Effect of the CaO sintering on the calcination rate of CaCO3 under atmospheres containing CO2

For the calcination of CaCO₃ under CO₂‐containing atmospheres, a mathematical model taking into account the CO₂‐catalyzed sintering of the CaO product layer is developed. In this model, a modified shrinking core model is coupled with a population balance‐based sintering model. By comparing model predictions with experimental data, it is found that CO₂ strongly affects the overall calcination rate both at high temperature and CO₂ partial pressure, since under these conditions CaO densification considerably reduces the effective diffusivity of CO₂ within product layer. It is observed that for large particles, the CO₂‐catalyzed sintering of CaO can produce the “die off” phenomenon, which takes place when the reaction stops due to the blockage of pores within product layer. Finally, it was determined that limestone impurities do not significantly affect the calcination reaction under atmospheres containing CO₂, because CO₂ causes a much greater increase of the CaO sintering rate than limestone impurities do. © 2018 American Institute of Chemical Engineers AIChE J, 64: 3638–3648, 2018     

Effect of CaO doping on densification and microstructure control of highly transparent La0.4Gd1.6Zr2O7 ceramics

Calcium oxide (CaO) as sintering additive was first used to fabricate La_0.4Gd_1.6Zr₂O₇ transparent ceramics by a simple solid-state reaction and one-step vacuum sintering method. The effects of CaO dopant amount on the densification, as well as sintering behaviors and microstructure evolution of the as-fabricated La_0.4Gd_1.6Zr₂O₇ ceramics, were systematically investigated. Under the different sintering temperatures, the relationships during the sintering process between grain growth and zpore elimination were analyzed as well. It was found that 0.1 wt% CaO doping can effectively control the rate of grain growth and promote densification dominated by surface diffusion. Furthermore, Ca²⁺ entered the lattice of La_0.4Gd_1.6Zr₂O₇ ceramics to accelerate ion diffusion and suppress grain boundary migration. With the introduction of 0.1 wt% CaO doping, the highly transparent La_0.4Gd_1.6Zr₂O₇ ceramics (T = 80.4% at 1100 nm) were successfully fabricated at the traditional sintering temperature (1850°C).     

Novel model for the sintering of ceramics with bimodal pore size distributions: Application to the sintering of lime

A mathematical model for the sintering of ceramics with bimodal pore size distributions at intermediate and final stages is developed. It considers the simultaneous effects of coarsening by surface diffusion, and densification by grain boundary diffusion and lattice diffusion. This model involves population balances for the pores in different zones determined by each porosimetry peak, and is able to predict the evolution of pore size distribution function, surface area, and porosity over time. The model is experimentally validated for the sintering of lime and it is reliable in predicting the so called “initial induction period” in sintering, which is due to a decrease in intra‐aggregate porosity offset by an increase inter‐aggregate porosity. In addition, a novel methodology for determination of mechanisms based on the analysis of the pore size distribution function is proposed, and with this, it was demonstrated that lattice diffusion is the controlling mechanism in the CaO sintering. © 2016 American Institute of Chemical Engineers AIChE J, 63: 893–902, 2017     

Kinetics and mechanisms for the densification and grain growth of the α-alumina fibers isothermally sintered at elevated temperatures

Understanding the densification and grain growth processes is essential for preparing dense alumina fibers with nanograins. In this study, the alumina fibers were prepared via isothermal sintering at 1200, 1300, 1400, and 1500 °C for 1–30 min. The phase, microstructure, and density of the sintered fibers were investigated using XRD, SEM, and Archimedes methods. It was found that the phase transformation during the isothermal sintering enhances the densification of Al₂O₃ fibers in the initial stage, while the pores generated during the phase transformation retard the densification in the later period. The kinetics and mechanisms for the densification and grain growth of the fibers were discussed based on the sintering and grain growth models. It was revealed that the densification process of the fibers sintered at 1500 °C is dominated by the lattice diffusion mechanism, while the samples sintered at 1200–1400 °C are dominated by the grain boundary diffusion mechanism. The grain growth of the Al₂O₃ fibers sintered at 1200–1300 °C is governed by surface-diffusion-controlled pore drag, and that sintered at 1400 °C is dominated by lattice-diffusion-controlled pore drag.     

Sintering behavior of calcium lanthanum sulfide ceramics in field‐assisted consolidation

In this study, calcium lanthanum sulfide (CaLa₂S₄, CLS) ceramics with the cubic thorium phosphate structure were sintered at different temperatures by field‐assisted sintering technique (FAST). Densification behavior and grain growth kinetics were studied through densification curves and microstructural characterizations. It was determined that the densification in the 850°C‐950°C temperature range was controlled by a mixture of lattice or grain‐boundary diffusion, and grain‐boundary sliding. It was revealed that grain‐boundary diffusion was the main mechanism controlling the grain growth between 950°C and 1100°C. The infrared (IR) transmittance of the FAST‐sintered CLS ceramics was measured and observed to reach a maximum of 48.1% at 9.2 μm in ceramic sintered at 1000°C. In addition, it was observed that the hardness of the CLS ceramics first increased with increasing temperature due to densification, and then decreased due to a decrease in dislocations associated with grain growth.     

Solid state sintering of nano-crystalline indium tin oxide

The sintering of single phase nano-crystalline In₂O₃ and ITO (In_1.9Sn_0.1O_3.05) powders is reported and discussed with particular focus on the underlying mass transport mechanisms. The mass transport in the initial stage of sintering was surface diffusion, resulting in necking and coarsening, and grain boundary diffusion, accompanied by grain growth. Lattice diffusion caused significant densification at higher temperatures, leading to densities higher than 95%. The onset of densification and the maximum densification rate were shifted significantly to higher temperatures for ITO compared to In₂O₃. The reduced sintering rate of ITO was related to the higher valence state of Sn⁴⁺ relative to In³⁺, and due to precipitation of SnO₂(s). The volatile sub-oxides In₂O(g) and SnO(g) caused significant weight losses at high temperatures, particularly in the case of ITO and inert conditions. The sintering at intermediate temperatures is discussed with focus on heat treatment of ITO thin films.     

Densification mechanism and microstructure characteristics of nano- and micro- crystalline alumina by high-pressure and low temperature sintering

Fully dense ceramics with retarded grain growth can be attained effectively at relatively low temperatures using a high-pressure sintering method. However, there is a paucity of in-depth research on the densification mechanism, grain growth process, grain boundary characterization, and residual stress. Using a strong, reliable die made from a carbon-fiber-reinforced carbon (C_f/C) composite for spark plasma sintering, two kinds of commercially pure α-Al₂O₃ powders, with average particle sizes of 220 nm and 3 μm, were sintered at relatively low temperatures and under high pressures of up to 200 MPa. The sintering densification temperature and the starting threshold temperature of grain growth (T_sg) were determined by the applied pressure and the surface energy relative to grain size, as they were both observed to increase with grain size and to decrease with applied pressure. Densification with limited grain coarsening occurred under an applied pressure of 200 MPa at 1050 °C for the 220 nm Al₂O₃ powder and 1400 °C for the 3 μm Al₂O₃ powder. The grain boundary energy, residual stress, and dislocation density of the ceramics sintered under high pressure and low temperature were higher than those of the samples sintered without additional pressure. Plastic deformation occurring at the contact area of the adjacent particles was proved to be the dominant mechanism for sintering under high pressure, and a mathematical model based on the plasticity mechanics and close packing of equal spheres was established. Based on the mathematical model, the predicted relative density of an Al₂O₃ compact can reach ～80 % via the plastic deformation mechanism, which fits well with experimental observations. The densification kinetics were investigated from the sintering parameters, i.e., the holding temperature, dwell time, and applied pressure. Diffusion, grain boundary sliding, and dislocation motion were assistant mechanisms in the final stage of sintering, as indicated by the stress exponent and the microstructural evolution. During the sintering of the 220 nm alumina at 1125 °C and 100 MPa, the deformation tends to increase defects and vacancies generation, both of which accelerate lattice diffusion and thus enhance grain growth.     

Enhancement of direct sulfation of limestone by Na2CO3 addition

For an oxy-fuel circulating fluidized bed combustion system, the limestone calcination is normally prevented due to excessive CO₂ partial pressures and the limestone is subject to a direct sulfation reaction. The enhancement of the direct sulfation of limestone by Na₂CO₃ was investigated under high CO₂ partial pressure in a thermogravimetric apparatus (TGA) and scanning electron microscope (SEM) analysis method. A commercial limestone with a mean size of 18.8 μm was used. Experimental results indicate that the incorporation of Na⁺ ions in solid product CaSO₄ lattice structures results in formation of more extrinsic point defects in the crystal lattices of CaSO₄ and a significantly increased solid-state diffusivity/mobility in the solid product. So the direct sulfation of Na₂CO₃-doped limestone shows higher rate and higher degree of conversion in the later stage of sulfation, in comparison with the direct sulfation of original limestone. The reaction changes from diffusional control to chemical reaction control in the presence of Na₂CO₃ because of the effect of foreign ions on accelerating the solid-state diffusion.     

Effect of CaO on the optical quality and microstructure of transparent MgO·1.5Al2O3 spinel ceramics prepared by reactive sintering

Transparent MgO·1.5Al₂O₃ spinel ceramics were successfully prepared via reactive sintering of Al₂O₃ and MgO raw powders followed by hot isostatic pressing (HIP) using CaO as the sintering additive. The effects of CaO on the densification process, microstructure and optical quality of samples were investigated. It was found that the amount of CaO played an important role in the sintering process. By adding 0.05?wt% CaO, the sample with high transmittance (82.3% at 400?nm), small grain size (<5?μm) and high strength (228?±?15?MPa) was obtained after HIPing at 1550?°C. However, when the amount of CaO increased to 0.1?wt%, non-cubic and columnar-shaped grains generated at low HIP temperatures (1550–1650?°C), which severely reduced the optical quality of resulting samples. The grains were calcium aluminates, whose formation was closely related to the molar ratio of Al₂O₃/MgO, CaO amount and sintereing temperature.     

CO2 uptake of modified calcium-based sorbents in a pressurized carbonation-calcination looping

This study focuses on enhancing CO₂ uptake by modifying limestone with acetate solutions under pressurized carbonation condition. The multicycle tests were carried out in an atmospheric calcination/pressurized carbonation reactor system at different temperatures and pressures. The pore structure characteristics (BET and BJH) were measured as a supplement to the reaction studies. Compared with the raw limestone, the modified sorbent showed a great improvement in CO₂ uptake at the same reaction condition. The highest CO₂ uptake was obtained at 700 °C and 0.5 MPa, by 88.5% increase over the limestone at 0.1 MPa after 10 cycles. The structure characteristics of the sorbents on N₂ absorption and SEM confirm that compared with the modified sorbent, the effective pores of limestone are greatly driven off by sintering, which hinders the easy access of CO₂ molecules to the unreacted-active sites of CaO. The morphological and structural properties of the modified sorbent did not reveal significant differences after multiple cycles. This would explain its superior performance of CO₂ uptake under pressurized carbonation. Even after 10 cycles, the modified sorbent still achieved a CO₂ uptake of 0.88.     

Calcium oxides for CO2 capture obtained from the thermal decomposition of CaCO3 particles coprecipitated with Al ions

Calcium-carbonate powders were coprecipitated with Al³⁺ and then decomposed in air and/or under a CO₂ flux between 590 °C and 1150 °C. The data were analysed using a consecutive-decomposition-dilatometer method and the kinetic results were discussed according to the microstructure analysis done by N₂ adsorption isotherms (78 K), SEM and FT-IR measurements. Below 1000 °C, CaCO₃ particle thermal-decomposition was pseudomorphic, resulting in the formation of a CaO grain porous network. When the CaO grains were formed, the Al³⁺ diffused among them, producing AlO₄ groups that promoted the CaO grain coarsening and reduced O²⁻ surface sites available to CO₂ adsorbed molecules to form CO₃²⁻. In pure CaO, CO₃²⁻ diffused through the grain boundary, enhancing Ca²⁺ and O²⁻ mobility; AlO₄ groups reduced CO₃²⁻ penetration and CaO sintering rate. Above 1000 °C, the sintering rate of the doped samples exceeded that of the undoped, likely because of Al³⁺ diffusion in CaO and viscous flow.     

Effects of rapid calcination on properties of calcium-based sorbents

The calcination process may influence subsequent fragmentation, sintering and swelling when CaO derived from limestone acts as a CO₂ or SO₂-sorbent in combustion, gasification and reforming. Sorbent properties are affected by CO₂ partial pressure, total pressure, temperature, heating rate, impurities and sample size. In this study, the effect of calcination heating rate was investigated based on an electrically heated platinum foil. The effects of heating rate (up to 800 °C/s), calcination temperature (700-950 °C), particle size (90-180 μm) and sweep gas velocity were investigated. Higher initial heating rates led to lower extents of limestone calcination, but the extents of carbonation of the resulting CaO were similar to each other. Calcium utilization declined markedly during carbonation or sulphation of CaO after calcination by rapid heating. Experimental results show that carbonation and calcium utilization were most effective for carbonation temperatures between 503 and 607 °C. Increasing the extent of calcination is not the best way to improve overall calcium utilization due to the vast increase in energy consumption.     

CO2 capture from syngas via cyclic carbonation/calcination for a naturally occurring limestone: Modelling and bench-scale testing

The intrinsic rate constants of the CaO-CO₂ reaction, in the presence of syngas, were studied using a grain model for a naturally occurring calcium oxide-based sorbent using a thermogravimetric analyzer. Over temperatures ranging from 580 to 700 °C, it was observed that the presence of CO and H₂ (with steam) during carbonation caused a significant increase in the initial rate of carbonation, which has been attributed to the CaO surface sites catalyzing the water-gas shift reaction, increasing the local CO₂ concentration. The water-gas shift reaction was assumed to be responsible for the increase in activation energy from 29.7 to 60.3 kJ/mol for limestone based on the formation of intermediate complexes. Changes in microporosity due to particle sintering during calcination have been credited with the rapid initial decrease in cyclic CaO maximum conversion for limestone particles, whereas the presence of steam during carbonation has been shown to improve the long-term maximum conversion in comparison to previous studies without steam present.     

Influence of vanadium substitution on sintering behaviour of Pb3(VO4)2(1−x)(PO4)2x ceramics

Intermediate-stage sintering has been investigated in lead orthophosphovanadates Pb₃(VO₄)_2(1−x)(PO₄)_2x. It was found that rich-vanadium compounds such as Pb₃(VO₄)₂ and Pb₃(VO₄)_1.6(PO₄)_0.4 densify rapidly with important grain growth. For these compounds grain growth is controlled by grain boundaries and densification occurs by a mixed mechanism with lattice and grain boundary diffusion. For Pb₃(PO₄)₂, sintering mechanism supports a model of grain-boundary-controlled densification and grain growth is a surface diffusion-controlled pore drag mechanism. Moreover, the presence of phosphorus in compounds' formulae, tends to decrease the grain-boundary mobility, preventing pore-boundary separation. The kinetics analysis highlights the importance of vanadium substitution in modifying the diffusion coefficient of rate-limiting species.     

Densification behaviors of Al2O3 ceramics during flash sintering

The densification behaviors of MgO-doped-Al₂O₃ ceramics in the flashing stage and the steady stage were investigated using the classic kinetic model. The results show that the most densification of MgO-doped Al₂O₃ was completed during the flashing stage. The densification mechanism transferred from particle rearrangement resulted from Columbic force among particles under the effect of electrical field in the flashing stage to the lattice diffusion in the steady stage. Therefore, the densification rate in the steady stage dramatically decreased. Additionally, the estimated densification activation energy in the steady stage of flash sintering is 396 kJ/mol, much lower than the activation densification of lattice diffusion measured from conventional sintering, likely due to the effect of electric field/current-induced point defects on the diffusion.     

Enhanced CO2 adsorption capacity and stability using CaO‐based adsorbents treated by hydration

The synthesis of highly efficient CaO‐based sorbents using Ca(Ac)₂ as a precursor and ethanol as a modification agent for CO₂ capture is described. This adsorbent has several characteristics such as large surface area and pore volume and small particle size. The influence of ratio of ethanol and water on CO₂ adsorption capacity was evaluated considering that the ethanol concentration could affect the pore structure of sorbents. The results showed that CaO modified by ethanol solution had a higher carbonization and better stability. Particularly, when the volume ratio of ethanol and water was 3, a performance of adsorption capacity of 74% and conversion of 94% was observed. CaO modified by ethanol solution had a superior performance due to the decrease of grain size and the formation of loose porous structure. The influence of steam on stability of adsorbents at high temperatures was examined, and it was found that with the existence of steam diffusion, the capacity of the sorbent could remain at a higher level and the stability was evidently improved. After 18 cycles of adsorption/desorption process, the capacity remained as high as 65%. It was proposed that dynamic and cyclic steam injection was favorable for preventing the sintering of sorbents and facilitating the diffusion of CO₂. © 2013 American Institute of Chemical Engineers AIChE J, 59: 3586–3593, 2013     

Influence of calcination conditions on carrying capacity of CaO-based sorbent in CO2 looping cycles

This study examines the loss of sorbent activity caused by sintering under realistic CO₂ capture cycle conditions. The samples tested here included two limestones: Havelock limestone from Canada (New Brunswick) and a Polish (Upper Silesia) limestone (Katowice). Samples were prepared both in a thermogravimetric analyzer (TGA) and a tube furnace (TF). Two calcination conditions were employed: in N₂ at lower temperature; and in CO₂ at high temperature. The samples obtained were observed with a scanning electron microscope (SEM) and surface compositions of the resulting materials were analyzed by the energy dispersive X-ray (EDX) method. The quantitative influence of calcination conditions was examined by nitrogen adsorption/desorption tests, gas displacement pycnometry and powder displacement pycnometry; BET surface areas, BJH pore volume distributions, skeletal densities and envelope densities were determined. The SEM images showed noticeably larger CaO sub-grains were produced by calcination in CO₂ during numerous cycles than those seen with calcination in nitrogen. The EDX elemental analyses showed a strong influence of impurities on local melting at the sorbent particle surface, which became more pronounced at higher temperature. Results of BET/BJH testing clearly support these findings on the effect of calcination/cycling conditions on sorbent morphology. Envelope density measurements showed that particles displayed densification upon cycling and that particles calcined under CO₂ showed greater densification than those calcined under N₂. Interestingly, the Katowice limestone calcined/cycled at higher temperature in CO₂ showed an increase of activity for cycles involving calcination under N₂ in the TGA. These results clearly demonstrate that, in future development of CaO-based CO₂ looping cycle technology, more attention should be paid to loss of sorbent activity caused by realistic calcination conditions and the presence of impurities originating from fuel ash and/or limestone.     

Microstructural evolution of nanocrystalline Al2O3 sintered at a high heating rate

Experimental sintering studies on Al₂O₃ powder (200 nm and 600 nm) were done at a heating rate of 1600 °C/min. The microstructural changes of specimens were examined and corresponding detailed data on the densification and grain size as a function of sintering time were presented. The grain-growth transition behavior during sintering was discussed. The results showed that the neck growth caused principally by surface diffusion could be negligible within 2 min. With subsequent increases of sintering time, grain growth promoted by grain boundary and lattice diffusion occurred.     

Densification and grain growth of Gd2Zr2O7 nanoceramics during pressureless sintering

Gd₂Zr₂O₇ nanoceramics were fabricated using pressureless sintering method, in which the nanopowders were synthesized via solvothermal approach. The effects of starting powders on grain growth and densification during sintering of ceramics were revealed. Two distinct pressureless sintering methods were investigated, including conventional and two-step sintering. The sample grain size increases abruptly as sintering temperature increases during conventional sintering. In contrast, in two-step sintering, abnormal or discontinuous grain growth was suppressed in the second step, leading to Gd₂Zr₂O₇ nanoceramics formation (average grain size 83 nm, relative density ∼93%). Such distinct behaviors may originate from the interplay between kinetic factors such as grain boundary migration and diffusion. Moreover, suppression of grain growth and promotion of densification in the two-step sintering are mainly due to dominant role of grain boundary diffusion during the second-step sintering process.     

Electro‐Sintering of Yttria‐Stabilized Cubic Zirconia

Electro‐sintering, i.e., electrically enhanced densification without the assistance of Joule heating, has been observed in 70% dense 8 mol% Y₂O₃‐stabilized ZrO₂ ceramics at temperatures well below those for conventional sintering. Remarkably, full density can be obtained without grain growth under a wide range of conditions, including those standard for solid oxide fuel cell (SOFS) and solid oxide electrolysis cell (SOEC), such as 840°C with 0.15 A/cm². Microstructure evidence and scaling analysis suggest that electro‐sintering is aided by electro‐migration of pores, made possible by surface flow of cations across the pore meeting lattice/grain‐boundary counter flow of O^2?. This allows pore removal from the anode/air interface and densification at unprecedentedly low temperatures. Shrinkage cracking caused by electro‐sintering of residual pores is envisioned as a potential damage mechanism in SOFC/SOEC 8YSZ membranes.