxidation devices, honeycomb ceramic oxidation beds play a decisive role in the functionality of these devices. The thermal fatigue properties of mullite ceramic – which is commonly used in oxidation beds – was tested in the present research. Then, the service life of the oxidation bed was predicted according to the intensity attenuation law and the thermal fatigue experimental data. The results of the fatigue experiment indicated that in general, the bending strength of mullite ceramics decreases as thermal shocks increase. At higher temperature differences, the bending strength decreased at greater rates. At the temperature differences between 600 and 800°C, the bending strength initially declined. Then, after reaching a certain value, it remained unchanged for a while before declining again. The results of the equation that was developed from intensity attenuation theory and the thermal fatigue experimental data indicate that the thermal fatigue life of an oxidation bed is about 1–8 months. The predicted result is consistent with actual working conditions.
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UDC 539.4
Thermal Fatigue Life Prediction of Ventilation Air Methane Oxidation Bed
Y. Q. Liu,
1
Q. H. Shang, D. H. Zhang, Y. X. Wang, and T. T. Sun
School of Traffic and Vehicle Engineering, Shandong University of Technology, Zibo, China
1 liuyq65@163.com
Thermal flow-reversal oxidation is the main technology that can effectively reduce emissions of
ventilation air methane. As the core component of coal mine ventilation oxidation devices, honeycomb
ceramic oxidation beds play a decisive role in the functionality of these devices. The thermal fatigue
properties of mullite ceramic – which is commonly used in oxidation beds – was tested in the present
research. Then, the service life of the oxidation bed was predicted according to the intensity
attenuation law and the thermal fatigue experimental data. The results of the fatigue experiment
indicated that in general, the bending strength of mullite ceramics decreases as thermal shocks
increase. At higher temperature differences, the bending strength decreased at greater rates. At the
temperature differences between 600 and 800�C, the bending strength initially declined. Then, after
reaching a certain value, it remained unchanged for a while before declining again. The results of the
equation that was developed from intensity attenuation theory and the thermal fatigue experimental
data indicate that the thermal fatigue life of an oxidation bed is about 1–8 months. The predicted
result is consistent with actual working conditions.
Keywords: oxidation bed, mullite ceramics, thermal fatigue performance, fatigue life.
Introduction. The gaseous mixture that is emitted by coal mine ventilation systems is
known as ventilation air methane (VAM). In VAM, the methane content is generally less
than 1%. VAM is usually discharged into the atmosphere directly, and little is recycled.
Methane has a very strong greenhouse effect. Its greenhouse effect is 21 times greater than
CO2. In addition, it causes 7 times more destruction to the ozone layer than CO2 [1–4].
The thermal flow-reversal reactor is a good candidate to utilize the low methane
concentrations contained in VAM, and has been commercially used in Australia and China
[5, 6]. As the core component of coal mine ventilation oxidation devices, honeycomb
ceramic oxidation beds play a decisive role in the functionality of devices. The performance
of honeycomb ceramic oxidation beds determines the performance of the entire device. It is
therefore an important undertaking to create a method of predicting the lifespan of the
honeycomb ceramic. While most of the research has been focused on regenerative
oxidation beds’ heat transfer performance [7–9], few scholars have studied the service life
of a regenerative oxidation bed. To meet this need, thermal fatigue life of regenerative
oxidation bed is predicted in this paper.
1. The Thermal Fatigue Test.
1.1. Materials. Mullite ceramic was selected for use in the thermal fatigue experiments.
The specimens of the mullite ceramic are shown in Fig. 1. The specimen model was pressed
on a 30-ton hydraulic machine (the molding pressure is 25 MPa). The forming specimens
were sintered in an electric furnace at 1300�C. The basic physical parameters of the
specimens are shown in Table 1.
1.2. Methods. The specimens were first tested for fatigue by thermal shock. The
specimens’ bending strength was subsequently tested in order to obtain the representative
thermal fatigue properties of the materials. In the thermal shock process, the specimens
were placed into an electric furnace, which were heated to the preset temperature and kept
at that temperature for 20 minutes. Then, the specimens were removed from the furnace and
allowed to cool in the air to room temperature. The above steps were repeated according to
© Y. Q. LIU, Q. H. SHANG, D. H. ZHANG, Y. X. WANG, T. T. SUN, 2016
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 1 13
the thermal shock scheme. Considering the oxidation bed’s working temperature, the
thermal shock temperatures were selected in the range of 0 to 1000�C. The full thermal
shock scheme is shown in Table 2. According to GB3001-82, the bending strength of the
shocked specimens were tested on an universal testing machine (CMT5305), which was
produced by the SANS company. The loading rate was set at 0.5 mm/min. The residual
strength was calculated by the following formula [10]:
� f
PL
BW
�
3
2 2
, (1)
where � f is the residual bending strength, Pa, P is the fracture load, N, L is the roller
span, m, B is the width of the specimen, m, and W is the height of the specimen, m.
Because of porosity, impurities, and cracks in the specimens, it was anticipated that
the measured strength value will have a lot of dispersions. To guarantee the reliability of the
experimental data, 25 specimens in each group in the experiment were used.
1.3. Results and Discussion. Figure 2 shows the thermal fatigue curves for the varied
temperature differencees. The curves show that for every temperature difference, the
bending strength declined as the thermal shocks increased. At the same time, the attenuation
laws of bending strength for different temperature differences were different. At temperature
Y. Q. Liu, Q. H. Shang, D. H. Zhang, et al.
14 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 1
T a b l e 1
Basic Physical Parameters
Density
(g/cm3)
Elastic modulus
(GPa)
Poisson’s
ratio
Flexural strength
(MPa)
Fracture toughness
(MPa m�
1 2/ )
1.83 26.72 0.17 25.34 0.62
T a b l e 2
Scheme of Thermal Shock
Temperature difference (�T , �C) Number of thermal shocks Number of specimens
200 5, 10, 20, 30,
40, 50, 60, 70
8 25�
300 8 25�
... ...
700 8 25�
800 8 25�
a b
Fig. 1. Mullite specimens (a) and specimen dimensions (b).
differences of 200 and 300�C, the bending strength declined slowly with the increase of the
thermal shocks. For these two specimens, the largest drops of the bending strength at the
temperature differencees were 1.4 and 2.1 MPa, respectively. At temperature differencees of
400 and 500�C, the bending strength declined more quickly. The largest drops in the
bending strength were 5.8 and 7.6 MPa, respectively. At temperature differencees of 600,
700, and 800�C, the attenuation law of bending strength was significantly different from the
previous specimens. With the increase in thermal shocks, the bending strength declined
first. After reaching a certain value it remained unchanged for a while before declining
again. As the specimens were shocked for the first 10 times, the high thermal stress caused
cracks, which in turn caused the bending strength to drop sharply. In the range of 10–40
shocks, the bending strength remained unchanged because there was no new crack
generation, and the existing micro crack continued to develop in depth and length. A
schematic diagram of the crack’s extension is shown in Fig. 3. After 40 shocks, the strength
continued to decline.
Thermal Fatigue Life Prediction ...
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 1 15
a b
c
Fig. 2. Thermal fatigue test curve under different temperature differences: (a) at 200 and 300�C; (b) at
400 and 500�C; (c) at 600, 700, and 800�C.
a b
Fig. 3. Schematic diagram: (a) 0–10 shocks; (b) 10–40 shocks.
2. The Fatigue Life Prediction of Regenerative Oxidation Bed.
2.1. The Intensity Attenuation Theory. The exact damage process is difficult to
determine because of its complexity. It includes a number of factors, such as the development
and accumulation of micro cracks under thermal stress, grain boundary phase softening,
and hole size increases caused by creep or oxidation at high temperature. Still, no matter
what the damage mechanism is or how the damage process develops, the macroeffect is that
the residual strength of the ceramic is gradually decreased [11, 12].
Wang et al. [11] found that the intensity attenuation curves of ceramic materials can
be classified into several distinct types. As shown in Fig. 4, as the thermal shocks increase,
the residual strength can either:
(i) remain unchanged (curve A);
(ii) have a linear decreasing trend (curve B);
(iii) initially decrease and then remain unchanged at a certain value (curve C);
(iv) slowly decrease (curve D);
(v) exhibit a decreased acceleration (curve E).
All of the above curves can be described by Eq. (2):
� �
�
�
�
f
f
m
N
N
a N
( )
[ ( )] .1 (2)
The formula can be converted into
� �f
m
f
m N maN( ) ( ) ,0 � � (3)
where � f ( )0 is the original strength, N is the number of thermal shocks, � f N( ) is the
strength after N shocks, and parameters m and a are related to materials and thermal
shock conditions.
2.2. Life Calculation of Oxidation Bed. A fatigue equation for mullite ceramic was
formulated based on the intensity attenuation equations and the thermal fatigue experiment
data. From the resulting equation, the figure life of oxidation beds can be predicted by
combining the equation with the oxidation bed’s maximum thermal stress, which is
obtained by numerical simulation.
According to the results of numerical simulation of oxidation beds, the temperature
difference is normally about 240�C at a steady working state and the maximum stress is
22.4 MPa. To predict the thermal fatigue life of oxidation bed, the thermal fatigue life
16 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 1
Fig. 4. Different types of damage curve.
Y. Q. Liu, Q. H. Shang, D. H. Zhang, et al.
between �T � 200 and 300�C was calculated to estimate the life span of a ceramic bed at
�T � �240 C.
2.2.1. The Establishment of the Thermal Fatigue Equation. Based on the intensity
attenuation equation and the experimental data, the fatigue life equations of mullite
�T � 200 and 300�C were developed. The related experimental data is shown in Tables 3
and 4.
According to Eq. (2) and Tables 3 and 4, the thermal fatigue equation at �T � 200
and 300�C can be obtained using an lsqcurvefit function (Matlab). They resulting equations
are
� �f f N N81207 812070 109760 81207. .( ) ( ) .� � � � (�T � �200 C), (4)
� �f f N N7 325 7 3250 105630 7325. .( ) ( ) .� � � � (�T � �300 C). (5)
The graphs of Eqs. (4) and (5) are shown in Figs. 5 and 6.
It can be seen from Figs. 5 and 6 that both the curve for �T � �200 C and the curve
for �T � �300 C belong to curve type E. With E type curves, after the number of thermal
shocks reaches a certain value, the residual strength decreases at an accelerated rate as the
number of thermal shocks continues to increase. Therefore, the calculated life of the
material [� f N( )� 0] at �T � 200 and 300�C is 287,207 and 25,224 cycles, respectively.
2.2.2. Fatigue Life Estimation of Regenerative Oxidation Beds. The maximum stress
of oxidation beds is 22.4 MPa. This can be plugged into Eqs. (4) and (5) in order to obtain
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 1 17
T a b l e 3
Fatigue Experiment Data at �T � �200 C
Numbers of thermal shock 0 1 5 10 20 30 40
Residual intensity (MPa) 25.36 24.95 24.68 24.33 23.92 23.53 23.03
T a b l e 4
Fatigue Experiment Data at �T � �300 C
Numbers of thermal shock 0 1 5 10 20 30 40
Residual intensity (MPa) 25.36 24.97 24.60 24.16 23.60 23.23 22.70
Fig. 5. Damage curve at �T � �200 C. Fig. 6. Damage curve at �T � �300 C.
Thermal Fatigue Life Prediction ...
the oxidation bed’s life. The resulting life is 183,711 cycles at �T � �200 C and 15,178
cycles at �T � �300 C.
2.3. Validation and Analysis. In numerical simulation of oxidation beds, both the heat
released time and heat storage time is 60 s. This means that the oxidation bed was shocked
once every 2 minutes. If the regenerative oxidation bed worked continuously, the service
life of oxidation bed would be between 0.702 and 8 months. According to the statistics of
various kinds of engineering applications, the service life of the honeycomb ceramic
oxidation bed is generally no less than 2–3 months. Sometimes, oxidation beds last as long
as 6–12 months. For example, mullite honeycomb ceramic is used in steel rolling heating
furnaces to recover flue gas heat. At low temperatures, the service life of a heating furnace
can reach six months. At high temperatures, the service life of the heating furnace is no
more than 3 months. Therefore, the predicted results are reasonable.
In practical applications, the actual service life of a given oxidation bed will be
influenced by various conditions. For the oxidation beds that are used in VAM thermal
flow-reversal reactors, if the service life of the oxidation bed is too short, running costs of
the thermal flow-reversal reactor will be greatly increased. In order to effectively extend the
service life of the oxidation bed, the gas flow reversing cycle has been widely extended.
C o n c l u s i o n s
1. On the whole, the bending strength of mullite ceramics had a decreasing trend as
thermal shocks were increased. The bending strength at different temperature differences
had different trends: at �T � 400 and 500�C, the bending strength decreased more quickly
than it did at �T � 200 and 300�C; at �T � 600, 700, and 800�C, as subcritical extension
of cracks occurred, the bending strength declined initially, and after reaching a certain value
it remained unchanged for a while and then declined again.
2. Based on intensity attenuation theory and thermal fatigue data, the thermal fatigue
equations at �T � 200 and 300�C were established. The fatigue life of mullite ceramic at
�T � 200 and 300�C is 28 105. � and 25 104. � cycles, respectively.
3. According to the results of the simulation, the thermal fatigue life of an oxidation
bed is 1–8 months. This result is consistent with observations of oxidation beds that are
subjected to actual working conditions. These results illustrated that the prediction method
is reasonable.
Acknowledgments. This work is supported by a grant from the National High
Technology Research and Development Program of China (863 Program) (2009AA063202)
and the Shandong Province Natural Science Fund (ZR2013EEQ008, ZR2011EL017).
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18 ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 1
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Received 03. 08. 2015
ISSN 0556-171X. Ïðîáëåìû ïðî÷íîñòè, 2016, ¹ 1 19
Thermal Fatigue Life Prediction ...
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/HRV (Za stvaranje Adobe PDF dokumenata najpogodnijih za visokokvalitetni ispis prije tiskanja koristite ove postavke. Stvoreni PDF dokumenti mogu se otvoriti Acrobat i Adobe Reader 5.0 i kasnijim verzijama.)
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/NLD (Gebruik deze instellingen om Adobe PDF-documenten te maken die zijn geoptimaliseerd voor prepress-afdrukken van hoge kwaliteit. De gemaakte PDF-documenten kunnen worden geopend met Acrobat en Adobe Reader 5.0 en hoger.)
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| id | nasplib_isofts_kiev_ua-123456789-173413 |
| institution | Digital Library of Periodicals of National Academy of Sciences of Ukraine |
| issn | 0556-171X |
| language | English |
| last_indexed | 2025-12-02T05:45:13Z |
| publishDate | 2016 |
| publisher | Інститут проблем міцності ім. Г.С. Писаренко НАН України |
| record_format | dspace |
| spelling | Liu, Y.Q. Shang, Q.H. Zhang, D.H. Wang, Y.X. Sun, T.T. 2020-12-03T19:53:56Z 2020-12-03T19:53:56Z 2016 Thermal Fatigue Life Prediction of Ventilation Air Methane Oxidation Bed / Y.Q. Liu, Q.H. Shang, D.H. Zhang, Y.X. Wang, T.T. Sun // Проблемы прочности. — 2016. — № 1. — С. 13-19. — Бібліогр.: 12 назв. — англ. 0556-171X https://nasplib.isofts.kiev.ua/handle/123456789/173413 539.4 Thermal flow-reversal oxidation is the main technology that can effectively reduce emissions of ventilation air methane. As the core component of coal mine ventilation oxidation devices, honeycomb ceramic oxidation beds play a decisive role in the functionality of these devices. The thermal fatigue properties of mullite ceramic – which is commonly used in oxidation beds – was tested in the present research. Then, the service life of the oxidation bed was predicted according to the intensity attenuation law and the thermal fatigue experimental data. The results of the fatigue experiment indicated that in general, the bending strength of mullite ceramics decreases as thermal shocks increase. At higher temperature differences, the bending strength decreased at greater rates. At the temperature differences between 600 and 800°C, the bending strength initially declined. Then, after reaching a certain value, it remained unchanged for a while before declining again. The results of the equation that was developed from intensity attenuation theory and the thermal fatigue experimental data indicate that the thermal fatigue life of an oxidation bed is about 1–8 months. The predicted result is consistent with actual working conditions. This work is supported by a grant from the National High Technology Research and Development Program of China (863 Program) (2009AA063202) and the Shandong Province Natural Science Fund (ZR2013EEQ008, ZR2011EL017). en Інститут проблем міцності ім. Г.С. Писаренко НАН України Проблемы прочности Научно-технический раздел Thermal Fatigue Life Prediction of Ventilation Air Methane Oxidation Bed Прогнозирование термоусталостной долговечности реактора для окисления метана вентиляционных струй Article published earlier |
| spellingShingle | Thermal Fatigue Life Prediction of Ventilation Air Methane Oxidation Bed Liu, Y.Q. Shang, Q.H. Zhang, D.H. Wang, Y.X. Sun, T.T. Научно-технический раздел |
| title | Thermal Fatigue Life Prediction of Ventilation Air Methane Oxidation Bed |
| title_alt | Прогнозирование термоусталостной долговечности реактора для окисления метана вентиляционных струй |
| title_full | Thermal Fatigue Life Prediction of Ventilation Air Methane Oxidation Bed |
| title_fullStr | Thermal Fatigue Life Prediction of Ventilation Air Methane Oxidation Bed |
| title_full_unstemmed | Thermal Fatigue Life Prediction of Ventilation Air Methane Oxidation Bed |
| title_short | Thermal Fatigue Life Prediction of Ventilation Air Methane Oxidation Bed |
| title_sort | thermal fatigue life prediction of ventilation air methane oxidation bed |
| topic | Научно-технический раздел |
| topic_facet | Научно-технический раздел |
| url | https://nasplib.isofts.kiev.ua/handle/123456789/173413 |
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