Machining Performance and Surface Integrity of AISI D2 Die Steel Machined Using Electrical Discharge Surface Grinding Process

The aim of this study is to establish optimum machining conditions for EDSG of AISI D2 die steel through an experimental investigation using Taguchi Methodology. To achieve combined grinding and electrical discharge machining, metal matrix composite electrodes (Cu-SiC_p) were processed through powder metallurgy route. A rotary spindle attachment was developed to perform the EDSG experimental runs on EDM machine. Relationships were developed between various input parameters such as peak current, speed, pulse-on time, pulse-off time, abrasive particle size, and abrasive particle concentration, and output characteristics such as material removal rate and surface roughness. The optimized parameters were further validated by conducting confirmation experiments.     

Influence of Pd Precursor and Method of Preparation on Hydrodechlorination Activity of Alumina Supported Palladium Catalysts

A series of alumina supported Pd catalysts were prepared by the novel deposition-precipitation method adopting the chloride precursor (DP-Cl) of Pd and varying the metal content from 0.25 to 1.0 wt%. The catalytic properties of prepared catalysts were studied by various characterization techniques such as N₂ adsorption, CO chemisorption, TPR, XRD, XPS, and TEM techniques. The activity and stability of the catalysts were evaluated for the gas phase hydrodechlorination (HDC) of chlorobenzene operating at atmospheric pressure. At 1 wt% of Pd the catalyst showed higher chlorobenzene conversion with good stability when tested for a period of 25 h, whereas the other catalysts exhibited a loss in activity with time. In order to elucidate the exceptional activity and stability of this catalyst, a few more catalysts with 1 wt% Pd were prepared by impregnation technique and also using a non-chloride precursor, palladium nitrate. The 1 wt% DP-Cl catalyst again was found to be the best among the others. The activity and stability of the DP-Cl catalyst was also found to be superior to two low-dispersed catalysts, each with 10 wt% Pd, prepared by conventional impregnation method using the chloride and nitrate as the precursors. The characterization results reveal that the high activity and stability of the DP-Cl catalyst is related to the formation of electron deficient Pd species and its stabilization in the octahedral vacancies of alumina.     

High flux mesoporous MCM-48 membranes: Effects of support and synthesis conditions on membrane permeance and quality

This communication reports experimental efforts to synthesize defect-free mesoporous MCM-48 membranes with improved gas flux. We demonstrate a facile and inexpensive method of synthesizing defect-free supported MCM-48 membranes with improved N₂ and CO₂ permeance (>2 × 10⁻⁷ mol/m² s Pa) employing asymmetric supports for the membrane synthesis which contain layers of macropores possessing different pore sizes. The membranes prepared on asymmetric -alumina supports displayed higher gas permeance than those fabricated on symmetric supports (N₂ permeance <10⁻⁷ mol/m² s Pa) as confirmed by unsteady-state gas permeation experiments. Further improvement in gas permeance was achieved by covering one face and the sides of the support with a ceramic tape during membrane synthesis.     

Numerical studies of a tube-in-tube helically coiled heat exchanger

In the present study a tube-in-tube helically coiled (TTHC) heat exchanger has been numerically modeled for fluid flow and heat transfer characteristics for different fluid flow rates in the inner as well as outer tube. The three-dimensional governing equations for mass, momentum and heat transfer have been solved using a control volume finite difference method (CVFDM). The renormalization group (RNG) k– model is used to model the turbulent flow and heat transfer in the TTHC heat exchanger. The fluid considered in the inner tube is compressed air at higher pressure and cooling water in the outer tube at ambient conditions. The inner tube pressure is varied from 10 to 30 bars. The Reynolds numbers for the inner tube ranged from 20,000 to 70,000. The mass flow rate in the outer tube is varied from 200 to 600 kg/h. The outer tube is fitted with semicircular plates to support the inner tube and also to provide high turbulence in the annulus region. The overall heat transfer coefficients are calculated for both parallel and counter flow configurations. The Nusselt number and friction factor values in the inner and outer tubes are compared with the experimental data reported in the literature. New empirical correlations are developed for hydrodynamic and heat-transfer predictions in the outer tube of the TTHC.     

Performance of Kenics static mixer over a wide range of Reynolds number

The present study deals with the numerical simulation of flow patterns and mixing behaviour in Kenics static mixer over a wide range of Reynolds number. Three different sets of Kenics mixer (aspect ratio = 1.5) comprised of 3, 9 and 25 elements each have been characterized. The Reynolds number was varied in the range of 1 to 25,000 (i.e., from laminar to turbulent flow regime). The numerical approach takes into account the aspects of the fluid flow at higher Reynolds number values including circumferential velocity profiles at different cross-sections within the Kenics mixer, which were neglected in previous studies. It was observed that cross-sectional mixing in the turbulent flow regime takes place up to 30% of each element length at element-to-element transition; beyond that velocity profiles were uniform. The experiments were also carried out to measure the circumferential and axial velocity profiles and pressure drop in three different Kenics Mixers using air as fluid. The pressure drop per unit element (ΔP/η) was found to be independent of the number of Kenics mixing elements used in the system. The total pressure drop across Kenics mixer obtained by CFD simulations were compared with the experimental pressure drop values and correlations available in the literature. The numerical results were found in good agreement with the experimental as well as the results reported in the literature. A new pressure drop correlation in the Kenics static mixer has been developed.     

Low-Temperature Sintering of La(Ca)CrO3 Powder Prepared through the Combustion Process

Ultrafine La(Ca)CrO₃ (LCC) powder was prepared through the glycine–nitrate gel combustion process. It was shown for the first time that the use of relatively inexpensive CrO₃ as a starting material for chromium has potential for the bulk preparation of sinter-active LCC powder. As-prepared powder, when calcined at 700°C, resulted in LCC along with a small amount of CaCrO₄. The calcined powder was found to be composed of soft agglomerates with a particle size of ≈70–290 nm. The cold pressing and sintering of the calcined powder at 1200°C resulted in the mono-phasic La_0.7Ca_0.3CrO₃ with density ≈98% of its theoretical value. This is the lowest sintering temperature ever reported for La_0.7Ca_0.3CrO₃. The conductivity of the sintered La_0.7Ca_0.3CrO₃ at 1000°C was found to be ≈57 S/cm in air. The sintering and electrical behavior achieved for La_0.7Ca_0.3CrO₃ may find application as an interconnect material for high-temperature solid oxide fuel cells if problems with chemical expansion and poor conductivity in fuel can be overcome.     

Novel Synthesis of SrBi2Nb2O9 Powders From Hydroxide Precursors

Simple hydroxide precursors were used for the first time for the synthesis of a typical Aurivillius compound (SrBi₂Nb₂O₉ (SBN)) at a low temperature. This method is very advantageous because it circumvents the use of SrCO₃ in the case of conventional ceramics as well in the coprecipitation methods, thereby lowering the formation of the product phase. Commercially purchased strontium hydroxide is mixed thoroughly with freshly precipitated bismuth and niobium hydroxides in a stoichiometric ratio and heated at different temperatures ranging from 100°C to 750°C for 12 h. The sequence of the reaction and evolution of the product phase was monitored by X-ray diffraction (XRD) studies by recording the XRD for samples calcined at different temperatures. The incipient SBN phase begins to form at temperatures as low as 400°C, and phase formation was complete only at 650°C as revealed by the XRD observations. The differential thermal/thermogravimetric analyses) also corroborate this result. The morphology and average particle size of these powders were investigated by transmission electron microscopy studies.     

Continuous operation of membrane bioreactor treating toluene vapors by Burkholderia vietnamiensis G4

A laboratory-scale biofilm membrane bioreactor inoculated with Burkholderia vietnamiensis G4 was examined to treat toluene vapors in a waste gas stream. The gas feed side and nutrient solution were separated by a composite membrane consisting of a porous polyacrylonitrile (PAN) support layer coated with a very thin (0.3 μm) dense polydimethylsiloxane (PDMS) top layer. After inoculation, a biofilm developed on the dense layer. The biofilm membrane bioreactor was operated continuously at different residence times (28–2 s) and loading rates (1.2–26.7 kg m⁻³ d⁻¹), with inlet toluene concentrations ranging from 0.21 to 4.1 g m⁻³. The overall performance of the membrane bioreactor was evaluated over a period of 165 days. Removal efficiencies ranging from 78% to 99% and elimination capacities from 4.2 to 14.4 kg m⁻³ d⁻¹ were observed after start-up period depending on the mode of operation. A maximum elimination capacity of 14.4 kg m⁻³ d⁻¹ was observed at a loading rate of 17.4 kg m⁻³ d⁻¹. Overall, the results illustrate that biofilm membrane reactors can potentially be more effective than conventional biofilters and biotrickling filters for the treatment of air pollutants such as toluene.     

Tertiary treatment of distillery wastewater by nanofiltration

Tertiary treatment of aerobically treated distillery wastewater by nanofiltration was carried out in a spiral wound nanofiltration membrane module under different operating conditions. The results show that the percentage separation of organic and inorganic compounds was quite high, as reflected by the reduction of chemical oxygen demand (COD) and total dissolved solids (TDS) in the range of 96–99.5%, and 85–95% respectively. The color removal was in the range of 98–99.5%. The results of the effect of variation of the inlet concentration, feed circulation rate and pH conform to the mechanism of gel layer formation. Gel layer formation and Concentration polarization was found to play a major role in the treatment of distillery waste using nanofiltration (NF) membrane. It was observed that as concentration of feed solution increases the permeate flux was reduced. This change was higher compared to the separation of COD and TDS. The result indicates that the NF membrane showed very high performance efficiency for organic components (96–99.5%), as indicated by COD removal. In comparison, the separation of inorganic compounds was found to be in the range of 25–90% as estimated from relative separation of COD and TDS. The present study shows that nanofiltration is a promising technique for recovery of water from distillery waste, which could be used to achieve zero discharge status and solve a major environmental problem.