Laboratory-scale Tests Research Articles

Noncontact Structural Displacement Measurements Using a Low-Cost Motion Tracking System

Structural health monitoring (SHM) depends on precise displacement measurements to evaluate a structure’s condition. Current measurement systems face challenges such as contact-type restrictions, high costs, uniaxial limitations, and significant computational power requirements. A novel low-cost, non-contact displacement measurement system, called the HTC-VTS (Vive Tracking System), developed by Hongda International Electronics Co., Ltd. (New Taipei City, Taiwan), is proposed. The system setup and data acquisition of the HTC-VTS for SHM involve coordinate transformations to convert six degrees of freedom (DOFs) from raw motion data into 3-DOF structural displacement measurements. The HTC-VTS was experimentally validated using laboratory-scale free vibration tests on a cantilever beam and shaking table tests with actual bridge displacement measurements, demonstrating satisfactory performance in both scenarios. The proposed system expands the potential for cost-effective motion capture systems in both experimental and real-world structural applications.

Continuous Structural Displacement Monitoring Using Accelerometer, Vision, and Infrared (IR) Cameras.

With the rapid development of computer vision, vision cameras have been used as noncontact sensors for structural displacement measurements. However, vision-based techniques are limited to short-term displacement measurements because of their degraded performance under varying illumination and inability to operate at night. To overcome these limitations, this study developed a continuous structural displacement estimation technique by combining measurements from an accelerometer with vision and infrared (IR) cameras collocated at the displacement estimation point of a target structure. The proposed technique enables continuous displacement estimation for both day and night, automatic optimization of the temperature range of an infrared camera to ensure a region of interest (ROI) with good matching features, and adaptive updating of the reference frame to achieve robust illumination-displacement estimation from vision/IR measurements. The performance of the proposed method was verified through lab-scale tests on a single-story building model. The displacements were estimated with a root-mean-square error of less than 2 mm compared with the laser-based ground truth. In addition, the applicability of the IR camera for displacement estimation under field conditions was validated using a pedestrian bridge test. The proposed technique eliminates the need for a stationary sensor installation location by the on-site installation of sensors and is therefore attractive for long-term continuous monitoring. However, it only estimates displacement at the sensor installation location, and cannot simultaneously estimate multi-point displacements which can be achieved by installing cameras off-site.

Tablet coating in lab-scale drum coaters: Combining DEM simulations and spray experiments to predict tablet coating

In pharmaceutical industry the coating of granulates or tablets is an essential production step, which is often realised in a rotating drum moving the tablet bed and a number of spray nozzles installed above this bed. The nozzles atomise the coating liquid through a high-velocity annular air-stream and apply steering air nozzles for producing an oval-shaped spray. The operational conditions determine the produced droplet size spectrum. The collision of the droplets with the solid particles or tablets in the drum and the resulting coating and film thickness strongly influences the product properties of granulates or tablets. In order to be able to predict the coating result, without running time-consuming lab-scale experiments, it is intended to numerically simulate the entire tablet coating process by combining Computational Fluid Dynamics (CFD), the Discrete Element Method (DEM) and the Lagrangian Parcel Concept (LPC) for simulating the spray propagation originating at the nozzle. For doing so, knowledge on the spray droplet properties produced by the two-fluid spray nozzles is indispensable. Therefore, it is necessary to characterise as a first step the local droplet size and velocity distributions in different spray cross-sections, which is the main focus of the present contribution. Such measurements are efficiently done by applying Phase Doppler Anemometry (PDA). It was found that the velocity of the spray emitted from the two-fluid nozzle exceeds almost 200 m/s and the number mean droplet diameter was well below 20 μm. In the initial spray region droplet break-up was observed whereas downstream of 50 mm a slight growth of the mean droplet size indicated further coalescence. Due to the applied pattern air, the spray flux distribution at the normally located tablet bed (i.e., 100–150 mm downstream the nozzle) has an oval shape and the mean droplet velocity still exceeds almost 50 m/s with a mean droplet diameter of about 10 μm. The cross-sectional measurements are used to provide proper inlet conditions for the spray simulations, while the other cross-sections are used for validating the computed spray expansion and dispersion. For demonstrating the effect of a real measured spray flux distribution on the tablet coating quality, additionally DEM simulations were conducted. Here, the measured spray flux data were mapped onto the temporarily evolving and moving tablet surface simulated for a lab-scale test drum by DEM. The uniformity of tablet coating (inter-tablet variability) was judged by calculating the Coefficient Of Variation (COV) for the considered different tablet shapes and operational conditions.

Soil moisture content estimation using active infrared thermography technique: An exploratory laboratory study

Small scale laboratory testing was conducted to estimate the moisture content of sandy soils using a non-destructive and non-contact infrared thermography (IRT) technique. Tests were carried out by applying an external halogen lamp light (400 ​W). In this study, the aim was to explore the feasibility of using IRT to assess the moisture content of sandy soil. The laboratory tests conducted included evaluating soil physical characteristics such as grain size distribution. Soil samples were prepared with five different moisture content percentages. The soil moisture content was then evaluated using two different techniques. The first is the gravimetric oven dry method as per (ASTM D2216, 2019). The second is the IRT Technique. During the second procedure the samples were photographed with an ICI IR-Pad 640 ​P Series camera, which had an image resolution of 640 ​× ​480 pixels and a capture rate of 6 frames/minute. The emissivity correction used was 0.98. The soil surface temperature was captured in both the heating and the cooling phase, with the temperature taken from a specific thermal image area called the region of interest (ROI). Moisture content measurements were taken for each sample using the oven-drying method at the initial stage, and at the end of the heating and cooling phases. The procedure produced a good correlation between moisture content and surface temperature in the heating phase. The soil moisture content and surface temperatures were inversely related and formed a linear line with a high degree of accuracy (r2 ​= ​0.9138). A validation check is done at the end for a sample with random moisture content using the IRT technique where the moisture content was found to be 6.81%, this value was confirmed with the oven dry procedure. It was found that IRT successfully estimated soil moisture content.

Polymer/ionic liquid pilot scale membrane prototype for the recovery of difluoromethane (R-32) from refrigerant mixtures

Difluoromethane (R-32) is a hydrofluorocarbon (HFC) that has been massively used over the last 30 years in refrigeration and air conditioning as a primary component of azeotropic or close boiling refrigerant mixtures. Despite environmental directives commanded to drastically reduce the use of HFCs, R-32 has excellent thermodynamic properties and moderate GWP, thus its recovery from depleted mixtures collected from end-of-life equipment is sought to synthesize alternative low-GWP refrigerant blends. Membrane separation using composite polymer/ionic liquid membranes based on poly-ether-block-amide have shown potential to separate R-32 from other fluorinated hydrocarbons, yet the development of this type of composite membranes still remains at laboratory scale. In this work, a spray coating technique was successfully applied to create defect-free thin selective layers of neat Pebax®1657, Pebax®1657/40 wt% [C2C1im][BF4] and Pebax®1657/40 wt% [C2C1im][SCN] coated on porous PVDF substrates. This methodology was transferred from the lab-scale tests (12.6 cm2) to a custom pilot set-up (300 cm2). The pilot results confirmed the superior performance and stability of [C2C1im][SCN]-based membranes, which allowed the recovery of up to 64.3% and 67.1% R-32 from the refrigerant mixtures R-410A (69.8 mol % R-32 and 30.2 mol % R-125) and R-454B (82.1 mol % R-32 and 17.9 mol % R-1234yf) at 6 bar, increasing the R-32 permeate concentration up to 89.6 and 95.9 mol %, respectively. These results highlight the need to expand the knowledge of this type of gas separation membranes towards thinner and defect-free selective dense layers with the purpose of approaching their real applications.

Benchmarking and Simulation of Solid-Oxide Steam Electrolysis for Propellant Production in a Vacuum Chamber-Simulated Lunar Environment

Federal space agencies across the globe have prioritized development of in-situ resource utilization (ISRU) technology, such as propellants from lunar ice, to support space activities. High-temperature, solid oxide electrolysis cell (SOEC) systems integrated with an efficient balance-of-plant (BOP) have the potential to produce H2 and O2 at specific energy (kWhelec/kgH2) lower than conventional liquid-phase alkaline and PEM electrolysis systems, due to lower voltages for steam electrolysis (vs. liquid H2O). This NASA-sponsored collaboration explored the feasibility of achieving such low specific energy in a high-temperature SOEC system operating in a cryo-vacuum characteristic of permanently shadowed craters on the lunar surface where H2O ice can be found. A lab-scale »2.5-kWelec SOEC stack and BOP achieved a specific energy < 50 kWhelec/kgH2 at a production rate of > 0.075 kgH2/h operating in a cryo-vacuum chamber. System-level simulation models of the lab-scale SOEC stack were benchmarked with experimental tests and used to explore scaling of a system for lunar deployment. The lab-scale tests and scale-up modeling suggest a pathway to a MW-scale SOEC system that can achieve < 46 kWhelec/kgH2 with relatively low specific mass (kgsystem/(kgH2/h)).

Fatigue failure and energy evolution of double-stepped fissures contained marble subjected to multilevel cyclic loads: a lab-scale testing

The instability of rock mass induced by the deterioration and failure of rock bridge is often encountered in hard rock engineering. Under engineering disturbance, a steep and gentle stepped sliding surface is prone to forming along the rock bridges between the intermittent rock joints, which directly controls the rock mass instability modes. In order to reveal the influence of fissure angle on the fatigue deterioration and energy evolution mechanism of stepped double-flawed hard rock, the multilevel cyclic loading mechanical test were carried out on flawed marble samples with fissure angle of 10°, 30°, 50°, and 70° angles. The testing shows that rock strength, fatigue lifetime, peak strain and dissipated energy increase with increasing fissure angle and the increase rate of them becomes sharply in the high cyclic level. In addition, the increase of dissipated energy accelerates with the increase of cyclic loading level, and shows a sudden increase trend in the last cyclic loading stage. When the joint fissure angle is 10°, the dissipated energy is the smallest and the dissipated energy is the largest at 70°. Moreover, a damage evolution model based on dissipated energy is established to describe the characteristics of damage accumulation. The model is in good agreement with the experimental data and reflects the nonlinear characteristics of damage accumulation.

Non-contact Ultrasonic Sonar-based Ranging Technique for In-motion 3D Railroad Tie Deflection Measurements

This paper presents an ultrasonic technique for non-contact surface deflection mapping of railroad ties using concepts of sonar-based ranging. The technique utilizes an array of capacitive ultrasonic transducers arranged along the length of the railroad tie at a lift-off distance of 3 in. from the rail surface to ensure contactless measurements. The transducer array is used in pulse-echo mode and distances from the transducers to the tie surface are measured by tracking the time-of-flight of the waves reflected from the tie surface. A reference-based cross-correlation operation is introduced to compute the time-of-flight, wherein one of the transducers is used as a reference for the distance measurements. The reference-based cross-correlation ensures accurate peak-detection for time-of-flight based differential distance measurements. An acoustic signal strength-based technique is utilized to differentiate between signals reflected from ties and those reflected from ballast. Laboratory scale tests were first performed as a proof-of-concept on a slender wooden beam to measure deflections in loaded and unloaded conditions. Dynamic tests were also performed on this beam to determine the ability to track time-varying positions. Field tests on a replica test track with wood ties were performed at the Rail Defect Testing Facility at University of California San Diego by mounting the prototype on a test-cart moved at walking speed. A dynamic assessment of the prototype was also performed to determine natural frequencies of the mounting beam that may be relevant for future uses at higher speeds. The results indicate the potential of this non-contact system to measure full-field tie deflections in 3D in-motion. This ability may potentially be used to detect conditions of poor tie support that may cause derailments.

The Effect of Scaling Building Configuration Blast Experiments on Positive Phase Blast Wave Parameters

Explosions in an urban setting can have a significant negative impact. There is a need to further understand the loading effects caused by the blast’s interaction with structures. In conjunction with this, the effects of scaling and understanding the limitations of laboratory experiments are equally important given the cost incurred for full-scale experiments. The aim of this study was to determine the scaling effects on blast wave parameters found for reduced-scale urban blast scenario laboratory experiments. This paper presents the results of numerical modelling and physical experiments on detonating cuboidal PE-4 charges and measuring the pressure in direct line of sight and at three distinct positions around the corner of a small-scale “building” parallel to the rear wall. Two scales were used, namely 75% and 100%. Inter-scaling between 75% and 100% worked fairly well for positions shielded by the corner of the wall. Additionally, the lab-scale results were compared to similar (but not identical) field trials at an equivalent scale of 250%. The comparison between lab-scale idealised testing and the larger-scale field trials published by Gajewksi and Sielicki in 2020, indicated sensitivity to factors such as detonator positioning, explosive material, charge confinement/mounting, building surface roughness, and environment.

Design of a concept wedge-shaped self-levelling railway sleeper

Differential railway track settlement can result in ballast voids, leading to sleepers that hang from the rail and are no longer supported by the ballast. These hanging sleepers are damage for track component. As a solution, this paper proposes and investigates a new concept sleeper with a wedge-shaped geometry, intended to stimulate the migration of ballast into any voids, thus reducing the occurrence of hanging sleepers. A series of scaled laboratory tests and 2D and 3D discrete element simulations are used to investigate different wedge-shaped geometries. The investigations include the wedge type (single long wedge versus multiple mini-wedges) and the wedge angle (30, 45, 60 degrees). First, the scaled laboratory tests are used to study the performance of different wedge geometries. Next, 3D DEM simulations are performed to analyse the contact forces in the ballast due to different wedge designs. Finally, 2D DEM simulations are performed to study the settlement behaviour. The main conclusions are that a single long wedge is preferable compared to multiple smaller wedges. when the wedge sleeper angle is larger than the ballast’s angle of repose, particles have the freedom to migrate into the settlement induced voids. Also, an increased wedge sleeper angle stimulates greater particle migration and thus improves the support correction. However the longer wedge also leads to a decrease in effective ballast height under sleeper which may make retrofitting on existing lines challenging.

Comparative Assessment of Wildland Fire Rate of Spread Models: Effects of Wind Velocity

Wildland fire rate of spread prediction models are important tools for the effective coordination of resident evacuation and fire suppression efforts. A comparative assessment of ten empirical and semi-empirical rate of spread prediction models is performed, using a selection of 203 laboratory experiments of surface spreading fires; special emphasis is given to the effects of external wind velocity. Five of the evaluated models have been developed using measurements obtained in laboratory-scale tests; these models are combined with two supplementary sub-models that account for the effects of wind. In addition, a selection of five empirical models that have been developed using large-scale field tests are also assessed. The performance of the ten prediction models is evaluated, both qualitatively and quantitatively, by employing a range of statistical error metrics. The laboratory-developed models are found to exhibit high sensitivity on low fuel load values, when no external wind is present, as well as on low packing ratios and high wind velocity values. The field-developed models exhibit significant discrepancies against the experimental data, due to the use of specific parameters regarding fuel type, scale and wind velocity.

A numerical and experimental study on the performance of a conventional H- Darrieus wind rotor with auxiliary blades

This article presents a numerical and experimental investigation of the performance of a conventional H- Darrieus rotor (Known as H-rotor) equipped with auxiliary blades. The study aims to improve the starting ability and the power coefficient (Cp) of the H- rotor. A numerical model is developed using the computational fluid dynamics (CFD) software ANSYS Fluent to simulate the flow field around the rotor. The model is validated with experimental results obtained from a laboratory-scale test rig. From the pressure contour and flow streamline analysis, it can conclude that the auxiliary airfoil serves as a boundary control device, reducing the amount of flow separation and turbulence around the main blade, which further improves the performance of the H-rotor. From the experimental results, the maximum static torque coefficient (Cts) and Cp of the modified H- rotor were found to be 0.11 and 0.18, which is 84% and 22% higher than the conventional H-rotor, respectively. The study concludes that the use of auxiliary blades can enhance the performance of the H-rotor and make it a more competitive option for harnessing wind energy in low-wind speed regions. The findings of this study could have significant implications for the development of small-scale wind turbines.

Considerations for realistic atmospheric environments: An application to corrosion testing

Measured salt compositions in dust collected over roughly the last decade from surfaces of in-service stainless-steel alloys at four locations around the United States are presented, along with the predicted brine compositions that would result from deliquescence of these salts. The salt compositions vary greatly from ASTM seawater and from laboratory salts (i.e., NaCl or MgCl2) commonly used on corrosion testing. The salts contained relatively high amounts of sulfates and nitrates, evolved to basic pH values, and exhibited deliquescence relative humidity values (RH) higher than seawater. Additionally, inert dust in components were quantified and considerations for laboratory testing are presented. The observed dust compositions are discussed in terms of the potential corrosion behavior and are compared to commonly used accelerated testing protocols. Finally, ambient weather conditions and their influence on diurnal fluctuations in temperature (T) and RH on heated metal surfaces are evaluated and a relevant diurnal cycle for laboratory testing a heated surface has been developed. Suggestions for future accelerated tests are proposed that include exploration of the effects of inert dust particles on atmospheric corrosion, chemistry considerations, and realistic diurnal fluctuations in T and RH. Understanding mechanisms in both realistic and accelerated environments will allow development of a corrosion factor (i.e., scaling factor) for the extrapolation of laboratory-scale test results to real world applications.

From the laboratory to the field: Chemical analysis of colored smoke pyrotechnic formulations via mass spectrometry techniques.

Smoke dyes are complex molecular systems that have the potential to form many molecular derivatives and fragments when deployed. The chemical analysis of smoke samples is challenging due to the adiabatic temperature of the pyrotechnic combustion and the molecular complexity of the physically dispersed reaction products. Presented here is the characterization of the reaction byproducts of a simulant Mk124 smoke signal on a multigram scale, which contain the dye disperse red 9 (1-(methylamino)anthraquinone), by ambient ionization mass spectrometry. Our previous work has examined the thermal decomposition of a simplified smoke system consisting of disperse red 9, potassium chlorate, and sucrose by anaerobic pyrolysis gas chromatography mass spectrometry performed at the laboratory milligram scale. The results from the lab scale test were compared with a fully functioned Mk124 in the field. To achieve this, Mk124 smokes were functioned in the presence of sampling swabs that collected byproduct residues from the smoke plume in the ambient environment. These swabs were then analyzed using ambient ionization mass spectrometry to identify the expended pyrotechnic residues, with particular interest in halogenated species. Previous work determined the toxicity of unforeseen byproducts identified on the laboratory scale, which were also detected in the field demonstrating the correlation of the laboratory testing to the fielded systems. By understanding the chemical composition of smokes and their reaction products, potential toxicity effects can be easily assessed, leading to safer formulations with improved performance. These results can help assess how smoke byproducts may impact Warfighter performance, personnel health, and the environment.

An insulated column for lab-scale non-isothermal breakthrough: Impact of thermal effects during CO2 adsorption

Often lab-scale adsorptive breakthrough experiments are conducted in an isothermal manner, whereas industrial-scale adsorption processes are near-adiabatic. In this work, a polyurethane (PUR) insulating column was manufactured to mimic large-scale non-isothermal behavior via laboratory-scale breakthrough tests. Breakthrough tests with a CO2/N2 gas mixture on zeolite 13X (∼5 g) were performed. A bed temperature increase of 62 °C and long cooling times were observed. When compared to a regular steel column, showing a temperature rise of only 12 °C, the column efficiency was approximately 20% lower due to adiabatic effects. The heat evacuated from the adsorbent bed via the column exhaust was used as a measure for the degree of adiabaticity. Up to 46% of the theoretical heat of adsorption could be detected at the PUR column exhaust compared to 4% at the steel column exhaust. The important difference between isothermal, non-isothermal and adiabatic limit behavior was demonstrated through breakthrough experiments and simulations.

Numerically efficient two-step CFD simulation model of flow regime and heat transfer for hot water shower sterilizers

This work was carried out to create a numerically efficient validated simulation model for Hot Water Shower (SWS) sterilizers. The goal of the work was to achieve a more homogeneous temperature and water distribution inside the sterilizers developed in the future. A lab-scale test bench of an SWS sterilizer with a configurable water volume flow rate and temperature was designed to validate the Computational Fluid Dynamics (CFD) model that was created. The heating and cooling phases at water volume flow rates of 20 and 40m3/h per m2 spraying surface were analyzed. Additionally, the flow and film regime were studied. The CFD model was split into two simulation steps to significantly improve the numerical efficiency. The novel two-step approach developed is computationally 1800 times faster as compared with a complete sterilization cycle than a state-of-the-art approach. The simulated temperature of the test load was in good accordance with the experimental measurements. The flow regime was largely accurately replicated. Overall, the created validated CFD model is suitable for upscaling to an industry-sized SWS sterilizer due to its numerical efficiency.

Behavior of FeCrAl-ODS cladding tube under loss-of-coolant accident conditions

To evaluate the behavior of an oxide-dispersion-strengthened FeCrAl (FeCrAl-ODS) cladding tube under loss-of-coolant accident (LOCA) conditions of light-water reactors (LWRs), the following two laboratory-scale LOCA-simulated tests were performed: the burst and integral thermal shock tests. Four burst and three integral thermal shock tests were performed on unirradiated, stress-relieved FeCrAl-ODS cladding tube specimens, simulating ballooning and rupture, oxidation, and quenching, which were postulated during a LOCA. The burst temperature of the FeCrAl-ODS cladding tube was 200–▪ higher than that of the Zircaloy cladding tube, and the FeCrAl-ODS cladding tube's maximum circumferential strain was smaller than or equal to that of the Zircaloy-4 cladding tube. These results indicate that the FeCrAl-ODS cladding tube has higher strength at high temperatures than the conventional Zircaloy cladding tube. The FeCrAl-ODS cladding tube did not fracture after being subjected to an axial restraint load of ∼▪, which is more than 10 times higher than the axial restraint load estimated for existing LWRs, during quenching, following isothermal oxidation at ▪ for ▪. The FeCrAl-ODS cladding tube was hardly oxidized during this isothermal oxidation condition. However, it melted after a short oxidation at ▪ and fractured after abnormal oxidation at ▪ for ▪. Based on these results, the FeCrAl-ODS cladding tube should not fracture in the time range expected during LOCAs below ▪, where no melting or abnormal oxidation occurs.

Microstructural evolution of liquid metal embrittlement in 1.5-GPa-grade Zn-coated hot-press-forming steels

Zn-assisted liquid metal embrittlement (LME) in hot press forming (HPF) steels is attributed mainly to the cracking inside both Zn coating and HPF substrate, but very few studies on how the Zn coating composed of Fe–Zn intermetallic compound of Γ-Fe3Zn10 and Zn-containing ferrite (α-Fe(Zn)) and alloying elements influence the LME cracking have been conducted. In this study, mechanisms of LME were investigated by using laboratory-scale HPF simulation tests in relation with microstructural evolutions of Zn coating and LME cracking. The coating and steel substrate were composed mostly of α-Fe(Zn) and full martensite, respectively, in both reference (Ref) and 1-wt.%-Si-containing (1Si) HPF steels, while the Γ phase was additionally formed at the 1Si steel. The high-temperature tensile test results indicated that the loss of elongation increased with decreasing exposure time near or at 900 °C and with increasing test temperature or Si content. Based on the equilibrium Fe–Zn binary phase diagram, the amount of liquid remained after the austenitization was larger in the 1Si steel than in the Ref steel because the addition of 1 wt% Si retarded the Fe–Zn alloying reaction between the Zn coating and steel substrate to raise the susceptibility to LME. Thus, the Si content should be carefully controlled by appropriately using the HPF process parameters such as the time of austenitization at 900 °C to sufficiently achieve the Fe–Zn alloying reaction.

Application of a hybrid multiphase CFD approach to the simulation of gas–liquid flow at a trapezoid fixed valve for distillation trays

In the present contribution, we demonstrate the application of a hybrid multiphase CFD approach, which allows for simulating dispersed phases as well as resolved interfaces within an Eulerian framework, for the flow on distillation trays for the first time. The morphology adaptive multifield two–fluid model is exemplified for continuous gas–liquid flow on a generic tray setup with a single trapezoid fixed valve. Instead of fully resolving its geometry in the computational grid, the gas inlets are emulated by implementing mass and momentum sources that are applied to local cell zones. Different zone types in terms of volume and curtain area are tested and compared. The simulation results are verified with experimental data from a lab–scale test rig with air–water flow. Local phase fractions were measured using a conductivity sensor array. The comparison of simulated and experimental results reveals that the relevant time–averaged and transient flow characteristics can be predicted satisfactorily if at least an approximate representation of the valve’s geometry in the computational grid is given. However, local differences are observed among the simulated phase distributions due to the varying cell zone volume and hence maximum intensity of the injected momentum.

Removal of Mn (II) from aqueous solution via biosorption technology for a drinking water treatment plant: From laboratory-scale tests to semi-industrial scale predictions

Biosorbents have drawn increasing attention for removing pollutants on lab-scale systems. Although biosorbents are ecofriendly, their potential on large-scale columns has not been assessed yet. This study evaluated the potential of sugarcane bagasse (SB) for the removal of Mn (II) from aqueous media. Firstly, batch experiments were conducted to establish the equilibrium data and predominant adsorption mechanisms. Secondly, a mathematical model was proposed to predict the breakthrough curves in a fixed-bed column. Alternatively, lab- and pilot-scale removal experiments were performed to validate the accuracy of the proposed model. Once the model was validated on both scales, it was employed to predict breakthrough curves for a semi-industrial column under actual conditions of a drinking water treatment plant. Langmuir isotherm (qmax: 2.82 mg/g) and Langmuir kinetic model (R2>0.98 and x2<0.01) reproduced the experimental equilibrium and kinetic behavior. The mathematical model successfully replicated the lab- and pilot-scale breakthrough data (R2>0.95 and x2<0.1). Therefore, its prediction on the semi-industrial scale was reliable. However, short breakthrough and exhaustion times were obtained on this column, which hinders SB from applying in actual raw water. The described methodology can be employed to assess the potential of other biosorbents for industrial applications.