Industrial-scale Tests Research Articles

Water purification from pesticides by spiral wound nanofiltration membrane

An alternative ultrafiltration membrane integrity test was already developed in laboratory scale. It is based on the use of magnetic nanoparticles (Fe3O4) and measurement of magnetic susceptibility. The mean size of nanoparticles used is around 35 nm and they show a good disparity between 20 and 100 nm. In this paper, validation of this membrane integrity monitoring method was achieved by industrialscale tests. Two holes with 0.6 mm internal diameter in a module containing 10 000 fibers (35 m2 surface area) was efficiently detected by injecting 750 mL of 1.7 g.L−1 nanoparticle solution during 2s when the test was operated at low TMP (0.096 bar, corresponding to a flux of 2.2 m3.h−1). In addition, it has been demonstrated that within the detectable range, this membrane integrity test with magnetic nanoparticles has a very rapid response time. The response time depends on the permeate flux and the dead-volume of the pilot. This membrane integrity test, with the advantages of on-line operation, high detection sensitivity, detection specificity and very low influence on membrane fouling, seems to be suitable for large scale drinking water plants.

Selection of substitute fuel for the boilers in the 500 MW units of the Reftinskaya GRÉS

This is an analysis of computational and analytical studies of the suitability of a wide range of Russian coals, and of industrial-scale combustion tests of several Kuznetsk coals, including a mixture of Krasnobrodskii and Ekibastuz coals in a 1:1 proportion, for use in the 500 MWunits of the Reftinskaya GRES (State regional electric power plant), where Ekibastuz coal is traditionally used.

冷間鍛造現場における潤滑の可視化

Technology used to visualize lubrication behavior easily was developed for cold forging. The material described herein is a lubricant using fluorescence. Industrial-scale tests demonstrate that this technology is useful.

Gas-Liquid Reaction Model in Gas-Stirred Systems: Part 1. Numerical Model

A finite-element turbulent model for the fluid-dynamic and the interfacial mass transfer in gas-stirred ladles was developed. The model is based on a dispersed two-phase Eulerian–Eulerian approach and constructs the gas-phase velocity as the liquid velocity plus a gas-liquid slip velocity. In this work, such slip velocity is calculated in terms of the so called “drift flux model.’’ The model is able to describe both desgasification and gas absorption processes in liquid steel systems. The influence of different chemical species was taken into account. Validation was made using experimental data obtained from the literature. These data came from two sources: laboratory and industrial scale tests. The presented model can simulate the turbulent flow pattern and the gas-liquid mass transfer with reasonable accuracy.

Potential use of the slurry fraction of electrofused corundum in the production of periclase refractories

Results of laboratory and industrial-scale tests on the potential use of an unshaped periclase refractory mix modified with the slurry fraction of electrofused corundum containing 85% Al2O3 are reported. The optimum concentration of slurry fraction is shown to be 12–14 wt.%. Routes towards utilization of wastes in the production of abrasive materials are discussed.

Use of boron waste as a fluxing agent in production of red mud brick

The study was directed towards determining the usability of clay and fine wastes (CW and FW) of boron from the concentrator plant in Kirka (Turkey) as a fluxing agent in production of red mud (RM) brick. Both laboratory studies on the characterization of materials and industrial-scale tests for production of bricks were carried out. CW and FW, which have similar chemical composition but include different types and amounts of oxides, were added in amounts of 5, 10 and 15 wt% to RM, which consists of high amounts of Fe 2O 3, Al 2O 3, SiO 2 and alkalies. Six different sets of samples have been produced and fired at 700, 800 and 900 °C. Dry shrinkage of green body, bending and compressive strength, firing shrinkage, water absorption, frost resistance and harmful magnesia and lime tests on heat-treated bodies have been performed. The mineralogical and mechanical tests showed that usability of boron wastes as a fluxing agent in the production of RM bricks was possible. In addition, the samples obtained by adding 15 wt% CW and FW to RM showed the best mechanical characteristic.

Evaluation of models and correlations for pressure drop estimation in dense phase pneumatic conveying and an experimental analysis

This study reviews the models and correlations for dense phase conveying in an effort to explore existing and new data on the subject and to provide guidance to the designer on the best pressure drop model. Using various data sets the Mi (Konrad)-based model was found to be best for predicting the pressure drop across dense phase plugs. A series of industrial scale tests also shows agreement with the Mi (Konrad)-based model.

Industrial development of a novel sulfate system for copper pyro-refining

The results of a complete series of industrial-scale tests carried out at the Noranda Horne smelter using a novel molten sulfate salt for copper pyro-refining are described in this article. In the process, copper co-exists with a molten oxide layer and a molten CaSO4-Na2SO4 layer, both of which have refining capabilities. The effect of the composition of the sulfate salt and that of the copper oxide slag on the distribution of minor elements between copper, oxidic slag, and the sulfate phase are presented.

Development of the Radially Stratified Flame Core Low NOx Burner: From Fundamentals to Industrial Applications

Research and development of the low NOx radially stratified flame core (RSFC) burner is followed from its fundamental concept through prototype burner design, pilot scale experiments at M.I.T. and scale-up and commercial design by ABB-CE (now ALSTOM Power) to applications in industrial and utility plant boilers. The principle that turbulence can be significantly damped in a rotating flow field with a strong positive radial density gradient was used to increase the fuel rich zone residence time in internally staged low NOx burners. The continuous interaction of ideas from laboratory experimental and computational studies with those from the commercial design and industrial scale tests played a pivotal role in the development of the final product, the commercial RSFC burner. Examples of application in gas, oil, and coal fired industrial and utility boilers are discussed.

Thermal Exploitation of Wastes with Lignite for Energy Production

The thermal exploitation of wastewood with Greek lignite was investigated by performing tests in a laboratory-scale fluidized bed reactor, a 1-MWth semi-industrial circulating fluidized bed combustor, and an industrial boiler. Blends of natural wood, demolition wood, railroad sleepers, medium-density fiberboard residues, and power poles with lignite were used, and the co-combustion efficiency and the effect of wastewood addition on the emitted pollutants were investigated. Carbon monoxide, sulfur dioxide, and oxides of nitrogen emissions were continuously monitored, and, during the industrial-scale tests, the toxic emissions (polychlorinated dibenzodioxins and dibenzofurans and heavy metals) were determined. Ash samples were analyzed for heavy metals in an inductively coupled plasma-atomic emission spectroscopy spectrophotometer. Problems were observed during the preparation of wastewood, because species embedded with different compounds, such as railway sleepers and demolition wood, were not easily treated. All wastewood blends were proven good fuels; co-combustion proceeded smoothly and homogeneous temperature and pressure profiles were obtained. Although some fluctuations were observed, low emissions of gaseous pollutants were obtained for all fuel blends. The metal element emissions (in the flue gases and the solid residues) were lower than the legislative limits. Therefore, wastewood co-combustion with lignite can be realized, provided that the fuel handling and preparation can be practically performed in large-scale installations.

Use of soda-lime scrap-glass as a fluxing agent in a porcelain stoneware tile mix

Abstract The study was directed towards determining the feasibility of using soda-lime scrap-glass as a fluxing agent in a porcelain stoneware tile mix. Both laboratory and industrial scale tests were carried out. Starting from a reference mix composition, different amounts (5–20 wt.%) of sodium feldspar were replaced with the same amounts of soda-lime scrap-glass. The soda-lime scrap-glass was added in the form of powder, prepared by wet grinding in a centrifugal ball mill. The rheological study of the resulting slips showed that increasing the amount of glass in the mix composition increased the viscosity but decreased the yield stress. Both the laboratory experiments and results of industrial trials showed that the only mix in which the soda-lime glass acted as a good fluxing agent, i.e. lowered the firing temperature, was the mix in which the scrap-glass replaced 10 wt.% of the sodium feldspar. This mix also showed better mechanical characteristics, attributed to enhanced microstructural homogeneity.

Pyrometallurgical Separation of Boron from Iron in Ludwigite Ore.

Laboratory scale experiments and industrial scale tests have been performed in order to develop a new pyrometallurgical process for the separation of boron from iron in ludwigite ore. The results indicate that boron can be effectively separated from iron in ludwigite ore meantime two products can be got. The boron-containing pig iron can be a good substitute for the expensive boron alloys to produce B-series wear resistant cast while the boron-rich slag can be used to extract borax or boric acid.

Detection of incipient cavitation in pumps using acoustic emission

This work concerns the detection of incipient cavitation in pumps using acoustic emission (AE). Three activities have been pursued in this context: (a) the construction of a small-scale rig for the investigation of cavitation detection using AE sensors; (b) the acquisition of data on a 75 kW single-stage centrifugal pump in an industrial test loop under normal running and cavitation conditions; (c) the determination of parameters that could be used for the early diagnosis of cavitation within pumps. In the laboratory-scale apparatus water was pumped around a short loop by a 3 kW centrifugal pump. The flow loop contained a section specifically designed to induce cavitation by means of reducing the pressure level to that of the vapour pressure of the fluid. This apparatus was used to produce a variety of well-controlled cavitation conditions which were useful in determining the suitability of AE for the detection of cavitation. The industrial-scale tests consisted of progressively reducing the net positive suction head in a 75 kW pump while recording the AE signals at various points on the test loop and pump. Results are presented from both laboratory and full-scale tests which demonstrate the feasibility of detecting incipient cavitation using AE in the face of background noise from normal running of the pump. The features of AE which are indicative of cavitation are also seen to change continuously as NPSH is decreased. Thus early detection of cavitation is possible, certainly before any indication is seen on the dynamic head.

Vitrification of Fission Product Solutions: Investigation of the Effects of Noble Metals on the Fabrication and Properties of R7T7 Glass

The effects of incorporating additional qualities of insoluble dissolution fines containing noble metals together with the fission product feed solutions were investigated for application to the French T7 vitrification facility at La Hague. Three types of tests were conducted: nonradioactive laboratory tests, radioactive laboratory tests, and industrial-scale tests in a prototype vitrification unit. The laboratory test results showed that the quality of R7T7 glass containing from 1.5 to 4 wt% of platinoids is fully equivalent to that of standard R7T7 glass without platinoids. These findings were confirmed on glass casting samples containing 0 to 3 wt% of platinoids from a full-scale industrial vitrification prototype facility. Recent tests in which video cameras have been used to visualize the molten glass and model simulations of glass properties and of melting pot behavior suggest that industrial operating conditions can be optimized to produce glass with platinoid concentrations approaching this limit value.

The use of a qualitative method of control for some process parameters of distillation desalting plants

The advantages and drawbacks of the quantitative (by means of change of the pressure pipeline characteristics or other effects on the liquid flow at constant rotational speed of the centrifugal pump impeller) and qualitative (by means of change of rotational speed of the pump impeller) method of some process parameter control (liquid flow rates and its levels in the apparatus in the distillation desalting plants) are considered. The results of stand and industrial-scale tests of the qualitative method for flow control with nominal flow rate of 1,5 and 230 m 3/h are given. It is found out that the use of the qualitative method of control characteristics, to simplify the desalination installation process diagram, sharply decrease power consumption.

Advantages of Preozonation in the Upgrading of the Mont Valérien Plant in France

Abstract The Mont Valerien plant supplies water to the western suburbs of Paris. Raw water comes from the River Seine downstream from the city. The old plant comprised two treatment lines: a slow sand filtration line built 80 years ago and a rapid settling and filtration line built in 1960. The process for the upgraded plant was determined after an in-depth study including industrial-scale experiments and laboratory tests. The new treatment line includes the following: preozonation, oagulationflocculation and settling in a sludge-blanket type settling tank (PULSATOR), rapid gravity sand filtration, ozonation, and granular activated carbon filtration. Results from laboratory tests used for the design are presented: ozonation rate, advantages for the quality of the treated water, expected reagejit savings, etc.

The use of nonsymmetrical jets for the stabilization of low grade coal flames

Two new aerodynamic methods of flame stabilization have been developed which are especially suitable for low grade pulverized coals or coal-water-slurries. One is based on the Coanda effect, which causes the flat inlet jet of air to attach to the bottom of the precombustion chamber and creates a large recirculation in the upper half of the chamber with strong turbulence and mixing. The inertia of the coal particles projects them into the high temperature zone, thus they quickly ignite and burn, leading to a stable flame. The other is based on an off-axis, slightly tilted primary jet, which produces a three-dimensional flow-field with large recirculation and good mixing. The distribution of coal is also favorable for stable combustion. Precombustion chambers emploing these methods have been demonstrated to be capable of stably burning low grade coals with volatiles less than 15% and ash content higher than 30% in unpreheated combustion air. The construction is very simple, and no extra support such as compressed air, which was necessary on the previously developed method of coflowing jets with large velocity differences, is needed. Both these methods have been developed through experimental and computational cold flow studies, laboratory combustion tests and industrial scale tests. LDV studies were made in plexiglas models, and numerical simulation corroborated the experimental results. With their usefulness and reliability demonstrated on industrial installations, many utility and industrial boiler operators in China are installing them for startup and part-load flame stabilization to conserve the large quantity of oil presently used for these purposes.

CaC<SUB>2</SUB>による溶鋼の不純物除去

In order to reduce the susceptibility to embrittlement of steels such as a rotorshaft for power plant, which are to be used at high temperatures, experiments were carried out on the optimum conditions for the removal of tramp elements like Sn, Sb and As by the addition of CaC2. Industrial scale tests were also carried out, based upon the experimental results obtained. The results obtained can be summarized as follows.(1) These impurities can be removed by reduction, and the reduction was accelerated by the rapid decomposition of CaC2 at low initial carbon content and high temperatures.(2) The amount of impurities removed was found to be proportional to the increase in carbon content during reaction and the initial impurity content. The proportional constant increased in the order of Sn, P, Sb and As.(3) It was found from the industrial scale tests that the impurities could be favorably removed by using Ar stirring from the bottom of the ladle and by using CaC2 injection increasing the reaction surface area.

Production of low-phosphorus stainless steel by AOD process using Li2CO3-CaO-CaF2-FeO flux.

Industrial-scale tests were carried out to produce low phosphorus stainless steels by AOD process using Li2CO3 CaO-CaF2 FeO flux.It has become possible to manufacture low phosphorus stainless steels below 100ppm steadily from molten pig iron containing about 18%, Cr and 0.025% P, by introducing a desiliconization and carburization step and twice dephosphorization steps into a well-established ADD process. It required about 10min to carburize from 3.5 to above 5.0% in AOD vessel and the oxidation of silicon occurred simultaneously during the carburization operation with blowing oxygen. By treating molten pig iron containing chromium for SUS304 using about 65kg/t of the flux, 42-67% of the degree of dephosphorization was obtained stably per treatment for 8min in most cases.The phenomenon was observed that the apparent oxidation rate of phosphorus rather increased slightly, contrary to the decrease in that of chromium with increasing the carbon content of the hot metal before the dephosphorization treatment. The concentration of carbon also had a remarkable effect on the content of Cr2O3 in the slag after the treatment.

Refractory materials for casting diverse steels

The investigations demonstrated the advantages of using electrofused periclase and aluminomagnesia spinel for the manufacture of refractory products for casting rimmed steels and of zirconia and aluminomagnesia spinel for refractories for casting killed steels. These findings were confirmed in industrial-scale tests with batching devices and refractory plates produced from these materials.