Surface oxide and the role of magnesium during the sintering of aluminum

The effect of trace additions of magnesium on the sintering of aluminum and its alloys is examined. Magnesium, especially at low concentrations, has a disproportionate effect on sintering because it disrupts the passivating Al2O3 layer through the formation of a spinel phase. Magnesium penetrates the sintering compact by solid-state diffusion, and the oxide is reduced at the metal-oxide interface. This facilitates solid-state sintering, as well as wetting of the underlying metal by sintering liquids, when these are present. The optimum magnesium concentration is approximately 0.1 to 1.0 wt pet, but this is dependent on the volume of oxide and, hence, the particle size, as well as the sintering conditions. Small particle-size fractions require proportionally more magnesium than large-size fractions do.

A comparative study of the fluidized-bed coating of cylindrical metal surfaces with various thermoplastic polymer powders

This paper reports the results of an experimental investigation into the fluidized-bed coating of cylindrical metal specimens using two types of thermoplastic powders, Rilsan(R) PA11, a nylon-11 powder produced by Elf Atochem, France and Cotene(TM) 4612, a linear low density polyethylene powder produced by J.R Courtenay (New Zealand). The effects of dipping time, preheat temperature and particle size distribution on coating thickness and surface finish were investigated. Consistent trends in coating thickness growth with dipping time were obtained for both nylon-11 and polyethylene powders with increases in coating thickness with preheat temperature. For the same preheat temperature, the lower melting point of polyethylene results in thicker coatings compared to those of nylon-11. There is a negligible change in the coating thickness for sieved powders compared to that for unsieved powders. A pre-heat temperatures of between 240 degrees C and 300 degrees C is necessary to achieve an acceptable surface finish with both nylon-11 and polyethylene powders. To minimize errors in achieving the desired coating thickness, dipping times shorter than 2 s are not recommended. The use of graphs of coating thickness versus dipping time in combination with the coating surface roughness plots presented in this paper enable the optimal choice of pre-heat temperature and dipping time to achieve acceptable surface finish. (C) 1999 Elsevier Science S.A. All rights reserved.

Percolative fragmentation of char particles during gasification

Percolative fragmentation was confirmed to occur during gasification of three microporous coal chars. Indirect evidence obtained by the variation of electrical resistivity (ER) with conversion was supported by direct observation of numerous fragments during gasification. The resistivity increases slowly at low conversions and then sharply after a certain conversion value, which is a typical percolation phenomenon suggesting the occurrence of internal fragmentation at high conversion. Two percolation models are applied to interpret the experimental data and determine the percolation threshold. A percolation threshold of 0.02-0.07 was found, corresponding to a critical conversion of 92-96% for fragmentation. The electrical resistivity variation at high conversions is found to be very sensitive to diffusional effects during gasification. Partially burnt samples with a narrow initial particle size range were also observed microscopically, and found to yield a large number of small fragments even when the particles showed no disintegration and chemical control prevailed. It is proposed that this is due to the separation of isolated clusters from the particle surface. The particle size distribution of the fragments was essentially independent of the reaction conditions and the char type, and supported the prediction by percolation theory that the number fraction distribution varies linearly with mass in a log-log plot. The results imply that perimeter fragmentation would occur in practical combustion systems in which the reactions are strongly diffusion affected.

Loose abrasive truing and dressing of resin bond diamond cup wheels for grinding fibre optic connectors

A loose abrasive lapping technology was developed for truing and dressing ultrafine diamond cup wheels for grinding spherical end faces of fibre optic connectors. The relative densities of exposed grits and grit pull-outs measured from wheel surfaces prepared using the loose abrasive lapping and the bonded abrasive dressing were compared. It was found that the lapping method with loose abrasives produced wheel surfaces with more exposed grits and less grit pull-outs, especially for finer grit size wheels. For dressing ultrafine grit size wheels, the particle size of the lapping paste should be smaller than the wheel grit size to achieve a better result. It is also found that the wheels dressed using the lapping method demonstrate an excellent grinding performance. (C) 2004 Elsevier B.V.. All rights reserved.

Experimental study of the deposition of combustion aerosols in the human respiratory tract

The total deposition of environmental tobacco smoke (ETS), diesel and petrol smoke in the respiratory tract of 14 non-smokers between the ages of 20 and 30 was determined experimentally. A scanning mobility particle sizer (SMPS) measuring a size range of 0.016-0.626 mu m was used to characterise the inhaled and exhaled aerosol during relaxed nasal breathing over a period of 10 min. The ETS, diesel, and petrol particles had average count median diameter (and geometric standard deviation) of 0.183 mu m (1.7), 0.125 mu m (1.7), and 0.069 mu m (1.7), respectively. The average total number deposition of ETS was 36% (standard deviation 10%), of diesel smoke 30% (standard deviation 9%), and of petrol smoke 41% (standard deviation 8%). The analysis of the deposition patterns as a function of particle size for the three aerosols in each individual showed that there is a significant difference between each aerosol for a majority of individuals (12 out of 14). This is an important result as it indicates that differences persist regardless of inter-subject variability. (C) 2005 Elsevier Ltd. All rights reserved.

Thermogravimetric analytical procedures for determining reactivities of chars from New Zealand coals

Tightly constrained thermogravimetric experimental procedures (particle size < 212 mu m, sample mass 15.5 mg, CO2 reactant gas, near isothermal conditions) allow the reactivity of chars from high volatile New Zealand coals to be determined to a repeatability of +/-0.07 h(-1) at 900 degrees C and +/-0.5 h(-1) at 1100 degrees C. The procedure also provides proximate analyses information and affords a quick (< 90 min) comparison between different coal types as well as indicating likely operating conditions and problems associated with a particular coal or blend. A clear difference is evident between reactivities of differing New Zealand coal ranks. Between 900 and 1100 degrees C, bituminous coals increase thirtyfold in reactivity compared with fourfold for subbituminous, with the latter being three to five times greater in reactivity at higher temperature. (C) 1997 Elsevier Science B.V.

A new wavelet-based method for the solution of the population balance equation

A new wavelet-based method for solving population balance equations with simultaneous nucleation, growth and agglomeration is proposed, which uses wavelets to express the functions. The technique is very general, powerful and overcomes the crucial problems of numerical diffusion and stability that often characterize previous techniques in this area. It is also applicable to an arbitrary grid to control resolution and computational efficiency. The proposed technique has been tested for pure agglomeration, simultaneous nucleation and growth, and simultaneous growth and agglomeration. In all cases, the predicted and analytical particle size distributions are in excellent agreement. The presence of moving sharp fronts can be addressed without the prior investigation of the characteristics of the processes. (C) 2001 Published by Elsevier Science Ltd.

Process mineralogy of fluorosilicate minerals in OK Tedi ores

The impact of fluorine in copper flotation was relatively unknown until the introduction of skarn ores in the Ok Tedi concentrator. Fluorine in the copper concentrates reports to the gas phase during the smelting stage and forms a corrosive H2SO4-HCl-HF acid brine mixture which must be neutralised. This work was aimed at studying the mineralogy of the fluorosilicate minerals contained in the various oretypes present in the Ok Tedi porphyry copper deposit. The electron microprobe was used to analyse for fluorine and hence identify the fluorosilicate minerals in each oretype. This study revealed talc, phlogopite, biotite, clays, amphiboles, fluoroapatite and titanite to be the sources of fluorine in the orebody. Laboratory and plant investigations were conducted to study the flotation response of these minerals. Chemical assaying of the products of these tests was done to determine the bulk assay of fluorine, Using Rietveld analysis, quantitative estimates of the fluorosilicate minerals in these products were generated. Marrying of the bulk assay with the respective mineralogical assay enabled the understanding of the flotation behavior of fluorine and it's associated mineralogy. Talc and phlogopite were found to be the causes of the fluorine problem at Ok Tedi. (C) 2001 Elsevier Science Ltd. All rights reserved.

Adsorption kinetics for the removal of chromium(VI) from aqueous solution by adsorbents derived from used tyres and sawdust

The batch removal of hexavalent chromium (Cr(Vl)) from wastewater under different experimental conditions using economic adsorbents was investigated in this study. These adsorbents were produced from the pyrolysis and activation of the waste tyres (TAC) and from the pyrolysis of sawdust (SPC). The performance of these adsorbents against commercial activated carbon F400 (CAC) has also been carried out. The removal was favoured at low pH, with maximum removal at pH = 2 for all types of carbon. The effects of concentration, temperature and particle size have been reported. All sorbents were found to efficiently remove Cr(VI) from solution. The batch sorption kinetics have been tested for a first-order reversible reaction, a first-order and second-order reaction. The rate constants of adsorption for all these kinetic models have been calculated. The applicability of the Langmuir isotherm for the present system has been tested at different temperatures. The thermodynamic parameters (AGO, K,) obtained indicate the endothermic nature of Cr(Vl) adsorption on TAC, SPC and CAC. (C) 2001 Elsevier Science B.V. All rights reserved.

Liquid phase sintering of aluminium alloys

The principle that alloys are designed to accommodate the manufacture of goods made from them as much as the properties required of them in service has not been widely applied to pressed and sintered P/M aluminium alloys. Most commercial alloys made from mixed elemental blends are identical to standard wrought alloys. Alternatively, alloys can be designed systematically using the phase diagram characteristics of ideal liquid phase sintering systems. This requires consideration of the solubilities of the alloying elements in aluminium, the melting points of the elements, the eutectics they form with aluminium and the nature of the liquid phase. The relative diffusivities are also important. Here we show that Al-Sn, which closely follows these ideal characteristics, has a much stronger sintering response than either Al-Cu or Al-Zn, both of which have at least one non-ideal characteristic. (C) 2001 Elsevier Science B.V. All rights reserved.

Experimental investigation of liquid flow shift due to gas cross flow in non-wetted packed beds

An experimental study has been carried out for the gas-liquid two-phase flow in a packed bed simulating conditions of the gas and liquid flows in the lower part of blast furnace. The localised liquid flow phenomenon in presence of gas cross flow, which usually occurs around the cohesive zone and raceway in blast furnace, was investigated in detail. Such liquid flow is characterised in terms of liquid shift distance or liquid shift angle that can effectively be measured by the experiments involved in the current study. It is found that liquid shift angle does not significantly increase or decrease with different packing depth. This finding supports the hypothesis of the force balance model where a vectorial relationship among acting forces, i.e. gas drag force, gravitational force and solid-liquid friction force, and liquid shift angle does exist. Liquid shift angle is inversely proportional to particle size and liquid density, and proportional to square of gas superficial velocity, but is almost independent on liquid flowrate and liquid viscosity. The gas-liquid drag coefficient, an important aspect for quantifying the interaction between gas and liquid flows, was conceptually modified based on the discrete feature of liquid flow through a packed bed and evaluated by the combined theoretical and experimental investigation. Experimental measurements suggest that the gas-liquid drag coefficient is approximately a constant (C-DG(')=5.4+/-1.0) and is independent on liquid properties, gas velocity and packing structure. The result shows a good agreement with previous experimental data and prediction of the existing liquid flow model.

A classification of subantarctic Heard Island vegetation

The vascular and bryophyte floras of subantarctic Heard Island were classified using cluster analysis into six vegetation communities: Open Cushion Carpet, Mossy Feldmark, Wet Mixed Herbfield, Coastal Biotic Vegetation, Saltspray Vegetation, and Closed Cushion Carpet. Multidimensional scaling indicated that the vegetation communities were not well delineated but were continua. Discriminant analysis and a classification tree identified altitude, wind, peat depth, bryophyte cover and extent of bare ground, and particle size as discriminating variables. The combination of small area, glaciation, and harsh climate has resulted in reduced vegetation variety in comparison to those subantarctic islands north of the Antarctic Polar Front Zone. Some of the functional groups and vegetation communities found on warmer subantarctic islands are not present on Heard Island, notably ferns and sedges and fernbrakes and extensive mires, respectively.

Drop penetration into porous powder beds

The kinetics of drop penetration were studied by filming single drops of several different fluids (water, PEG200, PEG600, and HPC solutions) as they penetrated into loosely packed beds of glass ballotini, lactose, zinc oxide, and titanium dioxide powders. Measured times ranged from 0.45 to 126 s and depended on the powder particle size,viscosity, surface tensions, and contact angle. The experimental drop penetration times were compared to existing theoretical predictions by M. Denesuk et al. (J. Colloid Interface Sci. 158, 114, 1993) and S. Middleman (Modeling Axisymmetric Flows: Dynamics of Films, Jets, and Drops, Academic Press, San Diego, 1995) but did not agree. Loosely packed powder beds tend to have a heterogeneous bed structure containing large macrovoids which do not participate in liquid flow but are included implicitly in the existing approach to estimating powder pore size. A new two-phase model was proposed where the total volume of the macrovoids was assumed to be the difference between the bed porosity and the tap porosity. A new parameter, the effective porosity (epsilon)eff, was defined as the tap porosity multiplied by the fraction of pores that terminate at a macrovoid and are effectively blocked pores. The improved drop penetration model was much more successful at estimating the drop penetration time on all powders and the predicted times were generally within an order of magnitude of the experimental results. (C) 2002 Elsevier Science (USA).

Polymer product engineering utilising oscillatory baffled reactors

The Oscillatory baffled reactor (OBR) can be used to produce particles with controlled size and morphology, in batch or continuous flow. This is due to the effect of the superimposed oscillations that radially mixes fluid but still allows plug-flow (or close to plug flow) behaviour in a continuous system. This mixing, combined with a close to a constant level of turbulence intensity in the reactor, leads to tight droplet and subsequent product particle size distributions. By applying population balance equations together with experimental droplet size distributions, breakage rates of droplets can be determined and this is a useful tool for understanding the product engineering in OBRs. (C) 2002 Elsevier Science B.V All rights reserved.

Modelling activated sludge flocculation using population balances

Activated sludge flocculation was modelled using population balances. The model followed the dynamics of activated sludge flocculation providing a good approximation of the change in mean floe size with time. Increasing the average velocity gradient decreased the final floe size. The breakage rate coefficient and collision efficiency also varied with the average velocity gradient. A power law relationship was found for the increase in breakage rate coefficient with increasing average velocity gradient. Further investigation will be conducted to determine the relationship between the collision efficiency and particle size to provide a better approximation of dynamic changes in the floe size distribution during flocculation. (C) 2002 Published by Elsevier Science B.V.