Computational Approaches for Studying the Granular Dynamics of Continuous Blending Processes, 2 – Population Balance and Data‐Based Methods

The application of computationally inexpensive modeling methods for a predictive study of powder mixing is discussed. A multidimensional population balance model is formulated to track the evolution of the distribution of a mixture of particle populations with respect to position and time. Integrating knowledge derived from a discrete element model, this method can be used to predict residence time distribution, mean and relative standard deviation of the API concentration in a continuous mixer. Low‐order statistical models, including response surface methods, kriging, and high‐dimensional model representations are also presented. Their efficiency for design optimization and process design space identification with respect to operating and design variables is illustrated.

     

Structural and thermal characterization of CaO–MgO–SiO2–P2O5–CaF2 glasses

The influence of varying the CaO/MgO ratio on the structure and thermal properties of CaO–MgO–SiO₂–P₂O₅–CaF₂ glasses was studied in a series of eight glass compositions in the glass forming region of diopside (CaMgSi₂O₆)–fluorapatite [Ca₅(PO₄)₃F]–wollastonite (CaSiO₃) ternary system. The melt-quenched glasses were characterized for their structure by infrared spectroscopy (FTIR) and magic angle spinning (MAS)-nuclear magnetic resonance (NMR) spectroscopy. Silicon is predominantly present as Q² (Si) species, while phosphorus tends to coordinate in orthophosphate environment. The sintering and crystallization parameters of the glasses were obtained from differential thermal analysis (DTA) while crystalline phase fractions in the sintered glass–ceramics were analyzed by X-ray diffraction adjoined with Rietveld refinement. Diopside, fluorapatite, wollastonite and pseudowollastonite crystallized as the main crystalline phases in all the glass–ceramics with their content varying with respect to variation in CaO/MgO ratio in glasses. The implications of structure and sintering behaviour of glasses on their bioactivity were discussed.     

Corrosion behavior of Monofrax K-3 refractory in borosilicate-based model low activity waste glass melts

Owing to its good chemical and thermal durabilities at high temperatures, Monofrax K-3 refractory is widely used in nuclear waste vitrification as a lining material in melting vessels. However, the corrosion of K-3 refractory during the vitrification of nuclear waste is a serious problem because it affects the melter's safety, performance, and lifetime. Therefore, in the present study, we have focused on unearthing the impact of glass network formers, such as SiO₂, B₂O₃, and Al₂O₃, in a model nuclear waste glass composition on the corrosion of Monofrax K-3 refractory. The corrosion tests have been performed per ASTM C621 at 1150°C for 5 days. The dimensional measurements on corroded K-3 refractory suggest that Al₂O₃ and SiO₂ tend to reduce the refractory corrosion (neck loss), with the effect of Al₂O₃ being significant. A corroded region on the K-3 refractory at the melt–refractory interface is observed. The corrosion occurs via a coupling of the melt infiltration induced by a capillary effect and the dissolution of Al, Mg, and Fe components from K-3 into the melt through chemical reactions. A Cr-rich layer is retained on the glass contact surface of the corroded K-3 refractory.     

Model predictive in vitro dissolution testing in pharmaceutical continuous manufacturing: An equivalence study

A predictive mathematical model for tablet dissolution was developed and implemented in an end-to-end integrated continuous manufacturing pilot plant. The tablets were produced for immediate release with a proprietary extrusion-molding-coating (EMC) unit operation. Besides the mass balance of API solute in the buffer solution, the model consisted of the dissolution, diffusion, and population balance of API particles in the swollen tablet, which was mainly controlled by the swelling and erosion of the polymeric excipient matrix. An equivalence study was investigated by comparing the model prediction to the experiments that were conducted according to USP42-NF37 General Chapter <711> Dissolution, during which the drug dose level was varied in a range from 60 to 80 wt%. Consistent equivalence was demonstrated with the similarity factor f₂ > 50 for all sampled tablets. Concluding remarks and industrial perspectives on model predictive in vitro dissolution testing are provided.     

Evaluation of major factors influencing the TBC topcoat formation in axial suspension plasma spraying (SPS)

Suspension plasma spraying (SPS) is ideally suited to produce porous or dense columnar, strain-tolerant thermal barrier coatings (TBCs) and also offers the possibility of producing other microstructures such as feathery and dense vertically cracked coatings. The specific properties of the TBC are significantly influenced by the formed microstructure, that is, affected by feedstock material and process parameters. In this work, the effects of various process parameters in the SPS process are investigated. It was found that the suspension feed rate has a significant effect on the microstructure, especially on the column density of the coating, whereas the suspension solids content mainly affects the coating porosity. Additionally, the surface roughness and topography of the bond coat are crucial for the formation of columnar coatings and were therefore investigated. Despite comparable roughness values for as-sprayed bond coats for high velocity oxy fuel and vacuum plasma spray produced coatings, the surface structures differ significantly from each other and affect the microstructure of the deposited topcoat. Characterization of mechanical properties by means of micro-indenter can be suitable for columnar coatings to determine Young's modulus within a column. However, due to the heterogeneity of the coating, the method is not suitable to describe the mechanical properties of the topcoat.     

Structural Characteristics and Electrical Conductivity of Spark Plasma Sintered Ytterbia Co‐doped Scandia Stabilized Zirconia

The effect of replacing Sc₂O₃ with Yb₂O₃ on the structural and electrical properties of xYb₂O₃–(12–x)Sc₂O₃–88ZrO₂ has been investigated. Spark plasma sintering technique is employed to fabricate dense bulk samples from the nano‐sized powders. X‐ray diffraction and transmission electron microscopy performed on pellets indicate the existence of cubic and rhombohedral phases in 12ScSZ, and a single cubic phase in all the co‐doped compositions. However, Raman spectroscopic studies suggest the presence of a metastable tetragonal t″‐phase along with rhombohedral phases in 12ScSZ, whereas a single cubic phase in all the co‐doped compositions. Significant enhancement in the conductivity of grain and grain boundary is observed on replacing Sc₂O₃ with Yb₂O₃. In the intermediate temperature range, 1Yb11ScSZ exhibits the highest, while 12ScSZ shows the lowest conductivity values, which is attributed to corresponding phases present in that range. Through co‐doping with >1 mol% Yb₂O₃ leads to conductivity decrease, but the value remains higher than that of 12ScSZ. A sharp conductivity change is observed in 12ScSZ and 1Yb11ScSZ samples, which is attributed to partial phase transition as well to the formation of cation‐vacancy complexes. In this work, the beneficial effect of Yb₂O₃ co‐doping in 12ScSZ on the phase and conductivity has been highlighted.     

Microstructural evolution in infiltration‐growth processed MgB2 bulk superconductors

The study reports phase and microstructural evolution in MgB₂ bulk superconductors fabricated by an infiltration and growth (IG) process. Three distinct stages, (1) intermediate boride formation, (2) bulk liquid Mg infiltration, and (3) MgB₂ layer formation, were identified in IG process after detailed examination of series of samples prepared with varied heating conditions. The intermediate phase Mg₂B₂₅, isomorphous to β‐boron, was detected prior to MgB₂ phase formation in stage (1). Due to volume expansion involved in stage 1, cracks formed in the β‐boron particles and propagated radially inwards during stage 3. The growing MgB₂ particles sintered simultaneously with formation of grain boundaries during the process, as evidenced by the measured hardness and critical current density in these samples. From our observations, we estimate the total time needed for complete transformation to MgB₂.     

Understanding the structural origin of crystalline phase transformations in nepheline (NaAlSiO4)‐based glass‐ceramics

Nepheline (Na₆K₂Al₈Si₈O₃₂) is a rock‐forming tectosilicate mineral which is by far the most abundant of the feldspathoids. The crystallization in nepheline‐based glass‐ceramics proceeds through several polymorphic transformations — mainly orthorhombic, hexagonal, cubic — depending on their thermochemistry. However, the fundamental science governing these transformations is poorly understood. In this article, an attempt has been made to elucidate the structural drivers controlling these polymorphic transformations in nepheline‐based glass‐ceramics. Accordingly, two different sets of glasses (meta‐aluminous and per‐alkaline) have been designed in the system Na₂O–CaO–Al₂O₃–SiO₂ in the crystallization field of nepheline and synthesized by the melt‐quench technique. The detailed structural analysis of glasses has been performed by ²⁹Si, ²⁷Al, and ²³Na magic‐angle spinning — nuclear magnetic resonance (MAS NMR), and multiple‐quantum MAS NMR spectroscopy, while the crystalline phase transformations in these glasses have been studied under isothermal and non‐isothermal conditions using differential scanning calorimetry (DSC), X‐ray diffraction (XRD), and MQMAS NMR. Results indicate that the sequence of polymorphic phase transformations in these glass‐ceramics is dictated by the compositional chemistry of the parent glasses and the local environments of different species in the glass structure; for example, the sodium environment in glasses became highly ordered with decreasing Na₂O/CaO ratio, thus favoring the formation of hexagonal nepheline, while the cubic polymorph was the stable phase in SiO₂–poor glass‐ceramics with (Na₂O+CaO)/Al₂O₃ > 1. The structural origins of these crystalline phase transformations have been discussed in the paper.