Susteinable steelmaking by process integration

Environmental issues, including global warming, have been serious challenges realized worldwide, and they have become particularly important for the iron and steel manufacturers during the last decades. Many sites has been shut down in developed countries due to environmental regulation and pollution prevention while a large number of production plants have been established in developing countries which has changed the economy of this business. Sustainable development is a concept, which today affects economic growth, environmental protection, and social progress in setting up the basis for future ecosystem. A sustainable headway may attempt to preserve natural resources, recycle and reuse materials, prevent pollution, enhance yield and increase profitability. To achieve these objectives numerous alternatives should be examined in the sustainable process design. Conventional engineering work cannot address all of these substitutes effectively and efficiently to find an optimal route of processing. A systematic framework is needed as a tool to guide designers to make decisions based on overall concepts of the system, identifying the key bottlenecks and opportunities, which lead to an optimal design and operation of the systems. Since the 1980s, researchers have made big efforts to develop tools for what today is referred to as Process Integration. Advanced mathematics has been used in simulation models to evaluate various available alternatives considering physical, economic and environmental constraints. Improvements on feed material and operation, competitive energy market, environmental restrictions and the role of Nordic steelworks as energy supplier (electricity and district heat) make a great motivation behind integration among industries toward more sustainable operation, which could increase the overall energy efficiency and decrease environmental impacts. In this study, through different steps a model is developed for primary steelmaking, with the Finnish steel sector as a reference, to evaluate future operation concepts of a steelmaking site regarding sustainability. The research started by potential study on increasing energy efficiency and carbon dioxide reduction due to integration of steelworks with chemical plants for possible utilization of available off-gases in the system as chemical products. These off-gases from blast furnace, basic oxygen furnace and coke oven furnace are mainly contained of carbon monoxide, carbon dioxide, hydrogen, nitrogen and partially methane (in coke oven gas) and have proportionally low heating value but are currently used as fuel within these industries. Nonlinear optimization technique is used to assess integration with methanol plant under novel blast furnace technologies and (partially) substitution of coal with other reducing agents and fuels such as heavy oil, natural gas and biomass in the system. Technical aspect of integration and its effect on blast furnace operation regardless of capital expenditure of new operational units are studied to evaluate feasibility of the idea behind the research. Later on the concept of polygeneration system added and a superstructure generated with alternative routes for off-gases pretreatment and further utilization on a polygeneration system producing electricity, district heat and methanol. (Vacuum) pressure swing adsorption, membrane technology and chemical absorption for gas separation; partial oxidation, carbon dioxide and steam methane reforming for methane gasification; gas and liquid phase methanol synthesis are the main alternative process units considered in the superstructure. Due to high degree of integration in process synthesis, and optimization techniques, equation oriented modeling is chosen as an alternative and effective strategy to previous sequential modelling for process analysis to investigate suggested superstructure. A mixed integer nonlinear programming is developed to study behavior of the integrated system under different economic and environmental scenarios. Net present value and specific carbon dioxide emission is taken to compare economic and environmental aspects of integrated system respectively for different fuel systems, alternative blast furnace reductants, implementation of new blast furnace technologies, and carbon dioxide emission penalties. Sensitivity analysis, carbon distribution and the effect of external seasonal energy demand is investigated with different optimization techniques. This tool can provide useful information concerning techno-environmental and economic aspects for decision-making and estimate optimal operational condition of current and future primary steelmaking under alternative scenarios. The results of the work have demonstrated that it is possible in the future to develop steelmaking towards more sustainable operation.

Entsyymien talteenotto ja kierrätys selluloosaetanolin valmistuksessa

Bioetanolin valmistus selluloosapitoisista raaka-aineista vaatii selluloosapolymeerien pilkkomisen liukoisiksi sokereiksi. Tämä voidaan toteuttaa entsymaattisella hydrolyysillä. Selluloosan pilkkomiseen tarkoitetut entsyymit, sellulaasit, ovat entsymaattisen hydrolyysin jälkeen sitoutuneet joko kiintoainefaasiin tai ovat nestemäisessä faasissa ns. vapaina entsyymeinä. Prosessin taloudellisuuden kannalta on erityisen tärkeää minimoida siinä käytettävien entsyymien tarve, sillä tehokkaat entsyymivalmisteet ovat suhteellisen kalliita. Yksi varteenotettava vaihtoehto bioetanoliprosessin saamiseksi taloudellisemmaksi on käytettyjen entsyymien talteenotto ja kierrätys. Työn tarkoituksena oli selvittää kirjallisuudesta, millaisia menetelmiä on kehitetty entsyymien talteenottoon ja kierrätykseen lignoselluloosasta valmistettavan bioetanolin valmistuksessa. Työssä on keskitytty tuoreisiin tutkimuksiin ja menetelmien käyttökelpoisuuteen ja taloudellisuuteen. Viime vuosina sellulaasien talteenotto- ja kierrätysmenetelmiä koskevat tutkimukset ovat keskittyneet pääasiassa käsittelemään nanopartikkelien avulla tapahtuvaa entsyymien immobilisointia, ultrasuodatusta, erilaisia desorptiomenetelmiä, kiinteän hydrolyysijäännöksen kierrättämistä, tuoreen substraatin lisäämistä sekä myös tislausvaiheen jälkeistä entsyymien kierrättämistä. Jotta kierrätysmenetelmä olisi tehokas, tulisi sen pyrkiä säilyttämään entsyymien aktiivisuuksia, sokerisaantoa menettämättä ja sisältää sekä neste-, että kiintoainefaasista tapahtuva kierrätys. Jokaisella kierrätysmenetelmällä on hyvät ja huonot puolensa. Entsyymien talteenottoastetta saadaan kuitenkin parannettua yhdistämällä erilaisia menetelmiä. Useista tutkimuksista huolimatta, taloudellisinta ja käyttökelpoisinta entsyymien talteenotto- ja kierrätysmenetelmää ei ole vielä saavutettu.

Chocolate rheology

Rheology is the science that studies the deformation and flow of solids and fluids under the influence of mechanical forces. The rheological measures of a product in the stage of manufacture can be useful in quality control. The microstructure of a product can also be correlated with its rheological behavior allowing for the development of new materials. Rheometry permits attainment of rheological equations applied in process engineering, particularly unit operations that involve heat and mass transfer. Consumer demands make it possible to obtain a product that complies with these requirements. Chocolate industries work with products in a liquid phase in conching, tempering, and also during pumping operations. A good design of each type of equipment is essential for optimum processing. In the design of every process, it is necessary to know the physical characteristics of the product. The rheological behavior of chocolate can help to know the characteristics of application of the product and its consumers. Foods are generally in a metastable state. Their texture depends on the structural changes that occur during processing. Molten chocolate is a suspension with properties that are strongly affected by particle characteristics including not only the dispersed particles but also the fat crystals formed during chocolate cooling and solidification. Chocolate rheology is extensively studied, and it is known that chocolate texture and stability is strongly affected by the presence of specific crystals

Carponate precipitation with carbon dioxide gas

The aim of this thesis research work focused on the carbonate precipitation of magnesium using magnesium hydroxide Mg(OH)2 and carbon dioxide (CO2) gas at ambient temperature and pressure. The rate of dissolution of Mg(OH)2 and precipitation kinetics were investigated under different operating conditions. The conductivity and pH of the solution were inline monitored by a Consort meter and the solid samples gotten from the precipitation reaction were analysed by a laser diffraction analyzer Malvern Mastersizer to obtain particle size distributions (PSD) of crystal samples. Also the Mg2+ concentration profiles were determined from the liquid phase of the precipitate by ion chromatography (IC) analysis. Crystal morphology of the obtained precipitates were also investigated and discussed in this work. For the carbonation reaction of magnesium hydroxide in the present work, it was found that magnesium carbonate trihydrate (nesquehonite) was the main product and its formation occurred at a pH of around 7-8. The stirrer speed has a significant effect on the dissolution rate of Mg(OH)2. The highest obtained Mg2+ concentration level was 0.424 mol L-l for the 470 rpm and 0.387 mol L-1 for the 560 rpm which corresponded to the processing time of 45 mins and 40 mins respectively. The particle size distribution shows that the average particle size keeps increasing during the reaction as the CO2 is been fed to the system. The carbonation process is kinetically favored and simple as nesquehonite formation occurs in a very short time. It is a thermodynamically and chemically stable solid product, which allows for a long-term storage of CO2. Since the carbonation reaction is a complex system which includes dissolution of magnesium hydroxide particles, absorption of CO2, chemical reaction and crystallization, the dissolution of magnesium hydroxide was studied in hydrochloric acid (HCl) solvent with and without nitrogen (N2) inert gas. It was found on the dissolution part that the impeller speed had effect on the dissolution rate. The higher the impeller speed the higher the pH of the solution, although for the highest speed of 650rpm it was not the case. Therefore, it was concluded that the optimum speed of the stirrer was 560rpm. The influence of inert gas N2 on the dissolution rate of Mg(OH)2 particles could be seen based on measured pH, electric conductivity and Mg2+ concentration curves.

A reaction engineering approach to homogeneously catalyzed glycerol hydrochlorination

The production of biodiesel through transesterification has created a surplus of glycerol on the international market. In few years, glycerol has become an inexpensive and abundant raw material, subject to numerous plausible valorisation strategies. Glycerol hydrochlorination stands out as an economically attractive alternative to the production of biobased epichlorohydrin, an important raw material for the manufacturing of epoxy resins and plasticizers. Glycerol hydrochlorination using gaseous hydrogen chloride (HCl) was studied from a reaction engineering viewpoint. Firstly, a more general and rigorous kinetic model was derived based on a consistent reaction mechanism proposed in the literature. The model was validated with experimental data reported in the literature as well as with new data of our own. Semi-batch experiments were conducted in which the influence of the stirring speed, HCl partial pressure, catalyst concentration and temperature were thoroughly analysed and discussed. Acetic acid was used as a homogeneous catalyst for the experiments. For the first time, it was demonstrated that the liquid-phase volume undergoes a significant increase due to the accumulation of HCl in the liquid phase. Novel and relevant features concerning hydrochlorination kinetics, HCl solubility and mass transfer were investigated. An extended reaction mechanism was proposed and a new kinetic model was derived. The model was tested with the experimental data by means of regression analysis, in which kinetic and mass transfer parameters were successfully estimated. A dimensionless number, called Catalyst Modulus, was proposed as a tool for corroborating the kinetic model. Reactive flash distillation experiments were conducted to check the commonly accepted hypothesis that removal of water should enhance the glycerol hydrochlorination kinetics. The performance of the reactive flash distillation experiments were compared to the semi-batch data previously obtained. An unforeseen effect was observed once the water was let to be stripped out from the liquid phase, exposing a strong correlation between the HCl liquid uptake and the presence of water in the system. Water has revealed to play an important role also in the HCl dissociation: as water was removed, the dissociation of HCl was diminished, which had a retarding effect on the reaction kinetics. In order to obtain a further insight on the influence of water on the hydrochlorination reaction, extra semi-batch experiments were conducted in which initial amounts of water and the desired product were added. This study revealed the possibility to use the desired product as an ideal “solvent” for the glycerol hydrochlorination process. A co-current bubble column was used to investigate the glycerol hydrochlorination process under continuous operation. The influence of liquid flow rate, gas flow rate, temperature and catalyst concentration on the glycerol conversion and product distribution was studied. The fluid dynamics of the system showed a remarkable behaviour, which was carefully investigated and described. Highspeed camera images and residence time distribution experiments were conducted to collect relevant information about the flow conditions inside the tube. A model based on the axial dispersion concept was proposed and confronted with the experimental data. The kinetic and solubility parameters estimated from the semi-batch experiments were successfully used in the description of mass transfer and fluid dynamics of the bubble column reactor. In light of the results brought by the present work, the glycerol hydrochlorination reaction mechanism has been finally clarified. It has been demonstrated that the reactive distillation technology may cause drawbacks to the glycerol hydrochlorination reaction rate under certain conditions. Furthermore, continuous reactor technology showed a high selectivity towards monochlorohydrins, whilst semibatch technology was demonstrated to be more efficient towards the production of dichlorohydrins. Based on the novel and revealing discoveries brought by the present work, many insightful suggestions are made towards the improvement of the production of αγ-dichlorohydrin on an industrial scale.

Mesure de la concentration en métaux traces dans la solution de sol par microlysimétrie

La présente étude porte sur l’évaluation d’une méthode d’acquisition de la solution de sol présente à l’interface sol-racine, dans la rhizosphère. Cette interface constitue le lieu privilégié de prise en charge par les plantes des contaminants, tels que les métaux traces. Comme les plantes acquièrent ces éléments à partir de la phase liquide, la solution de sol de la rhizosphère est une composante clé pour déterminer la fraction de métaux traces biodisponibles. La microlysimétrie est la méthode in situ la plus appropriée pour aborder les difficultés liées à l’échelle microscopique de la rhizosphère. Ainsi, dans les études sur la biodisponibilité des métaux traces au niveau de la rhizosphère, les microlysimètres (Rhizon©) gagnent en popularité sans, toutefois, avoir fait l’objet d’études exhaustives. L’objectif de cette étude est donc d’évaluer la capacité de ces microlysimètres à préserver l’intégrité chimique de la solution, tout en optimisant leur utilisation. Pour ce faire, les microlysimètres ont été soumis à une série d’expériences en présence de solutions et de sols, où la quantité de solution prélevée et le comportement des métaux traces (Cd, Cu, Ni, Pb, Zn) ont été étudiés. Les résultats montrent que les microlysimètres fonctionnent de façon optimale lorsque le contenu en eau du sol est au-dessus de la capacité au champ et lorsqu’il y a peu de matière organique et d’argile. Les sols sableux ayant un faible contenu en C organique reproduisent mieux le volume prélevé et la solution sous la capacité au champ peut être récoltée. L’utilisation des microlysimètres dans ces sols est donc optimale. Dans les essais en solution, les microlysimètres ont atteint un équilibre avec la solution après 10 h de prélèvement. En respectant ce délai et les conditions optimales préalablement établies (pH acide et COD élevé), les microlysimètres préservent la composition chimique de la solution. Dans les essais en sol, cet équilibre n’a pas été atteint après dix jours et huit prélèvements. Le contenu en matière organique et l’activité microbienne semblent responsables de la modification des concentrations en métaux au cours de ces prélèvements, notamment, dans l’horizon FH où les microlysimètres performent très mal. En revanche, dans l’horizon B, les concentrations tendent à se stabiliser vers la fin de la série de prélèvements en se rapprochant des valeurs de référence. Bien que des valeurs plus élevées s’observent pour les microlysimètres, leurs concentrations en métaux sont comparables à celles des méthodes de référence (extrait à l’eau, lysimètres de terrain avec et sans tension). En somme, les microlysimètres se comportent généralement mieux dans l’horizon B. Même si leur utilisation est plus optimale dans un sol sableux, cet horizon est privilégié pour de futures études sur le terrain avec les microlysimètres.

Préparation d'échantillons pour l'étude par GISAXS des mécanismes de déformation des matériaux par faisceaux d'ions lourds de haute énergie.

Le mécanisme menant à des déformations structurales suivant le bombardement d'échantillons de a-Si d'un faisceau d'ions lourds et rapides est sujet de controverses. Nous nous sommes penchés sur l'hypothèse de la formation d'une zone liquide causée par la déposition d'énergie des ions incidents dans le contexte de la théorie du pic thermique. Des échantillons de silicium amorphe furent préparés dans le but d'observer les indices d'une transition de phase l-Si/a-Si suivant la déposition locale d'énergie sur le parcours d'un ion lourd énergétique dans le a-Si. Les échantillons furent implantés d'impuretés de Cu ou d'Ag avant d'être exposés à un faisceau d'ions Ag12+ de 70 MeV. L'utilisation de l'analyse GISAXS est projetée afin d'observer une concentration locale d'impuretés suivant leur ségrégation sur la trace de l'ion. Des masques d'implantation nanométriques d'oxide d'aluminium ont été fabriqués afin d'augmenter la sensibilité de l'analyse GISAXS et une méthode d'alignement de ces masques selon la direction du faisceau fut développée. Le bombardement d'échantillons au travers de ces masques a donné lieu à un réseau de sites d'impacts isolés presque équidistants.

The effects of additives and chemical modification on the solution properties of thermo-sensitive polymers

Cette thèse concerne l’étude de phase de séparation de deux polymères thermosensibles connus-poly(N-isopropylacylamide) (PNIPAM) et poly(2-isopropyl-2-oxazoline) (PIPOZ). Parmi des études variées sur ces deux polymères, il y a encore deux parties de leurs propriétés thermiques inexplicites à être étudiées. Une partie concerne l’effet de consolvant de PNIPAM dans l’eau et un autre solvant hydromiscible. L’autre est l’effet de propriétés de groupes terminaux de chaînes sur la séparation de phase de PIPOZ. Pour ce faire, nous avons d’abord étudié l’effet de l’architecture de chaînes sur l’effet de cosolvant de PNIPAMs dans le mélange de méthanol/eau en utilisant un PNIPAM en étoile avec 4 branches et un PNIPAM cyclique comme modèles. Avec PNIPAM en étoile, l’adhérence de branches PNIPAM de à un cœur hydrophobique provoque une réduction de Tc (la température du point de turbidité) et une enthalpie plus faible de la transition de phase. En revanche, la Tc de PNIPAM en étoile dépend de la masse molaire de polymère. La coopérativité de déhydratation diminue pour PNIPAM en étoile et PNIPAM cyclique à cause de la limite topologique. Une étude sur l’influence de concentration en polymère sur l’effet de cosolvant de PNIPAM dans le mélange méthanol/eau a montré qu’une séparation de phase liquide-liquide macroscopique (MLLPS) a lieu pour une solution de PNIPAM dans le mélange méthanol/eau avec la fraction molaire de méthanol entre 0.127 et 0.421 et la concentration en PNIPAM est constante à 10 g.L-1. Après deux jours d’équilibration à température ambiante, la suspension turbide de PNIPAM dans le mélange méthanol/eau se sépare en deux phases dont une phase possède beaucoup plus de PNIPAM que l’autre. Un diagramme de phase qui montre la MLLPS pour le mélange PNIPAM/eau/méthanol a été établi à base de données expérimentales. La taille et la morphologie de gouttelettes dans la phase riche en polymère condensée dépendent de la fraction molaire de méthanol. Parce que la présence de méthanol influence la tension de surface des gouttelettes liquides, un équilibre lent de la séparation de phase pour PNIPAM/eau/méthanol système a été accéléré et une séparation de phase liquide-liquide macroscopique apparait. Afin d’étudier l’effet de groupes terminaux sur les propriétés de solution de PIPOZ, deux PIPOZs téléchéliques avec groupe perfluorodécanyle (FPIPOZ) ou groupe octadécyle (C18PIPOZ) comme extrémités de chaîne ont été synthétisés. Les valeurs de Tc des polymères téléchéliques ont beaucoup diminué par rapport à celle de PIPOZ. Des micelles stables se forment dans des solutions aqueuses de polymères téléchéliques. La micellization et la séparation de phase de ces polymères dans l’eau ont été étudiées. La séparation de phase de PIPOZs téléchéliques suit le mécanisme de MLLPS. Des différences en tailles de gouttelettes formées à l’intérieur de solutions de deux polymères ont été observées. Pour étudier profondément les différences dans le comportement d’association entre deux polymères téléchéliques, les intensités des signaux de polymères correspondants et les temps de relaxation T1, T2 ont été mesurés. Des valeurs de T2 de protons correspondants aux IPOZs sont plus hautes.

Surface Properties and Catalytic Activity of Manganese Ferrospinels

In recent years considerable advances have been achieved in the study of the surface structure and mechanism of action of environmentally benign heterogeneous catalysts. The study entitled as surface properties and catalytic activity of manganese ferrospinels. In the present study we have prepared manganese ferrospinels of general formula Mn(1-x)BxFe2O4 via low temperature controlled co-precipation method. The study employed low temperature co-precipitation method for the preparation ofMn(1-x)BxFe2O4 specimens, where B is a metal cation such as Cr,Co, Ni,Cu and Zn. The catalytic activities of the systems were investigated for liquid-phase benzoylation of aromatic compounds and phenol hydroxylation and for vapour-phase reactions such as aniline alkylation, phenol methylation and ODH of ethylbenzene. The different series of manganese ferrites are proved to be excellent catalysts for various industrially important reactions such as Friedel-crafts benzoylation of aromatic compounds, methylation of aniline and phenol, hydroxylation of phenol and oxidative dehydrogenation of ethylbenzene. Due to the tightening of the environmental regulations, production of diphenols from phenol hydroxylation and reduction of phenolic pollutants in waste waters using these catalysts can be a promising approach because it demands only simple techniques and produce little environmental pollution.

Synthesis, characterisation and benzylation activity of vanadia impregnated iron pillared montmorillonite

Iron pillared Montmorillonite has been synthesised and it is then wet impregnated with vanadia with different vanadia composition. These catalysts are characterised using conventional techniques such as XRD analysis,FTIR analysis and surface area and pore volume measurements. Acidity is measured using spectrophotometric monitoring of adsorption of perylene, thermogravimetric desorption of 2.6 dimethylpyridine and temperature programmed desorption of ammonia. Activity studies are done in the liquid phase. It has been concluded that Lewis acidic sites are responsible for the benzylation of toluene when the benzylating agent is benzyl chloride while Bronsted acidic sites are responsible when the reagent is benzyl alcohol.

Catalytic activity of lanthanum oxide for the reduction of cyclohexanone

Lanthanum oxide, La2O3 has been found to be an effective catalyst for the liquid phase reduction of cyclohexanone. The catalytic activities of La2O3 activated at 300, 500 and 800·C and its mixed oxides with alumina for the reduction of cyclohexanone with 2-propanol have been determined and the data parallel that of the electron donating properties of the catalysts. The electron donating properties of the catalysts have been determined from the adsorption of electron acceptors of different electron affinities on the surface of these oxides.

Surface acidity/basicity and catalytic activity of Zr-Sm mixed oxide systems

The surface acidity and basicity of oxides of Sm and Zr and their mixed oxides have been determined using a set of Hammett indicators. The data have been correlated with the catalytic activity of these oxides towards the liquid phase reduction of cyclo-hexanone in 2-propanol.

Structural and catalytic investigation of vanadia supported on ceria promoted with high surface area rice husk silica

Rice husk silica was utilized as the promoter of ceria for preparing supported vanadia catalysts. Effect of vanadium content was investigated with 2–10 wt.% V2O5 loading over the support. Structural characterization of the catalysts was done by various techniques like energy dispersive X-ray (EDX), X-ray diffraction (XRD), BET surface area, thermal analysis (TGA/DTA), FT-infrared spectroscopy (FT-IR), UV–vis diffused reflectance spectroscopy (DR UV–vis), electron paramagnetic spectroscopy (EPR) and solid state magnetic resonance spectroscopies (29Si and 51V MASNMR). Catalytic activity was studied towards liquid-phase oxidation of benzene. Surface area of ceria enhanced upon rice husk silica promotion, thus makes dispersion of the active sites of vanadia easier. Highly dispersed vanadia was found for low V2O5 loading and formation of cerium orthovanadate (CeVO4) occurs as the loading increases. Spectroscopic investigation clearly confirms the formation of CeVO4 phase at higher loadings of V2O5. The oxidation activity increases with vanadia loading up to 8 wt.% V2O5, and further increase reduces the conversion rate. Selective formation of phenol can be attributed to the presence of highly dispersed active sites of vanadia over the support.

Catalytic activity of some of the perovskite-type mixed oxides (ABO3) consisting of rare earth and 3d transition metals

The catalytic activity of some of the ABO3 (A = La, Pr and Sm, B= Cr, Mn, Fe, Co and Ni) perovskite-type oxides for the liquid phase reduction of ketone and oxidation of alcohol in 2-propanol medium has been studied. The data have been correlated with the surface electron donor properties of these oxides. The surface electron donor properties have been determined from the adsorption of electron acceptors of varying electron affinities on the oxide surface.

The surface acidity/basicity and catalytic activity of ternary oxides of La, Ce and AI

The surface acidity and basicity of ternary oxides of La, Ce and AI have been determined using a set of Hammett indicators. The data have been correlated with the catalytic activity of these oxides towards the liquid phase reduction of cycIohexanone in 2-propanol.