Kinetics and equilibrium of Eco-debinding of PZT ceramics shaped by thermoplastic extrusion

Thermoplastic extrusion can present an alternative shaping process to a well-established powder pressing or tape casting method for lead zirconate titanate (PZT) ceramic sensor structures, if a complex debinding step can be achieved in an economic way.In this study PZT ceramic parts were made by thermoplastic extrusion using ethylene vinyl acetate and paraffin as a binder. Samples were thermally debinded according to different programs with and without a powder bed. A modified second order decomposition kinetics model is proposed which is especially suitable for describing partial debinding. Also a novel simplified model for wick-debinding is proposed to evaluate the contribution of a capillary extraction mechanism.Results show that isothermal debinding leads to partial debinded parts with a well-defined equilibrium residual binder, which is a function of a time-temperature program. We demonstrate that 90% of the binder can be removed at only 200 °C, even for a multicomponent binder system.     

Optimization of binder removal for ceramic microfabrication via polymer co-extrusion

The objective of this study is to assess the feasibility of solvent extraction (SE) for partial binder removal in the context of polymer co-extrusion with a thermoplastic binder component. Polymer co-extrusion is able to produce multilayered, functionally graded and/or textured structures in an efficient manufacturing process, but requires a polymer binder system with suitable flow characteristics. Traditionally, the binder is removed by thermal debinding (TD), which, however, is prone to form cracks or blisters, both of which are attributed to a lack of initial pore space that allows pyrolysis products to escape. The primary focus of this work is to demonstrate that a binder system with a high soluble binder content is suitable for conventional polymer co-extrusion and to document that a two-step binder removal process involving both SE and TD eliminates debinding defects. The overall fabrication process is documented for the extrusion of solid ceramic rods and co-extrusion of tubes, where alumina powder was batched with polyethylene butyl acrylate (PEBA) as backbone polymer and polyethylene glycol (PEG) as water soluble binder. SE for specimen with varying PEBA:PEG ratios was tested in water at three different temperatures for various times. The 1:1 mixture showed a PEG removal up to 80 wt.% of the original PEG content after 6 h extraction; after subsequent thermal debinding, rods and tubes sintered successfully without defects, demonstrating the viability of the process.     

Effects of debinding condition on microstructure and densification of alumina ceramics shaped with photopolymerization-based additive manufacturing technology

Alumina green bodies shaped with digital light processing (DLP) technology were debinded in four atmospheres, including air, argon (Ar), mixture of 95% argon and 5% hydrogen (95% Ar +5% H₂) and vacuum, at different heating rates (0.5 °C/min, 1 °C/min and 3 °C/min), followed by sintering in air at 1650 °C for 3 h. The effects of debinding atmosphere and heating rate on microstructure and densification of the brown bodies and sintered bodies were evaluated via morphology characterization, X-ray computed tomography (CT) reconstructions and other tests. Focusing on the quantitative analysis of the geometric characteristics and distribution of defects in the brown bodies and sintered bodies, it is found that the type (holes, cracks and delamination), content and volume distribution of defects during the debinding in aerobic and anaerobic environments are different. Our study indicates that low-rate vacuum debinding should be adopted as a promising debinding approach for ceramics shaped with photopolymerization-based additive manufacturing technology.     

Partial wick-debinding of low-pressure powder injection-moulded ceramic parts

Al₂O₃-based green bodies were shaped using low-pressure injection moulding. The binder content and the binder distribution during the thermal debinding inside a wicking embedment were analyzed. A distinct trailing front, which separates the binder-lean and binder-rich regions, was observed. This kind of binder distribution forms suddenly, after the moulded piece is heated above the melting point of the binder and is then cooled down. Mechanisms that can explain the observations are presented. The non-uniform binder distribution is explained by a capillary extraction of the binder with two different mobilities, which depend on the size of the pores inside the moulded piece. A sudden loss of binder at the beginning of the debinding process is the result of exudation, caused by a large thermal expansion of the binder as it melts. During cooling, the binder solidifies, which significantly affects the binder distribution due to a contraction of the binder.     

Pressure Distribution and Defect Formation in Green Ceramic Bodies During Supercritical Extraction of Binder

Supercritical extraction (SCE) with carbon dioxide at 10–40 MPa and 55°–90°C has been used to remove binder from multilayer green ceramic bodies. Defects such as cracking and delamination were occasionally observed in the green bodies following the extraction process, and these defects were attributed to pressure gradients that arise during isothermal depressurization from conditions of SCE. A model based on flow in porous media was developed to describe the temporal and spatial distribution of pressure within the green body during depressurization. The model incorporates both nonideal pressure–volume–temperature behavior and nonconstant viscosity of the supercritical fluid. The effects of the body size and gas-phase permeability on the pressure within the green body were examined.     

A green separation process for recovery of healthy oil from pumpkin seed

In this study, pumpkin seeds, called as “Ürgüp Sivrisi” and grown in Cappadocia region, were used as plant materials because of high aroma contents. In the supercritical fluid extraction of pumpkin seed oil, the effect of main process parameters as the particle size (250-2360 μm), the volumetric flow rate of supercritical solvent (0.06-0.30 L/h), the operating pressure (20-50 MPa), the operating temperature (40-70 °C), the type of entrainer (ethanol and n-hexane) and those concentrations (0-10 vol.%) on the extraction yield, the oil solubility and the initial extraction rate were investigated. A cross-over effect for the extraction of pumpkin seed oil using supercritical CO₂ was determined at the operating pressure of 20-30 MPa. The maximum extraction yield obtained with entrainer free was reached 0.50 g oil/g dry seed at 600-1180 μm, 0.12 L/h, 50 MPa and 70 °C for the operation time of 5 h. The maximum extraction yield obtained with ethanol as an entrainer in the experiments was reached 0.54 g oil/g dry seed at the conditions of 600-1180 μm, 0.12 L/h, 30 MPa, 40 °C and 8 vol.% for the operating time of 2 h. The oil compositions were determined by gas chromatography analysis and the results showed that the compositions of pumpkin seed oil which were obtained by means of organic solvent extraction and supercritical fluid extraction were similar. The average oil compositions determined as 9.3 (±0.43)% palmitic acid, 7.5 (±0.6)% stearic acid, 32.3 (±0.6)% oleic acid, 48.1 (±0.6)% linoleic acid and 0.7 (±0.3)% linolenic acid. The morphological changes in the seeds were determined by the scanning electron microscopy analysis.     

Yttria stabilized zirconia formed by micro ceramic injection molding: Rheological properties and debinding effects on the sintered part

Micro Ceramic Injection Molding (μCIM) is a near net-shape process to produce smaller and intricate parts at a competitive cost. The application of nano-sized ceramic powder in μCIM has the advantages of fine grain size growth and good surface finish. However, the nano size effect causes agglomeration and low powder loadings, which result in defects during the μCIM process and in the sintered components. This study extensively investigated the debinding and sintering of yttria-stabilized zirconia (YSZ), as well as its rheological properties, using polypropylene (PP) as the primary binder and palm stearin as the secondary binder. 50 nm Yttria stabilized zirconia (YSZ) powders were mixed with palm stearin and PP at a powder loading of 37–43 vol%. The results of rheological studies showed that the feedstock had a dilatant flow characteristic and a viscosity of around 10–40 Pa s. Feedstock with 38 vol% powder loading had the lowest activation energy of 9.48 kJ/mol. The green part of the injected feedstock had flexural strength ranging from 13 to16 MPa, within which the feedstock with 43 vol% powder loading had the highest green density. Solvent debinding was carried out at three temperatures (50, 60, and 70 °C) using heptane. A large porous region was clearly identified at 70 °C compared with 50 °C. A debinding split furnace with argon gas was used to remove PP at 450 °C for 4 h. The debound samples did not shrink when 94%–98% of the binder system was removed. All debound samples sintered at 1350 °C and 41 vol% had the highest mechanical properties with hardness of 900 HV and a flexural strength of 400 MPa.     

Supercritical fluid extraction from dried banana peel (Musa spp., genomic group AAB): Extraction yield, mathematical modeling, economical analysis and phase equilibria

Supercritical fluid extraction from dried banana peel (Musa spp., subgroup Prata, genomic group AAB, popularly known in Brazil as Enxerto) was studied. The aspects investigated were: overall extraction curve (OEC), mass transfer modeling of the yield curves, economical analysis of the process and phase equilibrium data for the pseudo-ternary system of banana peel extract, carbon dioxide and ethanol. The extraction operating conditions evaluated were: pressure ranging from 100 bar to 300 bar, temperature from 40 to 50 °C and constant solvent flow rate of 5.0 gCO₂/min. Experimental extraction data were correlated using three kinetic models based on mass transfer equations (logistic, diffusion and Esquível models). Phase equilibrium measurements were performed using pressure from 64.9 bar to 239.9 bar and mass fraction of supercritical extract from 0.52 to 3.55 wt%. Yield results ranged from 0.6 to 6.9% d.b. (dry basis). The lowest deviation between experimental and correlated data was obtained by the Logistic model, except for the curve at 300 bar and 40 °C which was best represented by the Esquível model. The economical analysis identified the possibility to apply the supercritical fluids to obtain extracts from banana peel in an industrial scale. Phase equilibrium for the supercritical extract from banana peel with carbon dioxide modified by ethanol exhibited liquid-liquid, vapor-liquid (bubble point) and vapor-liquid-liquid phase transitions. A crossover phenomenon for the systems evaluated was observed for pressures between 200 bar and 240 bar, for both groups of assays, i.e., supercritical extraction and phase equilibrium.     

Binder removal via a two-stage debinding process for ceramic injection molding parts

Debinding binders in two stages is critical to maintaining the shape of injected parts; the resulting decomposition affects the strength and rigidity of a structure. This study determines the optimal debinding process on the basis of a higher binder removal rate and the production of defect-free parts. The feedstock used was a combination of alumina–zirconia powder with a binder that consists of high-density polyethylene (HDPE), paraffin wax (PW), and stearic acid (SA). During the first stage, the injected parts were immersed in an n-heptane solution at 50 °C, 60 °C, 65 °C, and 70 °C to remove PW and SA. Binder weight loss was evaluated as a function of time. In the second stage, HDPE was removed by using thermal debinding. The results show that the optimum solvent debinding process runs for 16 h at 60 °C. The weight loss of the binder reaches 41.1% and results in the formation of defect-free parts. The binders are degraded at approximately 550 °C during thermal debinding. This degradation resulted in decomposition of nearly 96.9% of the binders. Low heating rates (1 °C/min to 2 °C/min) prevent defects from forming in the injected parts.     

Extraction of the essential oil of abajeru (Chrysobalanus icaco) using supercritical CO2

Abajeru (Chrysobalanus icaco) is a plant that has hypoglycemic properties and is often used in Brazilian popular medicine. In order to identify the flavoring and hypoglycemic substances present in this plant, this work has an objective for the extraction of the essential oil presented in the leaves of abajeru using the supercritical fluid extraction (SFE). The supercritical solvent used is CO₂, because of its moderate critical temperature and pressure, atoxicity, low cost and volatility. The experiments were conducted using dried leaves in an apparatus containing a high-pressure pump, a stainless steel extractor of 42 mL of volume and a micrometric valve for sampling. Different operational conditions were tested, varying mainly the temperature (313.15-353.15 K) and the pressure (10.5-20 kPa) in order to investigate the efficiency of the process. The results showed that the best operational condition was at 20 kPa and 353.15 K. To compare the supercritical carbon dioxide results, the essential oil was also extracted by hydrodistillation and soxhlet, using ethanol as solvent. The chromatographic analysis showed that the different technologies studied extracted the same classes of compounds but the SFE obtained the extract with potential hypoglycemic activity with the presence of lupenol.     

Chamomile extraction with supercritical carbon dioxide: Mathematical modeling and optimization

Supercritical fluid extraction of chamomile using carbon dioxide was investigated in the current study. A model that accounts for both particle and fluid phase was presented for the supercritical extraction. The distribution coefficient of chamomile extract, between solid and solvent has been determined using genetic algorithm method. The model was solved numerically and was successfully validated with experimental data. The model was found to give superior results when compared to experimental data. The effect of particle diameter on extraction yield was investigated using the proposed model. Using genetic algorithm optimization technique 313.15 K and 20 MPa were found as the optimum temperature and pressure, respectively.     

Supercritical fluid extraction of wormwood (Artemisia absinthium L.)

The objective of the work was to optimize the extraction of wormwood oil by supercritical fluid extraction (SFE) of growth-controlled plant material. Different extraction conditions, two growth techniques and various crops were tested and the evolution of the extracted oil composition was screened chromatographically. A comparison with conventional techniques such as hydrodistillation (HD) or organic solvent extraction (OSE) was also presented. Particularly, six CO₂ densities ranging from 285.0 kg/m³ to 819.5 kg/m³ were studied in the range of 9.0-18.0 MPa and 40-50 °C. A systematic study was carried out with plant material from 2005, while SFE of 2006, 2008 and aeroponically grown crops was performed for comparative purposes. The effect of ethanol as a modifier of the supercritical fluid extraction was also studied. The major compounds found in the SFE extracts as well as in the HD essential oils were Z-epoxyocimene, chrysanthenol and chrysanthenyl acetate. A model based on mass transfer equations, the Sovová model, was successfully applied to correlate the experimental data.     

Supercritical fluid extraction combined with dispersive liquid-liquid microextraction as a sensitive and efficient sample preparation method for determination of organic compounds in solid samples

The supercritical fluid extraction (SFE) followed by the dispersive liquid-liquid microextraction (DLLME) has been developed for extraction and determination of polycyclic aromatic hydrocarbons (PAHs) in marine sediments. PAHs were employed as model compounds to assess the extraction procedure and were determined by gas chromatography-flame ionization detection (GC-FID). SFE of PAHs was performed at 313 K and 253.2 bar, at static and dynamic times 10 and 30 min, respectively. The extracted PAHs were collected in 1 mL of acetonitrile. Subsequently, 16 μL of chlorobenzene (as extraction solvent) was added to collecting solvent (1.0 mL of acetonitrile). Then, the resulted mixture was injected into 5.0 mL of aqueous solution, rapidly. After centrifugation, the PAHs in the sedimented phase were analyzed by GC-FID. Effects of significant parameters on the extraction in SFE and DLLME methods were investigated. Under the optimum conditions, the calibration plots were linear in the range of 0.4-41.6 mg kg⁻¹ and the limits of detection (LODs) were 0.2 mg kg⁻¹ for all of the analytes. Analysis of PAHs in different solid samples showed that the improved technique has great potential for PAHs analysis in marine sediments. SFE-DLLME leads to high preconcentration factor, easy use of DLLME in solid samples and solving the main problem of SFE that is the extra step (vaporization of large volume of toxic organic solvent) after extraction needed prior to final analysis.     

Digital light processing-stereolithography three-dimensional printing of yttria-stabilized zirconia

Digital light processing (DLP)-stereolithography three-dimensional (3D) printing is a well known technique for fabricating components with complex geometries. However, the application of DLP 3D printing to functional ceramics such as 8 mol% yttria-stabilized zirconia (8YSZ), which is one of the most extensively used electrolyte materials for solid oxide fuel cells, is still a great challenge. Therefore, the fabrication of fully 8YSZ monoliths via DLP 3D printing was attempted herein, including the preparation of UV-curable ceramic suspensions, shaping of green bodies, and debinding and sintering. The results show that intact green bodies printed using a 30 vol% 8YSZ-photosensitive resin suspension with 0.1 wt% oleic acid as the dispersant under the optimized printing conditions was sufficiently dense without connected pores after vacuum debinding and sintering in air. The successful fabrication of 8YSZ monoliths with design flexibility via 3D printing provides a simple method for preparing functional ceramic components and may expand the application of 3D printing technology to the energy field.     

A porosimetric study of calcium sulfoaluminate cement pastes cured at early ages

Calcium sulfoaluminate and Portland cement pastes, both prepared with a water/solid mass ratio equal to 0.5 and cured for time periods comprised between 2 h and 28 days, show completely different pore size distributions by mercury intrusion. Portland cement pastes aged at 12 h and 1 day exhibit a unimodal distribution of pore sizes related to a continuous network of capillary pores with a threshold pore radius decreasing from nearly 650 to 350 nm. After 7 and 28 days of curing, this parameter shifts to about 150 nm and a region having smaller pores appears (with a second threshold pore radius roughly comprised between 10 and 30 nm), made discontinuous by blockages of hydration products which occlude the interconnected pore system and isolate the interior space. For calcium sulfoaluminate cement pastes, a bimodal distribution is rapidly established, in which the regions with a lower porosity (threshold pore radii up to about 25 nm) are dominant, while the decrease of total porosity almost ceases at later ages. The porosimetric behaviour of calcium sulfoaluminate-based cement is related to its very fast hydration rate and to the lack of water needed to continue the hydration reactions.     

Supercritical CO2 extraction of dittany oil: Experiments and modelling

The extraction of oil from dittany (Origanum dictamnus) using supercritical carbon dioxide was investigated. The experiments were performed in a bench scale apparatus at the pressures of 100 and 150 bar and at the temperatures of 40 and 60 °C. The effect of the solvent flow rate and the mean particle diameter of dittany on the extraction yield was also investigated at 100 bar and 40 °C. It is shown that the extraction yield increases with pressure, while the increase of temperature and mean particle diameter leads to the opposite effect. Different flow rates of SCCO₂ lead to similar extraction yields. Finally, the overall extraction curves are well correlated by a mass balance model of plug flow, in which the intraparticle diffusion resistance has the controlling role.     

Fischer-Tropsch synthesis: supercritical conversion using a Co/Al2O3 catalyst in a fixed bed reactor

Modeling of the supercritical fluid mixture indicated that an important increase in density occurs above a threshold of approximately 4 MPa for the reaction temperature of 220 °C studied. While transport parameters of the fluid are largely retained, the observed improvement in wax solubility was noteable.A cobalt catalyst (25%Co/γ-Al₂O₃) was used in a fixed bed reactor under a pressure/density tuned supercritical fluid mixture of n-pentane/n-hexane. By using inert gas as a balancing gas to maintain a constant pressure, the density of the supercritical fluid could be tuned near the supercritical point while maintaining constant space velocity within the reactor. The benefits of the mixture allowed for optimization of transport and solubility properties at an optimum reaction temperature for Fischer-Tropsch synthesis with a cobalt catalyst. Indeed, above 4 MPa, increases in wax yields from sampling and carefully controlled gas measurements using an internal standard demonstrated an important increase in conversion due to greater accessibility to active sites after extraction of heavy wax from the catalyst. Additional benefits included decreased methane and carbon dioxide selectivities. Decreased paraffin/(olefin+paraffin) selectivities with increasing carbon number were also observed, in line with extraction of the hydrocarbon from the pore. Faster diffusion rates of wax products resulted in lower residence times in the catalyst pores, and therefore, decreased probability for readsorption and reaction to the hydrogenated product. Even so, there was not an observable increase in the alpha value for higher carbon number products over that obtained with just the inert gas.     

Supercritical fluid extraction of lipids from spent coffee grounds

Supercritical fluid extraction of lipids from spent coffee grounds was studied in this work. Extraction experiments were carried out with supercritical carbon dioxide at different pressure and temperature conditions to study the influence of those process parameters on the extraction rate and oil composition. Supercritical carbon dioxide extracted up to 85% of the total amount of oil of spent coffee grounds after 3 h of extraction (corresponding to a maximum yield of 15.4 g_oil/100 g_{dry spent coffee}). The fatty acid composition of the extracted oil showed the presence of fatty acids of C14, C16, C18, and C20 carbon chains. Palmitic (C16:0) and linoleic (C18:2) acids were the major fatty acids and comprise about 35% each of the total fatty acid content of the oil. A soxhlet extraction with n-hexane was done for comparison resulting in a maximum yield of oil of 18.3 g_oil/100 g_{dry spent coffee}. Finally, a diffusional model that takes into account the properties of the substrate, the solute partition between the solid and the supercritical phase, and the mass transfer coefficient and axial dispersion in the fluid phase was applied to this system and a good agreement with experimental results was obtained.     

Defect Formation during Supercritical Extraction of Binder from Green Ceramic Components

Supercritical extraction in carbon dioxide has been used to remove binder consisting of 60 wt% poly(vinyl butyral) and 40 wt% dioctyl phthalate from multilayer ceramic capacitors containing barium titanate as the dielectric. The amount of binder removed increases as both the temperature and pressure of the supercritical fluid increases; a maximum of ∼50% of the binder can be removed using carbon dioxide in 3 h at 75°C and 40 MPa. During depressurization from the supercritical state, defects such as fracture and delamination were occasionally observed in the green body. The occurrence of defects is related to the rate of depressurization, the permeability of the body, and the green strength of the body. The origin of the defects is discussed, and ways to mitigate them are presented.     

超临界流体萃取脱除人参中痕量有机氯农药

利用在线固相吸附柱收集,淋洗剂洗脱超临界流体萃取出的真实人参样品中的有机氯农残实验,确定最佳的吸附柱和淋洗剂。通过实验确定利用C18作吸附剂,用正己烷洗脱可取得最优效果。此外,还对直接冷凝收集法、索氏提取法与固相吸附柱收集法进行了对比。