Abstract: A multi-grain selector device includes an outer body having exterior surfaces. The outer body includes a cooling side configured to face a cooling plate of a casting furnace and an opposite mold side configured to face into a mold. The outer body includes an array of multiple grain selector columns each formed from two or more transversely oriented, elongated channels that are fluidly coupled with each other in an end-to-end arrangement oriented along a growth direction that extends from the cooling side of the outer body toward the mold side of the outer body. The selector columns extend to growth openings on the mold side of the outer body. Each of the selector columns is configured to form a single grain column out of the corresponding growth opening that is part of a columnar grained article to be formed in the mold that grows along the growth direction.

Abstract: A directional solidification casting method includes fluidly coupling a feed line conduit with a source of molten metal and with a directional solidification mold at a gating. The mold has an interior chamber with a shape of an object to be cast using directional solidification in a growth direction. The feed line conduit is fluidly coupled with the gating in a downward direction oriented at an angle that is closer to the growth direction of the mold than to another direction that is perpendicular to the growth direction of the mold. The method also includes positioning a downstream portion of the feed line conduit below the gating, directing the molten metal into the mold via the feed line conduit, and casting the object in the mold using directional solidification.

Abstract: A directional solidification casting assembly includes a directional solidification mold having an interior chamber with a shape of an object to be cast using directional solidification of molten metal in a growth direction of the mold and a feed line conduit. The conduit is fluidly coupled with a container source of the molten metal and is coupled with the mold at a gating. The feed line conduit conveys the molten metal into the mold through the gating for directional solidification of the object to be cast in the mold. At least a downstream portion of the feed line conduit that is between the intermediate location of the feed line conduit and the second open end of the feed line conduit is located below the gating along the growth direction of the mold.

Abstract: A directional solidification casting assembly includes a directional solidification mold having an interior chamber with a shape of an object to be cast using directional solidification of molten metal in a growth direction of the mold and a feed line conduit. The conduit is fluidly coupled with a container source of the molten metal and is coupled with the mold at a gating. The feed line conduit conveys the molten metal into the mold through the gating for directional solidification of the object to be cast in the mold. At least a downstream portion of the feed line conduit that is between the intermediate location of the feed line conduit and the second open end of the feed line conduit is located below the gating along the growth direction of the mold.

Abstract: A cast component includes a body and a passage defined within the body. The passage includes a first portion, a second portion and a turn portion fluidly coupling the first and second portions. The turn portion includes a first surface and a second surface. A surface anti-freckling element extends through the turn portion of the passage from the first surface to the second surface of the turn portion. The element separates the passage in the turn portion into a first sub-passage and a second sub-passage. The element is formed by an opening in a removable core used during the casting that includes a surface anti-freckling opening at the location of the element that provides a path for low-density liquid alloy to flow through a core turn portion of the core to reduce surface freckling of the passage in the body of the component.

Abstract: A multi-grain selector device includes an outer body having exterior surfaces. The outer body includes a cooling side configured to face a cooling plate of a casting furnace and an opposite mold side configured to face into a mold. The outer body includes an array of multiple grain selector columns each formed from two or more transversely oriented, elongated channels that are fluidly coupled with each other in an end-to-end arrangement oriented along a growth direction that extends from the cooling side of the outer body toward the mold side of the outer body. The selector columns extend to growth openings on the mold side of the outer body. Each of the selector columns is configured to form a single grain column out of the corresponding growth opening that is part of a columnar grained article to be formed in the mold that grows along the growth direction.

Abstract: A power generation system is provided. The power generation system includes a reformer system for producing syngas for an internal combustion engine. The reformer system includes a reforming unit having a catalyst for thermochemical conversion of a first portion of a hydrocarbon fuel to the syngas. The power generation system also includes a waste heat recovery system including at least one organic Rankine cycle flow path of working fluid, at least one waste heat recovery exchanger, for extracting waste heat from the reformer system, and at least one evaporator for using the extracted waste heat for heating the working fluid.

Abstract: Embodiments of the present invention include methods for forming ceramic articles, such as cores and core dies used in investment casting. The method may provide ceramic articles having improved strength and smoothness compared to articles manufactured by conventional methods. One embodiment is a method that comprises introducing a liquid comprising a silicon-bearing fluid into pores of a porous ceramic body; and heating the porous ceramic body in an oxygen-bearing atmosphere to form silica within the pores of the body.

Abstract: A process for the plasma-assisted treatment of coal in which coal is directly converted to heavy hydrocarbons. The first step in the process is direct conversion of coal to aliphatic hydrocarbons under plasma conditions in the presence of light hydrocarbons, such as natural gas. In the second process step, the aliphatic hydrocarbons are upgraded to a liquid fuel. The energy for the process can be provided by radio frequency energy, such as microwave energy, that is powered by a renewable energy source. The process has flexibility to adjust aromatic content in the fuel to match fuel specification requirements.

Abstract: A power generation system is provided. The power generation system includes a reformer system for producing syngas for an internal combustion engine. The reformer system includes a reforming unit having a catalyst for thermochemical conversion of a first portion of a hydrocarbon fuel to the syngas. The power generation system also includes a waste heat recovery system including at least one organic Rankine cycle flow path of working fluid, at least one waste heat recovery exchanger, for extracting waste heat from the reformer system, and at least one evaporator for using the extracted waste heat for heating the working fluid.

Abstract: A treated refractory material includes a porous refractory material having one or more protective materials disposed within pores of the refractory material. Methods of preparing the treated refractory material are also provided. The treated refractory material provides protection from the penetration of slag and extends the service life of the refractory material.

Abstract: A system and method for measuring a thickness of a refractory wall of a gasifier using electromagnetic energy is disclosed. The system includes a waveguide with a bistatic or monostatic phased array antenna at one end. The waveguide is operably connected to a Network Analyzer that generates a pulse of electromagnetic energy with a desired bandwidth. The pulse is transmitted through a coaxial cable to the waveguide. The reflection of the pulse is received by the waveguide and input to a data acquisition system. An output device displays the resolvable discontinuities in impedance encountered by the pulse in its propagation path in the system.

Abstract: A treated refractory material includes a sintered porous refractory material having one or more protective materials disposed within pores of the refractory material, wherein the protective material is selected from the group consisting of aluminum oxide, chromium oxide, silica, rare earth oxides, rare earth zirconates, titanium oxide, mullite, zirconium oxide, zirconium silicate, yttrium oxide, magnesium oxide, iron oxide, and blends thereof. Methods of preparing the treated refractory material are also provided. The treated refractory material provides protection from the penetration of slag and extends the service life of the refractory.

Abstract: A process for the plasma-assisted treatment of coal in which coal is directly converted to heavy hydrocarbons. The first step in the process is direct conversion of coal to aliphatic hydrocarbons under plasma conditions in the presence of light hydrocarbons, such as natural gas. In the second process step, the aliphatic hydrocarbons are upgraded to a liquid fuel. The energy for the process can be provided by radio frequency energy, such as microwave energy, that is powered by a renewable energy source. The process has flexibility to adjust aromatic content in the fuel to match fuel specification requirements.

Abstract: A system and method for measuring a thickness of a refractory wall of a gasifier using electromagnetic energy is disclosed. The system includes a waveguide with a bistatic or monostatic phased array antenna at one end. The waveguide is operably connected to a Network Analyzer that generates a pulse of electromagnetic energy with a desired bandwidth. The pulse is transmitted through a coaxial cable to the waveguide. The reflection of the pulse is received by the waveguide and input to a data acquisition system.

Abstract: A treated refractory material includes a porous refractory material having one or more protective materials disposed within pores of the refractory material. Methods of preparing the treated refractory material are also provided. The treated refractory material provides protection from the penetration of slag and extends the service life of the refractory material.

Abstract: A system and method for gathering diagnostic information relating to an operating condition of a gas stream or processing path of a coal gasification system is disclosed. The information is gathered by deploying one or more specially constructed modules or seeds that proceed through the gas stream of the coal gasification system as part of the mass flow of the gas stream. The seed may be physically recoverable in which an outer material of the seed ablates when exposed to a predetermined temperature of the gas stream. The seed may be physically non-recoverable in which electronic circuitry transmits a signal to a receiver relating to the temperature of the gas stream.

Abstract: A system and method for gathering diagnostic information relating to an operating condition of a gas stream or processing path of a coal gasification system is disclosed. The information is gathered by deploying one or more specially constructed modules or seeds that proceed through the gas stream of the coal gasification system as part of the mass flow of the gas stream. The seed may be physically recoverable in which an outer material of the seed ablates when exposed to a predetermined temperature of the gas stream. The seed may be physically non-recoverable in which electronic circuitry transmits a signal to a receiver relating to the temperature of the gas stream.

Abstract: A treated refractory material includes a sintered porous refractory material having one or more protective materials disposed within pores of the refractory material, wherein the protective material is selected from the group consisting of aluminum oxide, chromium oxide, silica, rare earth oxides, rare earth zirconates, titanium oxide, mullite, zirconium oxide, zirconium silicate, yttrium oxide, magnesium oxide, iron oxide, and blends thereof. Methods of preparing the treated refractory material are also provided. The treated refractory material provides protection from the penetration of slag and extends the service life of the refractory.

Abstract: A thermal barrier coating (TBC 26) and method for forming the TBC (26) on a component (10) characterized by a stabilized microstructure that resists grain growth, sintering and pore coarsening or coalescence during high temperature excursions. The TBC (26) contains elemental carbon and/or a carbon-containing gas that increase the amount of porosity (32) initially within the TBC (26) and form additional fine closed porosity (32) within the TBC (26) during subsequent exposures to high temperatures. A first method involves incorporating elemental carbon precipitates by evaporation into the TBC microstructure. A second method is to directly incorporate an insoluble gas, such as a carbon-containing gas, into an as-deposited TBC (26) and then partially sinter the TBC (26) to entrap the gas and produce fine stable porosity within the TBC (26).