Sodium adsorption using activated alumina for application in the dairy industry

Basic activated alumina with negatively charged surface is considered as a potential adsorbent for a targeted molecule with positive polarity. Adsorption of sodium by basic activated alumina was investigated as a method for desalting dairy waste streams, in which sodium ion concentration averaged 600 mg/L. Sodium equilibrium and kinetic adsorption were investigated using basic activated alumina with synthetic brines. The results of equilibrium adsorption show that uptake of sodium by activated alumina is significantly higher when the pH is greater than 8 and increases as the pH of the brines increases until pH reaches around 10. The results of kinetic adsorption show that 90 hours were needed to reach equilibrium for sodium adsorption. Binding and diffusion processes are suggested to have taken place within the activated alumina.

Micro-porous nickel produced by powder metallurgy

Micro-porous nickel (Ni) with an open cell structure was fabricated by a special powder metallurgical process, which includes the adding of a space-holding material. The average pore size of the micro-porous Ni samples approximated 30 μm and 150 μm, and the porosity ranged from 60 % to 80 %. The porous characteristics of the Ni samples were observed using scanning electron microscopy (SEM) and the mechanical properties were evaluated using compressive tests. For comparison, porous Ni samples with a macro-porous structure prepared by both powder metallurgy
(pore size 800 μm) and the traditional chemical vapour deposition (CVD) method (pore size 1300 μm) were also presented. Results indicated that the porous Ni samples with a micro-porous structure exhibited different deformation behaviour and dramatically increased mechanical properties,
compared to those of the macro-porous Ni samples.

Characterization of superfine wool powder/poly(propylene) blend film

Superfine wool powder was blended and extruded with poly(propylene) (PP) to produce blend pellets, and the extruded pellets were hot-pressed into a blend film. SEM photographs show that the powder could be uniformly incorporated with PP after extrusion. FT-IR spectra shows that no substantial changes occurred in the chemical structure of both PP and wool powder in the blend film. X-Ray diffraction analysis indicates that crystallinity of the blend film was much higher than that of the wool powder and little lower than that of PP. TG-tested results indicate that the thermal stability of the blend film declined with an increase in the powder content. Endothermic peaks of the wool powder in the blend film become more obvious as the powder content increases. Mechanical properties decline greatly with an increase in the wool powder content in the blend film.

Aluminium powder forging process using a rotating platen

A torsional upset forging process is analysed on the basis of plasticity theory for powder metal forging. Torsional upset forging is a process to be performed by rotating a lower die with a punch travelling along the longitudinal direction of a work-piece. In this study, an upper bound analysis considering bulging effect, finite element method simulation (DEFORM3D), and experimental research have been performed for the process. A simple kinematically admissible velocity field for a three dimensional deformation is presented for the torsional upset forging of a cylindrical billet. Distributions of stress, strain, and forging load in the process have been obtained, and compared with those in conventional upset forging. In the process, an increase in a friction factor and rotation speed results in a decrease in magnitude of upset force, dead metal zone, and non-homogeneous deformation. This process can reduce forming load, which leads to improvement of die life, and also reduce bulging effect. In addition, the initial sintered-structure and density distribution is improved by the process and surface defect due to high deformation is decreased.

Synthesis of Ti–Sn–Nb alloy by powder metallurgy

The microstructural evolution and characteristics of the Ti–16Sn–4Nb powder particles and bulk alloys sintered from the powders ball-milled for various periods of time were studied. Results indicated that ball milling to 8 h led to the development of a supersaturated hcp α-Ti and partial amorphous phase due to the solid solution of Sn and Nb into Ti lattice. The bulk Ti–16Sn–4Nb alloy made from the powders ball milled for a short time, up to 2 h, exhibited a primary α and a Widmanstätten structure consisting of interlaced secondary α and β. With an increase in ball milling time up to 10 h, the microstructure evolved into a fine β phase dispersed homogeneously within α phase matrix. The microhardness values of the bulk alloy in both α- and β-phases increased with the increasing of the ball milling time and reached a plateau value at 8 h and longer, i.e. 687 and 550 HV for α- and β-phases, respectively. Likewise, the microhardness of the α phases was always higher than that of the β phases in the bulk alloys made from the powders ball milled for the same milling time.

Characterization of hot-pressed films from superfine wool powder

In this study, superfine wool powder was plasticized with glycerol and hot-pressed into a film. Scanning electron microscopy photos showed that the superfine wool powder could be molded into a smooth film and that the wool powder was distributed evenly in the cross section of the film. Fourier transform infrared analysis revealed no substantial changes in the chemical structure of the wool powder after hot pressing, but the absorbing peaks of glycerol were found in the spectrum. X-ray diffraction analysis showed that the overall crystallinity increased after the wool powder was hot-pressed into film. Thermogravimetry (TG) analysis indicated that the thermal stability of the hot-pressed film decreased. A transition point appeared in the TG curve of the wool hot-pressed film as glycerol was added. The differential thermal analysis curve of the film showed sharp absorbing peaks similar to that of wool powder. With increasing glycerol content, the film showed increasing ductility and softness.

Bleaching and dyeing of superfine wool powder/polypropylene blend film

Fibers based regenerated protein draw much attention for recycling discarded protein resources and can produce biodegradable and environmental friendly polymers. In this study, superfine wool powder is blended with polypropylene (PP) to produce wool powder/PP blend film through extrusion and hot-pressing. Hydrogen peroxide is used to bleach the black colored surface of the blend films. The effects of peroxide concentration, bleaching time and powder content on the final whiteness and mechanical properties of the blend films are investigated.

The bleached films are dyed with acid red dyes and the dyed color is evaluated using a Computer Color Matching System. Color characters of dyed films, such as L*, a*, b*, ΔE*ab, C*ab and K/S values are measured and analyzed. The study not only reuses discarded wool resources into organic powder, widens the application of superfine wool powder on polymers, but also improves the dyeing properties of PP through the addition of protein content.

The effect of hydrogenation on the ECAP compaction of Ti–6Al–4V powder and the mechanical properties of compacts

The effect of hydrogen content on the compaction of Ti–6Al–4V powder at low temperatures, namely 500 °C, using equal channel angular pressing (ECAP) with back pressure has been investigated. The properties of the compacts before and after a heat treatment and de-hydrogenation cycle have been determined. Compaction of powder by ECAP (500 °C and 260 MPa) has shown maximum levels of relative density of 99.3% and 99.4% when charged with 0.05–0.1 wt.% and 0.61–0.85 wt.% of hydrogen, respectively. After the de-hydrogenation heat treatment the diffusion bonding between individual powder particles was completed and the microstructure was altered, depending on the level of hydrogen content. Two local maxima of 99.2% and 98.1% were observed in the measured density of consolidated compacts for hydrogen contents between 0.05 wt.% and 0.1 wt.% and between 0.61 wt.% and 0.85 wt.%, respectively. However, the mechanical properties of the compacts within these two ranges of hydrogen content were significantly different due to a difference in the observed microstructure. An exceptionally high ductility of 29%, in combination with a relatively high strength of ~560 MPa, was measured in a shear punch test on specimens which had a prior hydrogen level of 0.05 wt.% before the heat treatment. It was shown that material consolidated from powder hydrogenated to low levels of hydrogen before compaction has the potential to offer substantial improvements in mechanical properties after a suitable heat treatment.

Fabrication of ultrafine powder from eri silk through attritor and jet milling

Fibroin protein derived from silk fibres has been extensively studied with exciting outcomes for a number of potential advanced biomaterial applications. However, one of the major challenges in applications lies in engineering fibroin into a  desired form using a convenient production technology. In this paper, fabrication of ultrafine powder from eri silk is reported. The silk cocoons were degummed and the extracted silk fibres were then chopped into snippets prior to attritor and air jet milling. Effects of process control agents, material load and material to water ratio during attritor milling were studied. Compared to dry and dry–wet attritor milling, wet process emerged as the preferred option as it caused less colour change and facilitated easy handling. Ultrafine silk powder with a volume based particle size d(0.5) of around 700 nm could be prepared following the sequence of chopping ➔ wet attritor milling ➔ spray drying ➔ air jet milling. Unlike most reported powder production methods, this method could fabricate silk particles in a short time without any pre-treatment on degummed fibre. Moreover, the size range obtained is much smaller than that previously produced using standard milling devices. Reduction in fibre tenacity either shortened the milling time even further or helped bypassing media milling to produce fine powder directly through jet milling. However, such reduction in fibre strength did not help in increasing the ultimate particle fineness. The study also revealed that particle density and particle morphology could be manipulated through appropriate changes in the degumming process.

Graphical Abstract:  Fabrication of eri silk powder using attritor and jet milling is reported. Volume based particle size d(0.5) of around 700 nm could be prepared following the sequence chopping ➔ wet attritor milling ➔ spray drying ➔ air jet milling. No pre-treatments were used and the particle size range obtained is much smaller than that previously produced using standard milling devices. Particle density morphology could be manipulated through appropriate changes of cocoon degumming conditions.

Thermoplastic film from superfine wool powder

In this paper a research work is described in which superfine wool powder was plasticised by glycerol and hot-pressed into a kind of thermoplastic film. SEM photos show that the powder is moulded into a smooth surface and is conglutinated into a continuous phase in the cross-section of the film. The glycerol content, moulding pressure, temperature and moulding time were changed in the moulding process. The sizes and thickness aw well as tensile strength, modulus, breaking elongation and breaking energy of the films were also tested to investigate the thermoplasticity and mechanical properties of the films. The best moulding techniques included a glycerol content of 30%, a moulding pressure of 5 MPa, a temperature of 160 °C and a moulding time of 5 minutes.

Evaluation of heat stress indices using physiological comparisons in an alumina refinery in a sub-tropical climate

The production of alumina involves the use of a process known as the Bayer process. This method involves the digestion of raw bauxite in sodium hydroxide at temperatures around 250°C. The resultant pregnant liquor then goes through a number of filtering and precipitation processes to obtain the aluminium oxide crystals which are then calcined to obtain the final product. The plant is situated in a sub tropical climate in Northern Australia and this combined with the hot nature of the process results in a potential for heat related illnesses to develop. When assessing a work environment for heat stress a heat stress index is often employed as a guideline and to date the Wet Bulb Globe Temperature (WBGT) has been the recommended index. There have been concerns over the past that the WBGT is not suited to the Northern Australian climate and in fact studies in other countries have suggested this is the case. This study was undertaken in the alumina plant situated in Gladstone Queensland to assess if WBGT was in fact the most suitable index for use or if another was more applicable. To this end three indices, Wet Bulb Globe Temperature (WBGT), Heat Stress Index (HSI) and Required Sweat Rate (SWreq) were compared and assessed using physiological monitoring of heart rate and surrogate core temperature. A number of different jobs and locations around the plant were investigated utilising personal and environmental monitoring equipment. These results were then collated and analysed using a computer program written as part of the study for the manipulation of the environmental data . Physiological assessment was carried out using methods approved by international bodies such as National Institute for Occupational Safety & Health (NIOSH) and International Standards Organisation (ISO) and incorporated the use of a ‘Physiological Factor’ developed to enable the comparison of predicted allowable exposure times and strain on the individual. Results indicated that of the three indices tested, Required Sweat Rate was found to be the most suitable for the climate and in the environment of interest. The WBGT system was suitable in areas in the moderate temperature range (ie 28 to 32°C) but had some deficiencies above this temperature or where the relative humidity exceeded approximately 80%. It was however suitable as a first estimate or first line indicator. HSI over-estimated the physiological strain in situations of high temperatures, low air flows and exaggerated the benefit of artificial air flows on the worker in certain environments ie. fans.

Anomalous evaporation behavior of ZnO powder milled mechanically under high-energy conditions

ZnO powder showed anomalous evaporation behavior after its mechanical milling treatment under high-energy conditions. The amount of generated vapor is about 10 times higher in the first 15 min of annealing at 1300 °C than that of unmilled ZnO powders. The strong ball impacts are responsible for the greatly enhanced evaporation ability. Low-energy ball milling involving shearing actions and rare weak impacts leads only to a small evaporation rate enhancement. The possible explanation of the high evaporation rate of the heavily milled material is the existence of large fraction of weakly bonded atoms in grain boundaries, surface defects and strained areas.

Process for the production of ultrafine plate-like alumina particles

A process for producing plate-like alumina particles with a high aspect ratio is described. Nano-sized particles of an aluminium precursor compound, optionally formed by milling, are mixed with a sufficient volume fraction of a diluent and heat treated to form substantially discrete plate-like alpha alumina particles dispersed in the diluent. A mineraliser may be added to lower the effective melting point of the system. Substantially discrete plate-like particles may be formed without agitation when the heat treatment is conducted below the melting point of the diluent.