Fluidized bed CrN coating formation on prenitrocarburized plain carbon steel

CrN coatings were formed on plain carbon steel by prenitrocarburizing, followed by thermoreactive deposition and diffusion (TRD) in a fluidized bed furnace at 570 °C. During TRD, Cr was transferred from Cr powder in the fluidized bed to the nitrocarburized substrates by gas-phase reactions initiated by reaction of HCl gas with the Cr. The microstructural processes occurring in the white layer, caused by N diffusion toward the surface during this stage were studied. This study compares TRD atmospheres employing inert gas and HCl or inert gas, H2, and HCl. Surface characterization was performed by scanning electron microscopy (SEM), x-ray diffraction (XRD), and glow-discharge optical-emission spectroscopy (GDOES).

Dynamic characteristics and efficiency of a fluidized bed heat treatment process

The dynamic characteristics of gas bubbles in fluidized beds are important to determine the heat and mass transfer rates at component surfaces and the treated profiles of components. They also have great impact on the components’ structural, mechanical and physical properties. However, it has been very difficult to monitor those characteristics dynamically. In this paper, a specifically designed fluidized bed was introduced to facilitate the capturing of its dynamic characteristics and a new video image processing and analysis algorithm was developed. The algorithm is robust and adaptive in terms of locating both bubbles and components in beds with a single or multiple components. It has many advantages in dynamic characterization of gas bubbles and monitoring component treatment. By using this algorithm, the properties of gas bubbles over any period of time can be accurately obtained. This technology will provide a potential on-line dynamic monitoring and quality control system for the chemical heat treatment processes with fluidized beds.

Qualitative assessment of bubble behaviour for central and asymmetric injection in 2D gas-solid fluidized bed using image analysis technique and CFD modelling

Bubble characteristics such as shape, size, and trajectory control the hydrodynamics and therefore heat transfer in fluidized bed reactors. Thus understanding these characteristics is very important for the design and scaleup of fluidized beds. An earlier developed Eulerian-Eulerian two-fluid model for simulating dense gas–solid two-phase flow has been used to compare the experimental data in a pseudo-two-dimensional (2-D) bed. Bubbles are injected asymmetrically by locating the nozzle at proximity to the wall, thus presenting the effect wall has on asymmetrical injection as compared to symmetrical injection. In this work, a digital image analysis technique was developed to study the bubble behaviour in a two-dimensional bubbling bed. The high-speed photography reveals an asymmetric wake formation during detachment indicating an early onset of mixing process. The wall forces acts tangentially on thebubble and has a significant impact on the bubble shape, neck formation during detachment and its trajectory through the bed. Larger bubbles drifting away from the centre with longer paths are observed. This qualitative behaviour is well predicted by CFD modelling. Asymmetric injection can significantly influence the heat and mass transfer characteristics.

Fluidised bed nitrocarburising of tool steels

The work examines how ferritic nitrocarburising, a common heat treatment process for steels, can be adapted to the fluidised bed furnace. The effect of fluidising powder contamination on repeatability, composition of the reactive gas mixture, the development of nitrocarburised tool steel microstructure and resulting wear properties were investigated.

Cr(N,C) diffusion coating formation on pre-nitrocarburised H13 tool steel

The microstructural processes of Cr(N,C) coating formation by thermoreactive deposition and diffusion (TRD) on pre-nitrocarburised H13 tool steel were studied. Both nitrocarburising and TRD were performed in fluidized bed furnaces at 570 °C. During TRD, chromium was transferred from chromium powder in the fluidized bed, to the nitrocarburised substrates by gas-phase reactions initiated by reaction of HCl gas with the chromium. Addition of 30% H2 to the input inert gas was found to increase the rate of coating formation, although hydrogen reduction resulted in rapid loss of nitrogen to the surface. The reason for the increased rate of coating formation could not be established without further investigation, although several possible explanations have been proposed. It was found that porosity and the formation of an iron nitride ‘cover layer’ during nitrocarburising were the biggest influences on the microstructure of the Cr(N,C) coating. Microstructural characterization of the coatings was performed by scanning electron microscopy (SEM), X-ray diffraction (XRD) and glow discharge optical emission spectroscopy (GDOES).

Measurement of the mass transfer coefficient at workpiece surfaces in heat treatment furnaces

The mass (e.g. carbon) transfer coefficient at a workpiece surface is an important kinetic factor to control the heat treatment process of the workpiece and to evaluate heat treatment equipment. The coefficient can be calculated from the carbon concentration at the surface of a sample carburized in a carburizing furnace for a given time. Two common measurement methods which use a thin plate and employ a component as samples respectively are evaluated and compared for sensitivity and uncertainty. The comparison shows that the use of a component produces higher measurement precision and also has the advantage in measuring the carbon transfer coefficients at different treated positions. This method is then extended and discussed methodologically. Also two equations are proposed to calculate the carbon transfer coefficient and its uncertainty, respectively. This method is also applied to measure the carbon transfer coefficient in a fluidized bed heat treatment furnace.

A novel approach for real mass transformation from V2O5 particles to nanorods

A solid-state, mass-quantity transformation from V2O5 powders to nanorods has been realized via a two-step approach. The nanorods were formed through a controlled nanoscale growth from the nanocrystalline V2O5 phase created by a ball milling treatment. The nanorods grow along the [010] direction and are dominated by {001} surfaces. Surface energy minimization and surface diffusion play important roles in their growth mechanism. Real large quantity production can be achieved when the annealing process is conducted in a fluidized bed which can treat large quantities of the milled materials at once. The crystal orientation of nanorods provides an improved cycling stability for lithium intercalation.

Pretreatment of seawater for biodegradable organic content removal using membrane bioreactor

Reverse osmosis (RO) is currently one of the most prevalent methods used for seawater desalination. During the past four decades, the research anddevelopment has reduced the energy consumption from about 20 to 4 kWh/m3, while improvements in membrane science has led to a 20-fold increase in the specific membrane flux. Nevertheless, research is still underway to reduce the operation and maintenance problems and thus improve the performance of RO systems. The most important maintenance problem associated with RO operation is the membrane fouling, especially biological fouling (biofouling). This work focuses on the aspects to eliminate biofouling in RO membranes, by adopting a proper pretreatment system. The experimental results revealed that fluidized bed biological granular activated carbon, at 15 min empty bed contact time (with dissolved organic carbon, DOC concentration of 6–8 mg/L) can be utilized effectively to remove nearly 100% biodegradable DOC from seawater. Continuous experiments of membrane bioreactor (MBR) have been conducted concomitantly to gain insight into the long-term effects of MBR on biodegradable organic content removal and biofouling control. The results show that MBR system produced better effluent with 78% DOC removal and quasi-total biodegradable DOC removal. Dissolved oxygen was not a limiting factor for the DOC degradation. Short-term experimental runs were conducted with RO membrane using both pretreated and non-pretreated seawater. The results showed that filtrate from MBR yielded the highest permeate flux improvement, which was approximately 300% compared with non-pretreated seawater.

Characterization and tribological performance of Cu-based intermetallic layers

Fluidized bed reactor chemical vapor deposition (FBR-CVD) has been used to enrich the surface of oxygen free high conductivity (OFHC) copper with titanium, silicon and aluminum. This technique enables the production of coherent and adherent intermetallic surface layers of uniform thickness and high hardness. The characterization of the coatings was performed using backscatter scanning electron microscopy (BS-SEM), X-ray diffraction (XRD), glow discharge optical emission spectroscopy (GDOES) and micro-hardness. The tribological properties of the coatings in dry sliding contact with steel were evaluated by pin-on-disc wear testing.

Computational simulation of the influence of inert particles on incomplete combustion of methane at a low air factor

It is well known that the gas–solid system plays a significant role in many industrial processes. It is a complex physical and chemical process, generally consisting of heat transfer, mass transfer, species diffusion, and chemical reactions. In this paper, the reaction of methane with air at a low air factor and the gas flow in a fluidized bed with 0.1 mm solid particles are computationally simulated to enable the study of the effect of the inert particles on the species diffusion and the chemical reactions. The reaction of methane and air is modeled by a two-step reaction mechanism that produces a continuous fluid phase composed of six gases (CH₄, CO, O₂, CO₂, H₂O, and N₂) and discrete solid particles in the reactor. The simulation results are compared with experiment and show that the finite rate model and the eddy dissipation model can well describe the reactions of gases in high-density gas–solid systems. The distribution of each gas and the particle behaviors are analyzed for incomplete combustion at different concentrations of loaded solid particles. The inert particles change the reactions by enhancing both the chemical kinetics and the species diffusion dynamics.