Simulation of 3D gas–solid fluidized bed reactor hydrodynamics

In this article, an attempt is made to develop a 3D gas–solid fluidized bed reactor (FBR). Basically, it deals with simulation of a FBR in computational fluid dynamics (CFD) using the software, Ansys Fluent v14. The simulation of gas–solid flow is carried out using Eulerian multifluid model which is integrated with the solid particle kinetic theory. The coefficients of exchange momentum are estimated using the Syamlal & O'Brien, Gidaspow, Wen-Yu, and Huilin–Gidaspow drag functions. The results of the simulation have been validated with the experimental data available in literature and had proven that the model is capable to predict the hydrodynamics of FBR. The variation in kinetic energy of the solid phase is calculated by varying the restitution coefficient (RC) from 0.90 to 0.99. The predictions of pressure drop compare excellently with the experimental data. Finally, the effect of particle diameter on the expanded bed height has been studied for FBR.     

Investigation of Fe2O3–Al and Cr2O3–Al reactions using a high speed video camera

Abstract

Self propagating high temperature synthesis is a simple, fast and energy efficient process with a wide range of applications, one of which is the coating of the internal surfaces of steel pipes using a centrifugal thermit process. The process involves a highly exothermic reaction between powder reactants distributed around a steel tube rotating at high speed. Although the process has been widely studied, important features, particularly how the reaction propagates, have not been completely revealed due to extremely high reaction rates and temperatures. In the present work, Fe₂O₃–Al and, to a lesser degree, Cr₂O₃–Al reactions were studied under stationary (non-rotating) and rotating conditions using a high speed video camera by which the centrifugal thermit process was, for the first time, recorded optically. Video recordings clearly demonstrate that, in contradiction to current belief, the reaction does not always propagate in a well ordered (spiral) pattern, but involves multiple, randomly distributed ignition sites.     

Synthesis of (Fe,Cr)3Al–Al2O3 nanocomposite through mechanochemical combustion reaction induced by ball milling of Cr,Al and Fe2O3 powders

In this work, (Fe,Cr)₃Al matrix nanocomposite reinforced by 47 vol.% Al₂O₃ was synthesized by mechanochemical reaction of Cr, 3Al and Fe₂O₃ powders mixture. The structural evaluation of powder particles during milling was done by X-ray diffraction (XRD), scanning electron microscopy (SEM), transmission electron microscopy (TEM) and differential thermal analysis (DTA). The results showed that at the early stage of milling, the thermite reaction between Fe₂O₃ and Al occurred and Fe and Al₂O₃ phases were formed. Then, the remaining Al and Cr were alloyed with Fe, leading to (Fe,Cr)₃Al–Al₂O₃ nanocomposite structure. Further investigations indicated that the presence of diluents (excess Al and Cr) did not change the modality of thermite reaction and the formation of (Fe,Cr)₃Al–Al₂O₃ nanocomposite proceeded with combustion process. The (Fe,Cr)₃Al–Al₂O₃ nanocomposite powder exhibited the hardness value of 1140 Hv which is significantly higher than 935 Hv obtained for (Fe,Cr)₃Al.     

Structure–property relationships in isotactic polypropylene/multi-walled carbon nanotubes nanocomposites

In this work, the influence of multi-walled carbon nanotubes (MWCNT) on electrical, thermal and mechanical properties of CNT reinforced isotactic polypropylene (iPP) nanocomposites is studied. The composites were obtained by diluting a masterbatch of 20 wt.% MWCNT with a low viscous iPP, using melt mixing. The morphology of the prepared samples was examined through SEM, Raman and XRD measurements. The effect of MWCNT addition on the thermal transitions of the iPP was investigated by differential scanning calorimetry (DSC) measurements. Significant changes are reported in the crystallization behavior of the matrix on addition of carbon nanotubes: increase of the degree of crystallinity, as well as appearance of a new crystallization peak (owing to trans-crystallinity). Dynamic mechanical analysis (DMA) studies revealed an enhancement of the storage modulus, in the glassy state, up to 86%. Furthermore, broadband dielectric relaxation spectroscopy (DRS) was employed to study the electrical and dielectric properties of the nanocomposites. The electrical percolation threshold was calculated 0.6–0.7 vol.% MWCNT from both dc conductivity and dielectric constant values. This value is lower than previous mentioned ones in literature in similar systems. In conclusion, this works provides a simple and quick way for the preparation of PP/MWCNT nanocomposites with low electrical percolation threshold and significantly enhanced mechanical properties.     

Synthesis of carbon and carbon–nitrogen nanotubes using green precursor: jatropha-derived biodiesel

The jatropha-derived biodiesel, a green precursor was found to be a new and promising precursor for the synthesis of carbon nanotubes (CNTs) and carbon–nitrogen (C–N) nanotubes. The CNTs and C–N nanotubes have been synthesised by spray pyrolysis of biodiesel with ferrocene and ferrocene–acetonitrile, respectively, at elevated temperature under an argon atmosphere. The typical length and diameter of as-grown CNTs are 20?µm and 20–50?nm, respectively. The C–N nanotubes are found in bundles with effective length of ～30?µm and diameter ranging between 30 and 60?nm with bamboo-shaped morphology. The as-grown CNTs and C–N nanotubes were characterised through scanning and transmission electron microscopes, X-ray photoelectron, Raman and Fourier transform infrared spectroscopic techniques. These investigations revealed that the nanotubes synthesised by jatropha-derived biodiesel are clean from carbonaceous impurities and the bamboo compartment formations in C–N nanotubes are due to nitrogen incorporation. The nitrogen concentration in C–N nanotubes decreases with the increase in synthesis temperature.     

Decrease of Cl contents in waste plastics using a gas–solid fluidized bed separator

In order to decrease Cl content in waste plastics, dry density float-sink separation of Cl-contained and Cl-free plastics was explored using a semi-continuous rotating-type gas–solid fluidized bed separator with silica sand. The separator has two distinctive features: (1) the plastics can be fed at a middle height of the sand bed, and (2) when the plastics are recovered with the sand from a container after the float-sink, the recovery height of the sand bed can be changed to designate the plastics as floaters or sinkers. The waste plastics of Cl content = 5.4 wt% were used in this study. The separation was investigated by changing the experimental conditions. As a result, the float-sink of the plastics was affected by the air velocity for fluidization, the float-sink time and the feed amount of plastics. The possible causes of the effects were discussed by focusing on the apparent density of fluidized bed, the fluidization intensity, the size segregation of fluidized particle, the shape of the plastics, and the interactions between the plastics during the float-sink. When the recovery height was changed at the adjusted conditions, the Cl content in the floaters was successfully decreased to be 0.4–0.85 wt%, at which the recovery of the Cl-free plastics was 40–60%.     

Dry separation of particulate iron ore using density-segregation in a gas–solid fluidized bed

A gas–solid fluidized bed has been used to separate particulate iron ore (+250–500 μm in size) by segregating the particles by density. The ore particles were put into a cylindrical column of inner diameter of 100 mm and bed height of 50 mm, and were fluidized at a given air velocity u₀/u_mf = 1.2–3.2 for 10 min. u₀ and u_mf are the superficial air velocity and the minimum fluidization air velocity, respectively. The bulk density of the ore particles after fluidization was measured as a function of height through the bed in 5 mm increments (the 50 mm height was divided into 10 layers) to investigate the density-segregation. The size of the particles in each of the 10 layers was also measured to investigate size-segregation. It was found that both density-segregation and size-segregation occurred as a function of height through the bed after fluidization at u₀/u_mf = 2.0. However, the segregation did not occur near the bottom of the bed for lower u₀/u_mf and did not occur near the top of the bed for larger u₀/u_mf. The origin of the segregation-dependence on the air velocity was discussed considering the air bubbles size and the fluidizing intensity at upper and lower sections of the bed. The Fe content of the 10 layers at u₀/u_mf = 2.0 was measured to calculate the Fe-grade and Fe-recovery. The ore-recovery was also calculated using the weight of ore particles as a function of height through the bed. The feed Fe-grade (before separation) was 52.1 wt%. If the ore particles in the bottom half of the bed were regarded as the product, the Fe-grade was 59.0 wt%, and the Fe-recovery and the ore-recovery were 68.5 wt% and 60.5 wt%, respectively.     

Phase Relations in the Systems Al2TiO5–Fe2O3 , Al2O3–TiO2–Fe2O3 , and Al2TiO5–Cr2O3

Phase relations in the systems Al₂TiO₅–Fe₂O₃, Al₂TiO₅–Cr₂O₃, and Al₂O₃–TiO₂–Fe₂O₃ are investigated, and the composition ranges of pseudobrookite Al_{2 – 2x} M_2x TiO₅ (M = Fe, Cr) solid solutions are determined.     

Production of Fe3Al–TiC nanocomposite by mechanical alloying of FeTi2–Al–C powders

Abstract

The aim of the present work was to produce Fe₃Al/TiC nanocomposite by mechanical alloying of the FeTi₂30Al10C60 (in at-%) powder mixture. The morphology and the phase transformations in the powder during milling were examined as a function of milling time. The phase constituents of the product were evaluated by X-ray diffraction (XRD). The morphological evolution during mechanical alloying was analysed using scanning electron microscopy (SEM). The results obtained show that high energy ball milling, as performed in the present work, leads to the formation of a bcc phase identified as Fe(Al) solid solution and an fcc phase identified as TiC and that both phases are nanocrystalline. Subsequently, the milled powders were sintered at 873 K. The XRD investigations of the powders revealed that after sintering, the material remained nanocrystalline and that there were no phase changes, except for the ordering of Fe(Al), i.e. formation of Fe₃Al intermetallic compound, during the sintering process.     

Numerical simulation of hydrodynamic characteristics in a gas–solid fluidized bed

The fluidization of quartz particles as bed materials in the fluidized bed has significant influences on the combustion and gasification of refused derived fuels. Three-dimensional (3-D) simulations and analyses are performed for Geldart B particles using the computational fluid dynamics (CFD) method based on the kinetic theory of granular flows (KTGF) to investigate the hydrodynamic behavior. The drag models of Syamlal–O’Brien, Gidaspow, and Wen and Yu are selected to analyze the applicability of the kinetic model. The pressure drop, velocity distribution and solid volume fraction are studied numerically when the gas inlet velocity is changed. The results show that the increase of superficial gas velocity would lead to heterogeneous expansion of solid volume fraction and velocity distributions in both the dense phase zone and free board with a similar distribution pattern. The near wall particles form a dense phase structure with the solid volume fraction being greater than 0.3.     

Dry dense medium separation of iron ore using a gas–solid fluidized bed

The dry dense medium separation of iron ore based on floating and sinking of ore particles in a gas–solid fluidized bed was investigated using zircon sand as the fluidized medium. The float-sink of ore particles with mean size D_ave = 23.6 mm was investigated as the fluidizing air velocity and the float-sink time were varied. It was found that gangue with density less than 2850 kg/m³ which float is able to be separated from valuable ore with density greater than 2850 km/m³ which sink. The set point (density where half the particles float and half the particles sink) decreases with increasing the air velocity, and that the float-sink separation is completed within 2 min. The influence of different sized ore particles in the float-sink experiments was also investigated. As a result, the iron ore with D_ave ? 17.6 mm are successfully separated. As D_ave decreases below 17.6 mm, the ore particles with density near the set point tend to scatter in the fluidized bed without floating or sinking, resulting in separation efficiency which decreases with decreasing D_ave. This indicates that the size of the ore particles is one of the major factors to achieve high separation efficiency.     

Synthesis of Cu–Zr–Al/Al2O3 amorphous nanocomposite by mechanical alloying

Two routes were used to produce Cu–Zr–Al/Al₂O₃ amorphous nanocomposite. First route included mechanical alloying of elemental powders mixture. In second route Cu₆₀Zr₄₀ alloy was synthesized by melting of Cu and Zr. Cu₆₀Zr₄₀ alloy was then ball milled with Al and CuO powder. It was not possible to obtain a fully amorphous structure via first route. The mechanical alloying of Cu₆₀Zr₄₀, Al and CuO powder mixture for 10 h led to the reaction of CuO with Al, forming Al₂O₃ particulate, and concurrent formation of Cu₆₂Zr₃₂Al₄ amorphous matrix. The thermodynamical investigations on the basis of extended Miedema’s model illustrated that there is a strong thermodynamic driving force for formation of amorphous phase in this system. Lack of amorphization in first route appeared to be related to the oxidation of free Zr during ball milling.     

Study on the structure and properties of core–shell Fe/Al composite powder synthesized by MOCVD in fluidized bed

Core–shell Fe/Al composite powder with different thicknesses of Fe layer has been prepared by MOCVD in a fluidized bed reactor. The products were characterized by scanning electron microscopy (SEM), energy dispersive X-ray spectrometer (EDX) and simultaneous thermogravimetry–differential scanning calorimetry (TG–DSC). The results show that a compact nano-Fe layer is covered on the surface of Al to form core–shell Fe/Al composite powder. Nano-Fe layer thickness can be controlled by adjusting deposition time. The Fe layer thickness is evaluated by weight increase in TG curve at the temperature range of 350–550 °C in air atmosphere. Combustion properties of Fe/Al composite powder have great improvement compared with raw Al.     

Numerical study of gas–solid drag models in a bubbling fluidized bed

Bubbling fluidized beds find application mainly in power conversion industries. For design, dimensioning, and operation of fluidized bed equipment, the understanding of multiphase gas–solid flows is of great importance. The use of computational fluid dynamics in the simulation of gas–solid systems is limited by the complexity of mathematical models, which rely on a series of empirical or theoretical correlations. In the present work, the code Multiphase Flow with Interphase eXchanges (MFIX) was employed to simulate flows in a bubbling fluidized bed and to compare results predicted using different gas–solid drag models. A two-fluid model with kinetic theory of granular flows (TFM-KTGF) was employed, in which gas–solid drag correlations, such as Gidaspow, Hill-Koch-Ladd, or Syamlal and O’Brien, were applied to model momentum transfer between phases. The results predicted were compared with each other and with experimental results from the literature. It was found that the results predicted using each model differ much. The Gidaspow and Hill-Koch-Ladd models yielded bubbles with shapes more similar to the experiments.     

The mechanical alloying mechanism of various Fe2O3–Al–Fe systems

The mixed powders of in situ Al₂O₃ particles and Fe (Al) solid solution were prepared via self-propagating combustion reaction initiated by mechanical alloying (MA), and the MA mechanism of several Fe₂O₃–Al–Fe systems with different Al₂O₃ mass fractions were studied. The adiabatic temperature (T_ad) of each system was calculated to estimate whether the self-propagating combustion reaction could be initiated in theory. The microstructure of the mixed powders was investigated by SEM, EDS and TEM. The phase analysis was evaluated by XRD, and the Fe lattice parameter was calculated from the XRD patterns. The results showed that with the addition of Fe during the MA process, the activation period was prolonged and the sharp increase of temperature occurred, and when the Al₂O₃ mass fraction was decreased to 10.94%, the self-propagating combustion reaction could not occur in theory and practice. When there was no added Fe, the final product was homogeneous Fe (Al) solid solution.     

Carbon nanotubes purification constrains due to large Fe–Ni/Al 2 O 3 catalyst particles encapsulation

Purification efficiency of carbon nanotubes (CNTs) by the method of chemical oxidation was considered as a function of position and size of catalyst remains and consequently of the tubes morphology. Oxidation of CNTs by means of both HNO₃ and NaOH treatment efficiently removes small catalyst particles embedded in the tubes top, following “tip-mode” CNTs growth mechanism. Destructive character of the purification can be assumed due to the resulting tiniest tube population increase as a consequence of their body tearing. However, limited purification efficiency was observed in the case of bigger metal particles with variable size and position in CNTs. Bigger particles occur on account of catalyst instability portrayed as small metal particles of active phase migration and merging. The formed agglomerates are not stable in the tubes hollow, but disintegrate leading to different sizes and position of metal particles in the tubes body. Consequently, CNT may be obtained with non-uniform thickness and morphology. The phenomenon is due to liquid-like behaviour of the active phase at reaction temperature (700 °C) which is higher than both Huttig and Tamman temperatures of applied metals. A mechanism is proposed assuming that an isolated bigger part of the mother particle stayed encapsulated inside the tube body inactive for further tube growth, while a smaller fragment of the collapsed particle resided at the tube top acting as a new-born active site. Owing to “replica effect” the tube further grows thinner following the size of the new active site. Consequently CNTs of irregular morphology occur as they resemble metal particles of various sizes following their disintegration.     

Computational and experimental studies on bed dynamics of a gas–solid fluidized bed using Geldart-A particle: A comparison

The bed dynamics of a two-dimensional gas–solid fluidized bed is studied experimentally and computationally using Geldart-A particles. Commercial software ANSYS FLUENT 13 is used for computational studies. Unsteady behavior of gas–solid fluidized bed is simulated by using the Eulerian–Eulerian model coupled with the kinetic theory of granular flow. The two-equation standard k?? model is used to describe the turbulent quantities. The simulation predictions are compared with experimentally observed data on volume fraction, bed pressure drop and bed expansion ratio. The results of simulations are found to be in close agreement with the experimental observations, implying that computational fluid dynamics (CFD) can be used for the design of an efficient bench-scale catalytic fluidized bed reactor.     

Synthesis and characterization of Al (Al2O3–TiB2/Fe) nanocomposite by means of mechanical alloying and hot extrusion processes

Synthesis and characterization of Al–(Al₂O₃–TiB₂/Fe) nanocomposite by means of mechanical alloying and hot extrusion processes was the goal of this study. For this regards, mechanical alloying was done in two steps; formation of Al₂O₃–TiB₂/Fe reinforcements and preparation of Al-base nanocomposite. Results showed that Al₂O₃–TiB₂/Fe nanocomposite powders can synthesis by mechanical alloying and subsequent heat treatment at 700 °C. Hot extrusion of powder samples lead to preparation of fully dense Al-base nanocomposite. With increasing the amount of complex reinforcements, the compression strength was increased and reached to 560 MPa. Consolidated samples show good ductility related to the nature of Al₂O₃–TiB₂/Fe reinforcements.     

Synthesis of clay–carbon nanotube hybrids: Growth of carbon nanotubes in different types of iron modified montmorillonite

In the present study, montmorillonite–carbon nanotube hybrids were synthesized by catalytic decomposition of ethylene over iron montmorillonite surfaces modified by different experimental procedures. SEM and STEM analyses reveal the presence of carbon nanotubes attached to the clay layers and X-ray diffraction results indicate that sodium montmorillonite layers were intercalated with iron species during the ion-exchange processes and further delaminated due to the growth of carbon nanotubes. It is expected that montmorillonite–carbon nanotube hybrids will be beneficiary for improvement of mechanical properties in polymer nanocomposites due to their pre-exfoliated internal structure and the presence of surface carbon nanotubes which may significantly enhance reinforcing effect.