Preparation of high-activity coal char-based catalysts from high metals containing coal gangue and lignite for catalytic decomposition of biomass tar

The potential of using high metals containing coal gangue and lignite to prepare high-activity coal char-based catalysts is investigated for effective biomass tar decomposition. Loose structure and rough surface are formed for these char-based catalysts with heterogeneous distribution of a large number of inorganic particles. In the biomass tar decomposition, the performance of the coal char-based catalysts is significantly influenced by the content of the metals in the raw materials and coal gangue char (GC) with the ash content as high as 50.80% exhibits the highest activity in this work. A high biomass tar conversion efficiency of 93.5% is achieved at 800 °C along with a significant increase in the fuel gas product. During the five-time consecutive tests, the catalytic performance of GC increases a little at the second or third times reuse and remains relatively stable, showing the remarkable stability of the catalyst in biomass tar decomposition applications.     

Evaluation of hydrodynamic behavior of the perforated gas distributor of industrial gas phase polymerization reactor using CFD-PBM coupled model

A 2D computational fluid dynamics (Eulerian–Eulerian) multiphase flow model coupled with a population balance model (CFD-PBM) was implemented to investigate the fluidization structure in terms of entrance region in an industrial-scale gas phase fluidized bed reactor. The simulation results were compared with the industrial data, and good agreement was observed. Two cases including perforated distributor and complete sparger were applied to examine the flow structure through the bed. The parametric sensitivity analysis of time step, number of node, drag coefficient, and specularity coefficient was carried out. It was found that the results were more sensitive to the drag model. The results showed that the entrance configuration has significant effect on the flow structure. While the dead zones are created in both corners of the distributors, the perforated distributor generates more startup bubbles, heterogeneous flow field, and better gas–solid interaction above the entrance region due to jet formation.     

Upscaled DEM-CFD model for vibrated fluidized bed based on particle-scale similarities

Simulation based on discrete element method (DEM) coupled with computational fluid dynamics (CFD), coupled DEM-CFD, is a powerful tool for investigating the details of dense particle–fluid interaction problems such as in fluidized beds and pneumatic conveyers. The addition of a mechanical vibration to a system can drastically alter the particle and fluid flows; however, their detailed mechanisms are not well understood. In this study, a DEM-CFD model based on a non-inertial frame of reference is developed to achieve a better understanding of the influence of vibration in a vibrated fluidized bed. Because the high computational cost of DEM-CFD calculations is still a major problem, an upscaled coarse-graining model is also employed. To realize similar behaviors with enlarged model particles, non-dimensional parameters at the particle scale were deduced from the governing equations. The suitability and limitations of the proposed model were examined for a density segregation problem of a binary system. To reduce the computational costs, we show that the ratio between the bed width and model particle size can be reduced to a minimum value of 100; to obtain similar segregation behaviors, the ratio between the bed height and model particle size is considered unchanged.     

Studying local liquid velocity in liquid–solid packed bed using the newly developed X-ray DIR technique

Combination of X-ray Digital Industrial Radiography (DIR) and Particle Tracking Velocimetry (PTV) techniques for local liquid velocity measurement (V_LL) has been newly developed and successfully applied for trickle bed reactor (TBR). The technique was validated against newly developed fiber optical probe technique. This work attempts to highlight the applicability of this newly developed technique on a liquid–solid packed bed reactor. In this work, liquid was represented by water and solids were represented by EPS beads. The EPS beads were chosen because of its low density property. Three superficial liquid velocities (V_SL) were applied to the system. The experiment was replicated four times. The digital industrial radiography (DIR) consists of a complementary metal oxide semiconductor (CMOS) digital detector and X-ray source. Results of this work suggest that the technique has been successfully applied and comparable with previous work that has been done in the literature. It also suggests that there will be a maximum measurable interstitial liquid velocity when it travel inside the packed bed. The measured V_LL can have a maximum range that is between 4 and 4.7 times that of its V_SL. For V_SL=0.42±±2%, the V_LL-Max is in between 1.7 cm/s and 1.9 cm/s, V_SL=0.84±±2%, the V_LL-Max is in between 3.6 cm/s and 4.0 cm/s, and for V_SL=1.11±±2%, the V_LL-Max is in between 4.3 cm/s and 4.8 cm/s.     

Preparation and characterization of mullite whisker reinforced ceramics made from coal fly ash

Ceramics with mullite whiskers were prepared from coal fly ash and Al₂O₃ raw materials, with AlF₃ used as an additive. The phase structures and microstructures of the ceramics were identified via X-ray diffraction and scanning electron microscopy, respectively. The results show that pickling of coal fly ash is an effective method for enhancing the flexural strength of ceramics. Sintering temperature and AlF₃ addition were also key factors influencing the creation of ideal ceramics. The ceramic made from pickled coal fly ash, 6?wt% AlF₃, and sintered at 1200?°C, exhibited the highest flexural strength of 59.1?MPa, and had a bulk density of 1.32?g/cm³ and porosity of 26.8%. The results show that ceramic materials made under these conditions are ideal candidates for manufacturing ceramic proppants for the exploitation of unconventional oil and gas resources.     

Additive manufacturing of bipolar plates for hydrogen production in proton exchange membrane water electrolysis cells

Water electrolysis is a process that can produce hydrogen in a clean way when renewable energy sources are used. This allows managing large renewable surpluses and transferring this energy to other sectors, such as industry or transport. Among the electrolytic technologies to produce hydrogen, proton exchange membrane (PEM) electrolysis is a promising alternative. One of the main components of PEM electrolysis cells are the bipolar plates, which are machined with a series of flow distribution channels, largely responsible for their performance and durability. In this work, AISI 316L stainless steel bipolar plates have been built by additive manufacturing (AM), using laser powder bed fusion (PBF-L) technology. These bipolar plates were subjected to ex-situ corrosion tests and assembled in an electrolysis cell to evaluate the polarization curve. Furthermore, the obtained results were compared with bipolar plates manufactured by conventional machining processes (MEC). The obtained experimental results are very similar for both manufacturing methods. This demonstrates the viability of the PBF-L technology to produce metal bipolar plates for PEM electrolyzers and opens the possibilities to design new and more complex flow distribution channels and to test these designs in initial phases before scaling them to larger surfaces.     

Development and monitoring of an integrated bioprocess for production of a potential malaria vaccine with Pichia pastoris

An engineered variant of the yeast Pichia pastoris was used to produce the potential malaria vaccine D1M1. This paper describes the implementation of an expanded bed adsorption chromatography step into a sequential cultivation process of the yeast in order to link protein expression, cell release, and product capture of the secreted protein in a fully automated plant. The process is operated with a semi-continuous strategy for an integrated production. Process improvements have been achieved using design of experiments. Resulting purities of product achieved up to 87% with recoveries of 51% in a single downstream operation. Furthermore, a multivariate analysis of historical batch data was used to develop a golden batch model for process monitoring.