Lauryl alcohol and amine oxide as foam stabilizers in the presence of hardness and oily soil

The effects of two potential foam boosters, n-dodecanol (or lauryl alcohol: LA) and tetradecyldimethylamine oxide (C₁₄DMAO), were investigated for two situations in which foam made from a 0.01 wt% solution of a common alkylethoxy sulfate surfactant was highly unstable in the presence of oil drops consisting of an n-hexadecane/oleic acid mixture. In one case in which dissolved CaCl₂ was present at alkaline pH, insoluble calcium oleate particles formed in situ and facilitated foam breakage. In the other, a much higher concentration of calcium was present at neutral pH, and drops of a microemulsion phase formed but no calcium oleate. In both cases, 0.005 wt% LA reduced the entry coefficient, E, of the oil to the air-water surface sufficiently to prevent drop entry and stabilized the foam. In contrast, 0.005 wt% C₁₄DMAO caused smaller reductions in E and was ineffective as a foam booster. LA was more effective because it was able to form a more compact monolayer with the surfactant than C₁₄DMAO at the air-water surface, which led to lower surface tensions and hence lower values of E.     

Influence of the glass–calcium carbonate mixture's characteristics on the foaming process and the properties of the foam glass

We prepared foam glasses from cathode-ray-tube panel glass and CaCO₃ as a foaming agent. We investigated the influences of powder preparation, CaCO₃ concentration and foaming temperature and time on the density, porosity and homogeneity of the foam glasses. The results show that the decomposition kinetics of CaCO₃ has a strong influence on the foaming process. The decomposition temperature can be modified by varying the milling time of the glass–CaCO₃ mixture and thus for a specific CaCO₃ concentration an optimum milling time exists, at which a minimum in density and a homogeneous closed porosity are obtained. Under the optimum preparation conditions the samples exhibit a density of 260 kg/m³. The thermal conductivity of the foam glass was measured to be 50–53 mW/(m K). The observed dependence of the foaming process on the decomposition kinetics of the foaming agent can be applied as a universal rule for foaming processes based on thermal decomposition.     

Copper mediated epoxidation of high oleic natural oils with a cumene–O2 system

The epoxidation of methyl oleate or high oleic FAMEs from different vegetable oils was carried out in a one-pot reaction over supported copper catalysts by using cumene as oxygen carrier. Cumene firstly reacts with O₂ generating cumene hydroperoxide, that by reaction with methyl oleate forms the epoxide. By using 8% Cu catalysts supported on alumina or on a polymer yields up to 87% could be obtained in a single pot at 100 °C.     

Improving the properties of ceramic foams by a vacuum infiltration process

Reticulated ceramic foams are widely used for industrial applications such as metal filtration, exhaust gas and air purification, catalyst support and others. In this work, the compression strength and specific surface area of reticulated foams have been improved, while at the same time maintaining a high level of permeability in the final foam structure. In particular, a vacuum infiltration step by using a suitable slurry, followed by a pre-sintering cycle was adopted for filling up the hollow struts, generated due to the burnout of the PU foam. Furthermore, various mixtures of fine and coarse-grained alumina as well as in combination with zirconia, were utilised with the aim of controlling the foam properties such as compression strength, specific surface area and permeability. The compression strength was improved by a factor of two for alumina foams by infiltrating the hollow struts, and by a factor of four when infiltrating the struts of ZTA foams, with the composition 70 mol% Al₂O₃ and 30 mol% ZrO₂. The weight gain resulting from the vacuum infiltration process was in the order of 10 wt%.     

Open-cell reaction bonded silicon nitride foams: Fabrication and characterization

In this study, a newly designed fabrication procedure was utilized to produce silicon nitride foams. The main goal of the present study was to obtain Si₃N₄ foams with high levels of porosity and pore interconnectivity via an economical fabrication procedure including sacrificial template technique, gel-casting and reaction bonding processes. The fabrication procedure was studied and optimized in terms of suspension preparation and rheology, gel-casting parameters, and reaction bonding conditions. The produced foams have a precisely controlled level of porosity which can be varied up to 87 vol%. BET analysis showed that the surface area of the foam is of the order of 2.01 m²/g. The pore interconnectivity of the foam was investigated via polyester resin infiltration. Based on XRD and SEM analysis, the dominant nitriding reactions are the gas-phase reactions which lead to α-Si₃N₄ in the form of whiskers.     

The effect of wet foam stability on the microstructure and strength of porous ceramics

Wet foam stability is of prime importance in fabricating porous ceramics with the desired microstructure and mechanical properties. In this research, wet foams were fabricated via direct foaming after separately adding an anionic surfactant (TLS) and a cationic surfactant (DTAC) into alumina slurries with a copolymer of isobutylene and maleic anhydride (PIBM) as both the dispersant and the gelling agent. The foam stability was evaluated by a stability analyzer. The bubble size rapidly increased in the wet foam with TLS as the foam stabilizer and many large bubbles appeared within 60 min. The wet foam containing DTAC was very stable. Cationic DTAC increased the hydrophobicity of alumina particles by interacting with the anionic PIBM adsorbed on the particles. The hydrophobically modified particles acted as the foam stabilizer and enhanced the wet foam stability. Furthermore, the fast gelling speed of the slurry containing DTAC also enhanced the wet foam stability. The average cell size of the ceramic with 82.9% porosity from the wet foam with TLS was 188 µm and the compressive strength was 9.7 MPa. The counterparts from the wet foam with DTAC were 54 µm of average cell size and 18.1 MPa of compressive strength. The superior stability of wet foam brought about a smaller cell size and higher strength of the resultant ceramic.     

Preparation of a novel BN/SiC composite porous structure

A kind of BN/SiC open cell ceramic foams were fabricated from complex co-polymeric precursors of polycarbosilane and tris(methylamino)borane [B(NHCH₃)₃] using a high pressure pyrolysis foaming technique. The as-fabricated foams exhibit cell sizes ranging from 1 to 5 mm with bulk densities varying from 0.44 to 0.73 g/cm³, depending on the proportion of the starting materials. Studies on microstructure and properties of the porous material shown that addition of BN into SiC can improve dramatically its oxidation resistance during 800–1100 °C and compression strength which was generally about a 5–10 times higher than that of a pure SiC foam.     

Processing of highly porous TiO2 bone scaffolds with improved compressive strength

In the present study, the effect of sintering time and recoating procedures on the pore architectural parameters and compressive strength of highly porous ceramic TiO₂ foams were investigated. Long sintering times (>5 h) at 1500 °C led to an inward collapse of one wall of the triangular voids typically found in the strut interior of foams prepared using the replication method. This strut folding led to increased compressive strength, while the pore architectural features were not significantly affected. Furthermore, majority of the internal porosity of the foam struts was partially eliminated and became accessible for infiltration with TiO₂ slurry. Recoating procedures were found to markedly reduce the flaw size and number in the TiO₂ foam struts, which led to significant strengthening of the ceramic structure (0.7 → 3.4 MPa) by improved structural uniformity and slightly increased strut diameter.     

Synthesis of dispersed CaCO3 nanoparticles by the ultrafine grinding

A one-step grinding process to obtain CaCO₃ nanoparticles from a micrometer-sized CaCO₃ was studied. A high-speed beads mill was employed to grind the particles, and poly(acrylic acid, sodium salt) was used to disperse the ground particles. The main parameters, which were investigated, were the slurry concentration, the rotor speed, the bead size, and the surfactant concentration. The larger bead size, higher slurry concentration, and faster rotor speed showed higher grinding efficiencies. However, there was severe agglomeration of the ground particles resulting in larger secondary particles as the grinding time increased after the certain point. The dispersion and enhanced grinding of particles were achieved by the surfactant. The particle size distribution of the ground particles had a narrow peak around 190 nm that was measured by the diffraction method. The primary particle size of the ground particles was around 40 nm.     

Effects of CaCO3 content on the densification of aluminum nitride

The effect of adding up to 13.4 wt.% CaCO₃ on the densification behavior of aluminium nitride (AlN) was investigated during pressureless sintering between 1100 and 2000 °C. The presence of second-phases, weight losses, Ca contents, and microstructures of sintered samples were correlated with the densification curves. Two microstructural aspects determined the densification of aluminum nitride with CaCO₃: second-phase evolution path and formation of large pores. Additions of small amounts of CaCO₃ caused the formation of higher melting point calcium aluminates (mainly CA₂) that increased the temperature at which liquid-phase sintering process started, but once activated rapid densification was observed. For larger CaCO₃ amounts, liquid-phase started to form at lower temperature, but the initial densification was slow, diminishing the advantage of lower C₁₂A₇ related eutectic temperature. Irrespective of the initial CaCO₃ content, all second-phase evolution paths converged to CA phase above 1600 °C, suggesting that during sintering of AlN with CaO at high temperatures, a liquid phase with composition of CA phase is more stable than others compositions. The effect of this composition changing on densification is discussed. Large pores were formed in the sites originally occupied by large particles of CaCO₃ and retarded the bulk densification in samples with high additive contents.     

Preparation and characterization of polystyrene foams from limonene solutions

The foaming process has been traditionally performed at high temperature because the CO₂ and the polymer should behave as a homogeneous solution. The addition of a solvent could avoid the high working temperature while the homogeneity is ensured. Among the terpene oils, limonene outlines as a good candidate to carry out the dissolution of polystyrene because it respects the green chemistry principle, it is highly soluble in CO₂ and very compatible with the polymer.The sorption of CO₂ is the first step of the foaming process. The presence of the terpene oil enhances the solubility of the gas which is solubilized in the Polystyrene as well as in the limonene. During the foaming process, many parameters can be tuned to customize the foams. In this work, a fractional factorial design of experiment was proposed to determine the effect of pressure, temperature, concentration of the solution, contact time and vent time over the diameter of cells, its standard deviation and the cells density. The proposed foaming process can be simply performed at mild pressure and temperature thanks to the presence of the solvent. The results showed that the most suitable conditions to foam polystyrene from limonene solutions are 90 bar, 30 °C, 0.1 gPS/ml Lim, 240 min contacting and 30 min venting. Finally, the samples were characterized to determine the amount of residual solvent, their glass transition and degradation temperature checking that the foams presented around 5% of solvent traces but did not show any evidence of degradation.     

B-doped hardystonite bioceramics from preceramic polymers and fillers: Synthesis and application to foams and 3D-printed scaffolds

Highly porous hardystonite-based bioceramics, in the form of foams and 3D scaffolds, were obtained by the thermal treatment, in air, of silicone resins and engineered micro-sized oxide fillers. Besides CaO and ZnO precursors (CaCO₃ and ZnO powders), calcium borate, in both hydrated and anhydrous form (Ca₂B₆O₁₁·5H₂O and Ca₂B₆O₁₁, respectively), was added to commercial silicone resins, with a significant impact on the microstructural evolution. In hydrated form, calcium borate led to a substantial foaming of silicone-based mixtures, at low temperature (420 °C); after dehydration, upon firing, the salt provided a liquid phase, favouring ionic interdiffusion, with the development of novel B-contaning hardystonite-based solid solutions (Ca₂Zn_1-xB_2xSi_2-xO₇). Although fired at lower temperature than previously developed silicone-derived hardystonite cellular ceramics (950 °C, instead of 1200 °C), the newly obtained foams and scaffold exhibit substantial improvements in the mechanical properties.     

Porosity,mechanical and insulating properties of geopolymer foams using vegetable oil as the stabilizing agent

Geopolymer foams, as a new type of potential eco-friendly building material, are increasingly being discussed in the literature. This study reports the synthesis and characterization of geopolymer foams using hydrogen peroxide (H₂O₂) solution as pore-forming agent and oil as the stabilizing agent. The geopolymer foams with low bulk densities (0.37 < ρ_b < 0.74 g/cm³), low thermal conductivities (0.11 < λ < 0.17 W/(m.K)), high porosity (66 < p < 83 vol%), and acceptable compressive strength (0.3 < σ < 11.6 MPa) were successfully fabricated at appropriate conditions. Factors that influence the insulating, mechanical, porous, and microstructural properties were investigated. It was found that the content of the stabilizing agent and the blowing agent had a significant influence on the porous structure and associated foam performance.     

Preparation of CaCO3 using mega-crystalline calcite in electrical furnace and batch type microwave kiln

Mega-crystalline calcite (m-CC) breaks apart easily during calcination, and cannot be easily converted to CaO due to its characteristic that requires massive heat consumption. To solve this problem, the calcination characteristics were compared using electrical furnace (EF) and batch type microwave kiln (BM). After hydrating the manufactured CaO, Ca(OH)₂ was produced, and through the carbonation process, CaCO₃ was synthesized.The results of the XRD pattern of CaO that was formed through calcinations indicated that decarbonation reaction occurred as 98.2 wt.% by EF for 240 min, and 97.8 wt.% by BM for 30 min at the same temperature of 950 °C. Hydration results revealed that CaO by EF was high-reactive whereas CaO by BM was medium-reactive. CaCO₃ was synthesized through the carbonation process. At 25 °C, in both cases, colloidal-shaped CaCO₃ was found, and the more spindle-shaped CaCO₃ by cubic-shaped self assembly was synthesized at higher temperatures. However, in case of EF, Ca(OH)₂ existed in products.     

The influence of process parameters on in situ inorganic foaming of alkali-bonded SiC based foams

Silicon carbide (SiC) foams were developed with a low temperature process by using an inorganic alkali aluminosilicates binder, also known as geopolymer. The foaming agent was the metallic silicon present as impurity in the SiC powder. Si⁰ in the alkaline solution led to gas evolution that induced the foaming of the slurries. The binder was a geopolymeric resin with atomic ratio Si/Al = 2 and potassium as alkaline cation, classified as (K)poly(silalate-siloxo). The geopolymeric resin was prepared using metakaolin as aluminosilicatic raw powder, while the alkali aqueous solution was KOH/K₂SiO₃. Metakaolin in alkaline conditions dissolved and re-precipitated to form geopolymeric nano-particulates that acted as a glue to stick together SiC particles (90 wt.%). Process parameters such as water addition, mixing time and curing temperature were correlated to the foam structure. The formation of prolate pores induced anisotropy in the compressive strength. The foams were studied by dilatometric analysis in inert and oxidative atmospheres up to 1200 °C.     

Characteristics of precipitated calcium carbonate by hydrothermal and carbonation processes with mega-crystalline calcite using rotary microwave kiln

In the conventional kiln, mega-crystalline calcite (m-CC) breaks apart easily during calcinations, and cannot be easily converted to CaO due to that it requiring a lot of heat. In this study, m-CC was calcined to CaO of around 1 mm using the rotary microwave kiln. Furthermore, CaCO₃ was produced by the carbonation process and hydrothermal process, and the form of CaCO₃ was characterized.Calcination of m-CC using the rotary microwave kiln resulted in CaO (97 wt%) of relatively fine size.CaCO₃ of colloidal-shaped and 6 μm in size could be prepared by applying the carbonation process to Ca(OH)₂ using a bubble reactor at 25 °C. As the carbonation temperature increased from 25 to 80 °C, the shape of prepared CaCO₃ changed from a colloidal-type to spindle-type of 1 μm due to self-assembly. Also, hexagonal-shaped aragonite could be prepared by the hydrothermal process with the supersaturated Ca(HCO₃)₂ solutions.     

Preparation and characterization of kaolin/starch foam

The objective of this work was to study the effect of the kaolin content on the properties of starch foams. The kaolin/starch foams were made with kaolin contents that ranged from 0 to 15 m% by baking in a hot mold. The starch and kaolin/starch foams were stored at room temperature with a relative humidity (RH) of 55% for 7 days prior to testing. An increase in the kaolin content increased the foam density. The izod impact strength increased up to 1151.37 J/m² at the highest kaolin content (15 m%). The improvement was about five times the izod impact strength of pure starch foam. Moreover, the presence of any kaolin reduced the water absorption ability of the starch foam. Scanning electron microscopy revealed that kaolin increased the size of the starch foam cells and was itself well dispersed. Kaolin/starch foams showed a higher thermal stability than pure starch foam.     

Homogeneously distributed magnetite in the polystyrene spherical particles using the miniemulsion polymerization

The polystyrene spherical particles with homogeneously distributed magnetites were prepared using the conventional miniemulsion polymerization. In the first, the magnetite nanoparticles were coated with oleic acid in aqueous Fe³⁺/Fe²⁺ solution using excess ammonium hydroxide via co-precipitation method. In the second, the miniemulsion polymerization of styrene was carried out using various concentrations of potassium persulfate (KPS) as an initiator, H-08E as an emulsifier, hexadecane as a co-emulsifier and acrylic acid as a dispersing agent in the presence of oleic acid coated magnetite at 70 °C for 24 h. The particle size and its distribution of the homogeneously embedded magnetites were influenced by the concentration of the initiator (KPS) and acrylic acid (AAc). In addition, the emulsifier, H-08E, affects the size and the shape of the PS particles. The optimum conditions for the homogeneously distributed magnetite in the spherical PS particles with the narrow distribution were 5 wt.% styrene, 0.2 g KPS, 0.2 g AAc, and 0.12 g H-08E by inducing 364 nm in diameter, 12.04% in the coefficient of variation (C_v) and 22.1% of the maximum magnetite content.     

Washcoating method for Pd/γ-Al2O3 deposition on metallic foams

A method for coating open celled metal foams with a thin layer of Pd–Al₂O₃ was developed. The method makes use of a sol–gel of pseudobohemite as a precursor of γ-Al₂O₃ to fill the porous structure by percolation whilst the excess of material is flushed away with an air jet. The influence of solid content, acid content and ageing on the sol–gel rheological behaviour was studied to find a sol–gel dispersion with an appropriate viscosity whose deposition resulted in a 20 μm thick coating layer. Foam samples of different nominal porosities (10, 20 and 40 PPI) were coated with this method and activated with palladium using a wet impregnation procedure with loadings of 3% (w/w) palladium on the alumina.As an alternative approach, dry impregnation of γ-Al₂O₃ with palladium was performed and a slurry was prepared adding water and nitric acid. The slurry was deposited by percolation through the foam structure. The coating quality was evaluated with adhesion tests and the activity of coated foams was measured by performing catalytic oxidation of CO in a 9 mm i.d. tubular reactor. Both methods produced highly active foams, resulting in light off temperatures between 175 and 250 °C depending on CO concentration. Moreover, the mass transfer controlled regime was achieved in all runs independently of the coating method. Nevertheless, conversions reached when the sol–gel dispersion was deposited and activated via wet impregnation were higher than the ones obtained with the coating method based on slurry deposition of active powders, indicating that the sol–gel deposition resulted in more uniform coating.     

CaCO3–CO2–H2O system in falling film on a bank of horizontal tubes: Model verification

The purpose of this work is to model the CaCO₃–CO₂–H₂O system in falling film on a bank of horizontal tubes. The model was applied on a 5-effects reference thermal vapor compression multiple-effect distiller (MED-TVC) operating at top brine temperatures (TBT) of 60–70 °C. The model can predict pH values, CaCO₃ deposition and fouling resistance with greater accuracy. Through the MED stages, the HCO₃^? and CO₂ concentrations slightly increased while the CO₃^2? concentration slightly decreased. The pH decreased from 8.8 in the first stage to 8.4 in the 5th stage. The CO₂ release rates as well as the CaCO₃ deposition rates increase with increasing top brine temperature (TBT). CO₂ release rates decrease from 36.4 g/t feed water in the first stage to 32.5 g/t in the last stage. The specific CaCO₃ deposition decreases from 127.3 g/t feed water in the first stage to 100.1 g/t in the last stage.