Environmental impact evaluation of wear protection materials

IF 5.3 1区 工程技术 Q1 ENGINEERING, MECHANICAL Wear Pub Date : 2024-10-28 DOI:10.1016/j.wear.2024.205612
H. Rojacz , D. Maierhofer , G. Piringer
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Abstract

Wear protection materials, especially those for high-temperature service, often contain substantial amounts of chromium, cobalt and/or nickel and/or with embedded hard phases or forming harder intermetallic phases. Due to the comparatively high environmental impact of those elements, more sustainable alternatives must be found. This study presents a life cycle assessment quantifying the environmental impacts of three groups of cast alloys for wear protection: iron-, nickel-, and cobalt-based alloys. The assessment includes the production stage from raw materials extraction to casting (upstream impacts from cradle-to-gate), with the functional unit defined as 1 dm³ wear protection material. Global average process data were used to estimate the environmental impact of the respective alloy. Results indicate that iron-based alloys as studied here cause lower greenhouse gas (GHG) emissions during production (57–103 kg CO2eq/dm³ or 8.4–13.8 t CO2eq/t) compared to nickel-based (185–205 CO2eq/dm³ or 20–22 t CO2eq/t) and cobalt-based alloys (318–347 CO2eq/dm³ or 31.2–39.5 t CO2eq/t). The lowest emissions during production are caused by iron aluminide-based alloys at around 57 kg CO2eq/dm³ or approx. 8.4 t CO2eq/t, which is up to 90 % less than cobalt-based alloys, of up to 60 % less than nickel-based alloys, and around 50 % relative to Cr-rich iron-based alloys. Further, lifetime considerations based on actual wear data of the respective alloys at ambient and elevated temperatures were accounted for, and three different case studies were evaluated, namely abrasive wear at feeder plates, erosive wear on sieves (both at ambient and high temperatures) as well as wear on grate bars of a sintering plant for pig iron. Here, it was shown that the wear materials’ lifetime of wearing materials has a crucial effect on the environmental impact, since a prolonged lifetime reduces the need for spare parts and of replacement of the goods with their embedded carbon footprint. For example, an average hot sieve can achieve GHG emission savings of approx. 50 t CO2eq/a when using an iron-aluminium alloy instead of a cobalt-based wear protection. The exchange of 10 m³ worn grate bars for a sintering plant made of an iron aluminide instead of a white cast iron saves over 500 t CO2eq/a. Further, over 50 % emission savings in other environmental impact categories can be achieved by this measure.
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磨损防护材料的环境影响评估
磨损保护材料,尤其是用于高温条件下的磨损保护材料,通常含有大量的铬、钴和/或镍和/或嵌入硬质相或形成较硬的金属间相。由于这些元素对环境的影响相对较大,因此必须找到更具可持续性的替代品。本研究提出了一项生命周期评估,量化了三组用于磨损保护的铸造合金对环境的影响:铁基合金、镍基合金和钴基合金。评估包括从原材料提取到铸造的生产阶段(从摇篮到大门的上游影响),功能单位定义为 1 dm³ 耐磨保护材料。全球平均工艺数据用于估算相应合金对环境的影响。结果表明,与镍基合金(185-205 CO2eq/dm³ 或 20-22 t CO2eq/t)和钴基合金(318-347 CO2eq/dm³ 或 31.2-39.5 t CO2eq/t)相比,本文研究的铁基合金在生产过程中产生的温室气体(GHG)排放量较低(57-103 kg CO2eq/dm³ 或 8.4-13.8 t CO2eq/t)。生产过程中排放量最低的是铝基铁合金,约为 57 kg CO2eq/dm³ 或约 8.4 t CO2eq/t,比钴基合金少达 90%,比镍基合金少达 60%,比富含铬的铁基合金少约 50%。此外,还根据各合金在环境温度和高温条件下的实际磨损数据考虑了使用寿命,并对三个不同的案例进行了评估,即给料板的磨料磨损、筛网的侵蚀磨损(环境温度和高温条件下)以及生铁烧结厂篦条的磨损。研究表明,耐磨材料的使用寿命对环境影响至关重要,因为使用寿命的延长可以减少对备件的需求,并减少因更换而产生的碳足迹。例如,当使用铁铝合金而不是钴基耐磨保护材料时,普通热筛的温室气体排放量可减少约 50 吨 CO2eq/a。将 10 立方米的磨损篦条换成由铝铁合金代替白口铸铁制成的烧结设备,可节省超过 500 吨 CO2eq/a。此外,这项措施还可在其他环境影响类别中实现 50% 以上的减排。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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来源期刊
Wear
Wear 工程技术-材料科学:综合
CiteScore
8.80
自引率
8.00%
发文量
280
审稿时长
47 days
期刊介绍: Wear journal is dedicated to the advancement of basic and applied knowledge concerning the nature of wear of materials. Broadly, topics of interest range from development of fundamental understanding of the mechanisms of wear to innovative solutions to practical engineering problems. Authors of experimental studies are expected to comment on the repeatability of the data, and whenever possible, conduct multiple measurements under similar testing conditions. Further, Wear embraces the highest standards of professional ethics, and the detection of matching content, either in written or graphical form, from other publications by the current authors or by others, may result in rejection.
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