Dewatering of Biomaterials by Mechanical Thermal Expression

Dewatering by mechanical thermal expression (MTE) for a range of materials is explored using a laboratory-scale MTE compression-permeability cell. It is shown that MTE can be used to effectively dewater a range of biomaterials including lignite, biosolids, and bagasse. The underlying dewatering mechanisms relevant to MTE, namely (1) filtration of water expelled due to thermal dewatering, (2) consolidation, and (3) flash evaporation, are discussed. At lower temperatures, the dominating dewatering mechanism is consolidation, but with increasing temperature, thermal dewatering becomes more important. A major focus is an investigation of the effects of processing parameters, including temperature (20 to 200°C) and pressure (1.5 to 24 MPa), on material permeability, a fundamental dewatering parameter. It is illustrated that permeability is particularly dependent on the processing temperature, owing to changes in both the material structure and the water properties. In addition, a comparison of permeability in the direction of applied force (axial) and perpendicular to the direction of applied force (radial) is presented. It is shown that, due to alignment of particles under the applied force, the permeability and, hence, rate of water removal in the radial direction is greater than in the axial direction. SEM micrographs are presented to illustrate the particle alignment.     

Pore Destruction Resulting from Mechanical Thermal Expression

Mechanical thermal expression (MTE) is a dewatering technology ideally suited for the dewatering of internally porous biomaterials. For such materials, the combined application of temperature and compressive force in the MTE process enhances the collapse of the porous structure, resulting in effective water removal. In this article, a comparison of the dewatering of titanium dioxide, which is an ideal incompressible, non-porous material, and lignite, which is a porous plant-based biomaterial, is presented. The comparison is based on the parameters critical to dewatering, namely the material compressibility and the permeability. With the aid of mercury porosimetry results, a detailed discussion of the pore destruction of lignite resulting from MTE processing is presented. It is illustrated that there is a well-defined relationship between the pore size distribution after MTE dewatering and the MTE temperature and pressure. The discussion is extended to an investigation of the effects of MTE processing conditions on the effective and non-effective porosity. The effective porosity is defined as the interconnected porosity, which contributes to flow through the compressed matrix, while the non-effective porosity is the remaining porosity, which does not contribute to flow. It is illustrated that there is a linear relationship in both the effective and non-effective porosity with the total porosity. The linear relationship is independent of the processing conditions. It is also shown that MTE processing collapses the effective and non-effective pores at roughly the same rate.     

Pore Destruction Resulting from Mechanical Thermal Expression

Mechanical thermal expression (MTE) is a dewatering technology ideally suited for the dewatering of internally porous biomaterials. For such materials, the combined application of temperature and compressive force in the MTE process enhances the collapse of the porous structure, resulting in effective water removal. In this article, a comparison of the dewatering of titanium dioxide, which is an ideal incompressible, non-porous material, and lignite, which is a porous plant-based biomaterial, is presented. The comparison is based on the parameters critical to dewatering, namely the material compressibility and the permeability. With the aid of mercury porosimetry results, a detailed discussion of the pore destruction of lignite resulting from MTE processing is presented. It is illustrated that there is a well-defined relationship between the pore size distribution after MTE dewatering and the MTE temperature and pressure. The discussion is extended to an investigation of the effects of MTE processing conditions on the effective and non-effective porosity. The effective porosity is defined as the interconnected porosity, which contributes to flow through the compressed matrix, while the non-effective porosity is the remaining porosity, which does not contribute to flow. It is illustrated that there is a linear relationship in both the effective and non-effective porosity with the total porosity. The linear relationship is independent of the processing conditions. It is also shown that MTE processing collapses the effective and non-effective pores at roughly the same rate.     

On the apparent permeability of a porous layer backed by a perforated plate

Two-dimensional slow viscous flow from a fluid reservoir, through a porous layer and then through a perforated plate is studied assuming Stokes flow in the fluid reservoir and Darcy flow within the porous medium. It is first shown that the coupled Stokes/Darcy problem can be reduced to a Darcy problem when the various length scales are constrained such that Darcy's law is appropriate to describe flow in the porous layer in the vicinity of the perforations of the plate. The apparent permeability of the porous layer is studied as a function of the (uniform) thickness of the layer, and as a function of the size and spacing of the performations in the plate. The apparent permeability is shown to be significantly lower than the intrinsic permeability of the porous layer when the layer is sufficiently thin. Closed-form expressions for the apparent permeability are derived using conformal transformation techniques. We then present a model of particle deposition onto the perforated plate. The growth of the porous layer resulting from the deposition is studied, as is the evolution of its apparent permeability.     

Modeling of Multiphase Transport during Drying of Honeycomb Ceramic Substrates

Multiphase transport model to simulate drying of honeycomb ceramic substrates in a conventional (hot air) drier is developed. Heat and moisture transport in the honeycomb walls as well as channels is modeled. The model predictions are validated against experiments done for drying of cylinder-shaped substrates by comparing histories and axial profiles of moisture loss and point temperature histories at various locations. Drying experiments are performed at two different values of air temperature, 103°C and 137°C, at a relative humidity value of 5%. Sensitivity analysis reveals that the drying process is controlled by heat and water vapor transport. External heat transfer is the dominant resistance mechanism for energy transport, whereas internal convection and binary diffusion dominate the resistance to vapor transport.     

Stepwise Development of a Mathematical Model for Air Flow in Vacuum Dewatering of Paper

Part of the dewatering in a paper machine takes place via vacuum suction boxes situated below the moving web. In addition to the removal of liquid water, considerable amounts of air are sucked through the paper. The air flow that accompanies dewatering is a crucial parameter for the electricity consumption of a vacuum system. The present study models this air flow, combining differential conservation equations with fiber characterization. Measured air flow rates for different vacuum levels, basis weights, and pulp types are compared to model predictions. More than 70% of the data agree within the range of experimental error.     

A Study of Surface Wetting When Coating Paper

Abstract

The objective of this work will be to look at basic micro-level simulations of liquid state and movement. Defining liquid movement at fiber-coating boundaries is essential when modeling surface wetting of paper fibers. Drying studies have shown that chemical additives in base paper or coating color may reduce or increase quality, productivity, and energy efficiency considerably. The latest question is, Which are the factors that are significantly influencing liquid movement at fiber-coating boundaries? A phenomenon of less liquid drainage at lower paper moisture content is studied in this work together with the fiber hornification process. Fiber hornification is a complex change in the physicochemical properties of the fiber surface and the state of boundary molecules. Another important objective is to show how hornification may be accounted for in basic calculations. This while, printing properties of paper (mottling, etc.), may then be connected to the formation of the base paper and its drying history, explaining in more detail the importance of microlevel physicochemical property changes at fiber surfaces.     

Mechanical Dewatering and Thermal Drying of Sludge in a Single Apparatus

This article describes the Centridry® technology (marketed in the UK by Euroby Ltd.) used at the Monsanto wastewater treatment plant in Antwerp, Belgium, for handling excess wastewater-activated sludge. In one single enclosed machine, sludge with an initial solids concentration of 1.5 to 4% w/w dry substance is mechanically dewatered with a high-solids decanter centrifuge and thermally dried in a flash dryer, yielding a final product with a concentration of solids ranging from 80 to 95% w/w dry substance. Operational experience with varying sludge characteristics affecting the fouling sensitivity of the system is presented for the Centridry technology at the Monsanto plant in Antwerp.     

Calcium‐Ion Removal from Peat by a Mechanical Filter Cake Washing Process

This contribution aims to bridge two different fields of science, viz., geoecology and mechanical process engineering. The study reports on the application of mechanical washing processes especially filter cake washing, on calcium‐ion removal from peat, which is a natural material that is used in different fields of application such as agriculture, medicine, cosmetics, etc. The interesting properties of peat such as its porous structure and the sorption behavior influence the distribution of liquid inside the bulk and the liquid flow behavior through the porous structure. Experimental results are obtained from filtration tests using differential gas pressure in a filter nutsche. The washing efficiency is determined for different pressures and specific amounts of applied wash liquor. It is found that the water repellent phenomena that occurs when peat has been dried, affects the washing efficiency in a very negative way. The results obtained are compared to the conventional filter cake washing process.     

Capillary Pressure Determination from Sorption Isotherms for Mixtures of Porous Solids

Capillary pressure and relative permeability are important parameters for characterization of the draining of fluid phases in porous media. In this work, capillary pressure and relative permeability were evaluated in porous solids with distinct morphological properties, namely NaY zeolite, kaolin, and alumina as well as their binary mixtures in the compositions of 20, 40, 60, and 80% in mass fraction. The objective of the present work was to verify the influence of the composition of the solid mixture and the structural characteristics of the components on capillary pressure and relative permeability. Capillary pressure as a function of saturation of the material was determined from moisture desorption isotherms. The results showed that structural characteristics greatly influence capillary pressure and permeability. The obtained capillary pressure in microporous materials was higher than that in macroporous and mesoporosous materials at the same saturation. It was verified that when microporous materials were present in the mixture, the capillary pressure of the binary mixtures tended to approach the capillary pressure of the microporous materials, since micropores control the adsorption and desorption processes.     

Capillary Pressure Determination from Sorption Isotherms for Mixtures of Porous Solids

Abstract

Capillary pressure and relative permeability are important parameters for characterization of the draining of fluid phases in porous media. In this work, capillary pressure and relative permeability were evaluated in porous solids with distinct morphological properties, namely NaY zeolite, kaolin, and alumina as well as their binary mixtures in the compositions of 20, 40, 60, and 80% in mass fraction. The objective of the present work was to verify the influence of the composition of the solid mixture and the structural characteristics of the components on capillary pressure and relative permeability. Capillary pressure as a function of saturation of the material was determined from moisture desorption isotherms. The results showed that structural characteristics greatly influence capillary pressure and permeability. The obtained capillary pressure in microporous materials was higher than that in macroporous and mesoporosous materials at the same saturation. It was verified that when microporous materials were present in the mixture, the capillary pressure of the binary mixtures tended to approach the capillary pressure of the microporous materials, since micropores control the adsorption and desorption processes.     

Characterization of the First Falling Rate Period During Drying of a Porous Material

Abstract

This study deals with the evolution of the surface state and its influence on the drying of porous media. Surface temperature and saturation values are obtained using optical metrology. Analysis of the experimental results allows discussion of the apparition of constant drying rate period and to characterize the transition to the falling rate period. A mathematical model is developed to account for these observations and experimental results for some physical properties of a model material. It allows determination of the internal profile of moisture and the penetration of the drying front during the falling rate period.     

Characterization of the First Falling Rate Period During Drying of a Porous Material

This study deals with the evolution of the surface state and its influence on the drying of porous media. Surface temperature and saturation values are obtained using optical metrology. Analysis of the experimental results allows discussion of the apparition of constant drying rate period and to characterize the transition to the falling rate period. A mathematical model is developed to account for these observations and experimental results for some physical properties of a model material. It allows determination of the internal profile of moisture and the penetration of the drying front during the falling rate period.     

Permeability of soft porous media under one-dimensional compaction

A novel experimental approach to measure permeability of porous material samples under variable longitudinal compaction has been developed. The material has a non-linear structural behavior and exhibits a small hysteresis during mechanical loading and unloading experiments. The new permeameter includes a piston moving inside a Plexiglas cylinder with controllable speed and a test section where the porous material sample is placed under compaction by two grids with adjustable positions. Time-dependent pressure was recorded at four different locations along the sample together with the velocity of the piston. Experiments with two different sample lengths have been performed at three different Reynolds numbers based on the apparatus diameter. The results show that pressure gradient and permeability data do not depend on initial uncompacted sample length. All experiments included measurements at various compaction ratios of the material followed by measurements during relaxation/expansion of the material. No hysteresis was observed in the pressure gradient and permeability data during compaction and expansion of the material for a wide range of compaction ratio. The effects of small velocity fluctuations due to variable friction of the moving piston with cylinder’s wall were also considered. These velocity fluctuations cause pressure fluctuations within the sample which are high close to the inlet part of the material sample and are reduced almost completely towards its outlet. However these pressure fluctuations when scaled with the corresponding mean pressure retained their time-dependent amplitude and phase unchanged along the material. These relative pressure fluctuations cancelled out the flow velocity fluctuations resulting insignificant fluctuations in permeability. It was found that permeability, which is a material property, is drastically reduced with increased compaction ratio of the material while its solid fraction changes substantially but its porosity remains practically unchanged. A comparison with the Cármán–Kozeny expression for random porous media was also examined. Cármán–Kozeny expression predicts qualitatively the reduction of permeability with compaction. However, the predicted values of permeability are very sensitive to the initial value of porosity.     

Permeability and thermal expansion properties of porous LAS ceramic prepared by gel-casting method

The porous lithium aluminosilicate (LAS) ceramics with controllable pore structure were fabricated by gel-casting method. The porosity, pore structure, compression strength, gas permeability, and coefficient of thermal expansion (CTE) of the porous LAS ceramics with different monomer content were investigated. The sample with 5 wt.% monomer content has maximum value of compression (26.62 ± 0.54 MPa). When the monomer content increased to 20 wt.%, the porosity, Darcian gas permeability, and thermal expansion coefficient increased to maximum (63.66 %, 13.3 × 10⁻¹³ m², and 1.1–2.6 × 10⁻⁶ K⁻¹). The non-Darcian gas permeability showed irregular variation (1.35–3.61 m) with the increase of monomer content. A thermal vibration model was induced to investigate the effect of temperature and monomer content on the CTE. The results showed that the CTE increased with the increase of temperature due to the nonlinear thermal vibration of the atoms in lattice and the asymmetry of the force between particles.     

Discrete and Continuous Modeling of Heat and Mass Transport in Drying of a Bed of Iron Ore Pellets

Drying of a porous bed of iron ore pellets is here considered by modeling a discrete two-dimensional system of round pellets. As a complement to the two-dimensional model, a continuous one-dimensional model enabling fast calculations is developed. Results from the discrete model show that the temperature front advances faster in areas with large distances between the pellets. In areas with low flow speed, the temperature of the pellets increases with a relatively slow rate. The water inside these pellets will therefore remain for a long time. The continuous model fits the discrete model very well for a regular distribution of equal-sized particles. A discrete model with irregular packing will, compared to the continuous model, show a larger variation in the distribution of temperature and moisture content in the final phase of drying.     

Microstructure and permeability of porous YSZ ceramics fabricated by freeze casting of oil-in-water suspension

Porous yttria-stabilized zirconia (YSZ) ceramics are fabricated through freeze casting of oil-in-water suspension followed by sintering at 1250−1550 °C. The pore structure, compressive strength and permeability of porous YSZ ceramics are tailored via altering the emulsion content and sintering temperature. The samples obtained using higher emulsion content or at lower sintering temperature show larger Darcian and non-Darcian constants due to their higher open porosity and larger pore size. Furthermore, the investigation on individual contributions of viscous and inertial resistances on the total pressure drop during permeation process indicates that the viscous resistance increases but the inertial resistance decreases with increasing the emulsion content or decreasing the sintering temperature for samples. Porous YSZ ceramics obtained in this work with a k₁ range of 3.14 × 10⁻¹³–1.12 × 10⁻¹² m² are appropriate for applications in filters and membrane supports.