Research Article
Comprehensive Approach to Flue Gas Flow Optimization in Electrostatic Precipitators and Material Selection for Baffle Plates
Issue:
Volume 1, Issue 1, March 2026
Pages:
1-24
Received:
26 July 2025
Accepted:
23 January 2026
Published:
9 February 2026
Abstract: This research presents a comprehensive evaluation of Unit #4, a 210 MWe BHEL-designed boiler in a thermal power station, focusing on Flue Gas Duct Airflow Assessment (FGDAA) and Computational Fluid Dynamics (CFD) analysis of the associated flue gas duct system. The unit operates with six Electrostatic Precipitators (ESPs), three Induced Draft (ID) fans, and two Forced Draft (FD) fans, and the primary objective is to optimize flue gas distribution among ESPs to enhance plant efficiency and reliability. Cold air velocity measurements using calibrated S-type Pitot tubes provided accurate estimation of mass flow distribution in various ducts, while FGDAA under different ID fan operating conditions highlighted important operational efficiency considerations. The study identified non-uniform mass flow distribution across ESPs, which motivated detailed CFD simulations and the development of improved engineering designs for baffle and guide plates to regulate flow. In addition, material selection for these components was investigated through cost analysis and mechanical characterization. Results showed that tungsten carbide-clad plates are significantly more expensive than ceramic guide plates, while microhardness testing indicated silicon carbide as a superior material due to its higher hardness and wear resistance. Wear testing on AISI 1018 steel further demonstrated the influence of mass concentration on erosive damage, underscoring the importance of optimized flow management in flue gas environments. Overall, the study provides valuable insights into airflow control, material selection, and design optimization to improve the performance and service life of flue gas duct systems in thermal power plants.
Abstract: This research presents a comprehensive evaluation of Unit #4, a 210 MWe BHEL-designed boiler in a thermal power station, focusing on Flue Gas Duct Airflow Assessment (FGDAA) and Computational Fluid Dynamics (CFD) analysis of the associated flue gas duct system. The unit operates with six Electrostatic Precipitators (ESPs), three Induced Draft (ID) ...
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Research Article
Formation and Facet Less Immersion of Discrete Al-Si Areas on Unpolished Wafers in Silicon Thermomigration Technology
Vitalii Kravchyna*
,
Oleksii Polukhin
Issue:
Volume 1, Issue 1, March 2026
Pages:
25-33
Received:
30 September 2025
Accepted:
31 January 2026
Published:
11 February 2026
DOI:
10.11648/j.sdm.20260101.12
Downloads:
Views:
Abstract: The paper considers the technology of thermal migration for the formation of a through-layer insulation of individual crystals in the manufacture of power electronics devices. The initial Al-Si layer for the thermal migration process is formed in SiO2 windows from the Al melt and the surface disordered Si layer dissolved in it. Selective dissolution of Si occurs when the surface of the moving wafer sequentially contacts the Al melt ribbon, where the convection flows of the melt remove the dissolved Si atoms to the melt volume. In the process, it is possible to control the thickness of the Al-Si melt formed in the SiO2 windows. The formation of the p+-Si*(Al) layer, which is deposited during recrystallization from the Al-Si melt during the cooling of the wafers, the high concentration of Si and the homogeneity of the Al-Si layer ensure the isotropic nature of the dissolution process and, accordingly, the faceless immersion of the discrete zone during the subsequent thermal migration process. The observed change in the polarity of the brightness contrast of the surfaces of the discrete zone and adjacent silicon in the temperature range of 1100-1130°C allows us to control the beginning of the high-temperature immersion process. The article also shows the dependence of the thickness of the Al-Si layer on the parameters of its formation process.
Abstract: The paper considers the technology of thermal migration for the formation of a through-layer insulation of individual crystals in the manufacture of power electronics devices. The initial Al-Si layer for the thermal migration process is formed in SiO2 windows from the Al melt and the surface disordered Si layer dissolved in it. Selective dissolutio...
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Research Article
Design and Structural Analysis of a Connecting Rod Using Different Materials
Issue:
Volume 1, Issue 1, March 2026
Pages:
34-49
Received:
17 August 2025
Accepted:
27 January 2026
Published:
11 February 2026
DOI:
10.11648/j.sdm.20260101.13
Downloads:
Views:
Abstract: A connecting rod or connective rod is a very important part of internal combustion engines that connect the piston to crankshaft, which enables conversion of the reciprocating motion to another rotary motion. Connecting rods have traditionally been constructed out of forged steel because of its fatigue strength, although its density adds weight and decreases efficiency to engines. As the requirements for lightweight and fuel-efficient engines increase, so too do the negative influences of the mass of forged steel connecting rods leading to easier induction of inertial forces and loss of performance. The purpose of the research is to design and analyze connecting rod materials alternative to reduce weight, increase stiffness and fatigue life compared to conventional forged steel connecting rods. A connecting-rod was modeled parametrically in SolidWorks and assessed using SolidWorks Workbench finite element analysis (FEA). The paper compared Forged Steel to Titanium Alloy, Beryllium Alloy-25, Magnesium Alloy and Aluminum 360 such in stress strain, deformation, safety factor and fatigue life. Out of the tested material, Aluminum 360 had the lowest deformation (1.950e-05 mm), least stress (2.992e+04 N/m 2), greatest margin of safety and substantial weight reduction compared to forged steel. The results encourage the use of Aluminum 360 in place of forged steel used in two-wheeler engines since it provides better performance, efficiency, and a longer life.
Abstract: A connecting rod or connective rod is a very important part of internal combustion engines that connect the piston to crankshaft, which enables conversion of the reciprocating motion to another rotary motion. Connecting rods have traditionally been constructed out of forged steel because of its fatigue strength, although its density adds weight and...
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