Solid Mixing Research Articles

An experimental flow regime map to dynamically structure gas–solid bubbling fluidized beds

AbstractEmploying oscillatory gas flows to create ordered bubble dynamics in fluidized beds represents a promising approach in reactor design, enhancing efficiency, scalability, and control. This study reports an extensive experimental campaign that identifies the operational regime for structuring Geldart B fluidized beds, introducing a novel pattern recognition algorithm to quantify flow stability and distinguish between “structured” and “unstructured” oscillating beds. The analysis reveals the characteristic features of structured units, including enhanced scalability, homogeneity with narrower bubble size and separation distributions, controlled bubble dynamics, and compartmentalized solid mixing. A nondimensional bubble size, derived from natural frequency and two‐phase theory, is proposed to describe the relationship between oscillation characteristics and bubble nucleation. This allows the formulation of a general map to fine‐tune oscillating bed operations. The study provides the first comprehensive framework for real‐time control of structured beds and sets the stage for further exploration in process intensification and scaling.

Strategy for Fabricating Multiple-Shape Memory Polymeric Materials Based on Solid State Mixing.

Traditionally, multiple shape memory polymers (multiple-SMPs) are created by forming either immiscible blends with high phase continuity (cocontinuous or multilayer phase morphology) or miscible blends that exhibit compositional heterogeneity at the nanoscale. Here, a new strategy for the fabrication of multiple-SMPs is proposed. It consists of the possibility of homogeneous mixing of immiscible polymers in the solid state under high pressure and shear deformation conditions. The blends formed in this way exhibit homogeneity of mixing down to the nanoscale, up to 40-95 nm. The transition from immiscible to miscible blends leads to an improvement not only in shape memory but also in the mechanical performance of the blends formed. Polypropylene (PP) and polystyrene (PS) were selected as pairs of immiscible polymers. The method of solid phase mixing is high pressure torsion (HPT). It was shown that the HPT-processed 50% PP/50% PS blend is able to exhibit an excellent triple shape memory effect (shape fixation of ∼94-95%, and recovery of ∼85-95%) with widely tunable (low and high) transition temperatures.

Recycling Plastic Waste by Solid Phase Mixing

Recycling Plastic Waste by Solid Phase Mixing

Reexamining the Enhanced Solubility of Sodium Laurate/Sodium Oleate Eutectic Mixtures.

Mixtures of multiple surfactants that have superior performance to the individual components are highly sought-after commercially. Mixtures with a reduced Krafft point (TK) are particularly useful as they enable applications at lower temperatures. Such an example is the soap maker's eutectic: the mixture of sodium laurate (NaL) and sodium oleate (NaOl). A true eutectic implies that the two surfactants do not mix in the solid state but mix readily in the micellar solution above TK, leading to a sharp TK depression at a specific composition. However, the NaL/NaOl mixture shows a broad TK depression of >15 °C at a NaOl weight fraction (wO) of about 0.5. Our tie-line analysis shows that pure NaL and NaOl do not coexist in the solid phase on either side of the TK minimum. X-ray analysis of the isolated solids with varying wO reveals that a unique intermediate compound (I.C.) forms in the solid state with a NaL-to-NaOl mole ratio of about 4/3. Below the TK minimum, NaL and the I.C. coexist in the solids for wO < 0.5, whereas the I.C. and NaOl coexist in the solids for wO > 0.5. Each pair of solids exhibits eutectic or monotectic solubility behavior, and the congruent I.C. melting point is so close to that of the eutectic point(s) that a broad TK minimum ensues. Thermal analysis and modeling via the freezing-point depression approach support the above interpretation. The fact that surfactants with other headgroups but the same blend of chain lengths do not exhibit similar depressed TK is a topic for further study.

A Study on the Automatic IoT Based Multiple Solid Mixing and Product Measurement System

Abstract: This project presents an automated system for mixing multiple solid materials and measuring the final product, using Internet of Things (IoT) technology. The system automatically mixes different solid ingredients in the right proportions, ensuring consistency and accuracy. It uses sensors to monitor the mixing process in real-time, sending data to a central control system that makes adjustments as needed. The system also measures the weight and volume of the final product to ensure it meets the required specifications. With IoT integration, the system allows remote monitoring, data tracking, and performance analysis, reducing human error and improving efficiency. This technology is flexible and can be used in industries like food processing, pharmaceuticals, and chemicals, offering a more precise and automated approach to solid mixing and product measurement.

Valorization of Protein Materials Through Mechanochemistry and Self-Assembly.

The concept of combining mixing of solids by milling (a type of mechanochemistry) with aqueous self-assembly provides interesting possibilities for energy efficient production of advanced nanomaterials. Many proteins are outstanding building blocks for self-assembly, a prominent example being the conversion of proteins into protein nanofibrils (PNFs) - a structure related to amyloid fibrils. PNFs have attractive mechanical properties and have a tendency to form ordered materials. They are accordingly of interest as materials for bioplastics and potentially also for more high-tech applications. In this concept article we highlight our effort on valorization of such proteins with hydrophobic organic compounds such an organic dyes and drug molecules, by developing scalable methodology combining mechanochemistry and self-assembly. Compared to more established methodology, mechanochemical methodology is a valuable complement as it allows potential scalable production of hybrids between e. g. proteins and highly hydrophobic compounds - a class of hybrid material that is difficult to access by other means. This may allow for development of sustainable processes for fabrication of advanced protein-based materials derivable from renewable source materials.

A Robust Static Model of Basic Oxygen Furnace for Analyzing Emerging Steelmaking Scenarios

A robust static model, which incorporates emerging steelmaking scenarios in terms of solid charge mix with the given hot metal in basic oxygen furnace process, is developed. It employs mass and enthalpy balances to comprehend nonequilibrium conditions, considering four key empirical parameters: iron loss, post‐combustion ratio, heat loss, and undissolved lime content in slag, which are fine‐tuned using plant data through a multivariate approach, ensuring the reliability. The model is validated in a basic oxygen furnace (BOF) shop using data from over 4000 heats, achieving a strike rate of ≈77% for input lime prediction within ±1 ton and ≈80% for input oxygen prediction within ±600 Nm3. Model implementation in BOF shop provides valuable guidance to the operators, resulting in the reduction of average oxygen and lime consumption by 139 Nm3 and 652 kg heat−1, respectively. The model also enables the determination of the maximum scrap utilization of ≈16% for 0.8% silicon and ≈14% for 0.6% silicon in hot metal, respectively. The model aids in calculating the maximum tap temperature for varying hot metal silicon and iron ore addition. Overall, the model optimizes primary steelmaking, enhancing efficiency, reducing resource consumption, and offering insights into alternative iron sources like direct reduced iron.

Enhancing the efficiency of high-order harmonics with two-color non-collinear wave mixing in silica

The emission of high-order harmonics from solids under intense laser-pulse irradiation is revolutionizing our understanding of strong-field solid-light interactions, while simultaneously opening avenues towards novel, all-solid, coherent, short-wavelength table-top sources with tailored emission profiles and nanoscale light-field control. To date, broadband spectra in solids have been generated well into the extreme-ultraviolet (XUV), but the comparatively low conversion efficiency in the XUV range achieved under optimal conditions still lags behind gas-based high-harmonic generation (HHG) sources. Here, we demonstrate that two-color high-order harmonic wave mixing in a fused silica solid is more efficient than solid HHG driven by a single color. This finding has significant implications for compact XUV sources where gas-based HHG is not feasible, as solid XUV wave mixing surpasses solid-HHG in performance. Moreover, our results enable utilizing solid high-order harmonic wave mixing as a probe of structure or material dynamics of the generating solid, which will enable reducing measurement times compared to the less efficient regular solid HHG. The emission intensity scaling that follows perturbative optical wave mixing, combined with the angular separation of the emitted frequencies, makes our approach a decisive step for all-solid coherent XUV sources and for studying light-engineered materials.

Combustion characteristics on ammonia injection velocity and positions for ammonia co-firing with coal in a pilot-scale circulating fluidized bed combustor

Ammonia (NH3) co-firing with coal in thermal power plant offers a viable solution for reducing CO2 emissions. Optimizing the NH3 injection method is crucial to achieving comparable performance and pollutant emissions in NH3–coal co-firing compared to coal only combustion in a circulating fluidized bed combustion system. The impact of NH3 co-firing with coal on the injection velocity and location in related to the NH3 supply method was evaluated. Injection velocity was controlled by varying the number of ammonia supply ports and their heights (0.2 m and 1.8 m from the distributor). Injecting NH3 through one port at a high velocity of 2.4 m/s increases CO emissions while decreasing NO emissions due to the formation of a reducing environment. Conversely, utilizing two ports with low NH3 injection velocity of 1.2 m/s exhibited the opposite trend in CO and NO emissions, achieving the highest combustion efficiency without the formation of N-containing components. This injection velocity promotes better mixing of gases (air and NH3) and solids (bed materials and coal) without hindering coal combustion. Regarding greenhouse gases emissions, the part of CO2 emissions decreased by considering CO2 concentration and flue gas flow rate, while the part of N2O emissions significantly increased due to N-chemistry by > 5 times.

Advancing the Sustainability of Geopolymer Technology through the Development of Rice Husk Ash Based Solid Activators

Rice husk ash (RHA), an agricultural waste byproduct, has already been tested as a component in geopolymeric binders, typically as part of the precursor solid mix, alongside materials like fly ash (FA), slag, and cement. This study presents a novel approach where RHA is employed to create a solid activator, aimed at entirely replacing commercial sodium silicates. The synthesis process involves mixing RHA, NaOH (NH), and water by applying a SiO2/Na2O molar ratio equal to 1, followed by mild thermal treatment at 150 °C for 1 h, resulting in the production of a solid powder characterized by high Na2SiO3 content (60–76%). Additionally, microwave treatment (SiO2/Na2O = 1, 460 W for 5 min) increases the environmental and economical sustainability of alkali silicates production from RHA since this processing is 12 times faster than conventional thermal treatment reducing at the same time the final product’s embodied energy. The efficacy of this new material as a sole solid activator for the geopolymerization of Greek FA is investigated through various techniques (XRD, FTIR, SEM). One-part geopolymers prepared with RHA-based solid activators demonstrated mechanical performance comparable to those prepared with commercial products (~62 MPa at 7 days). This research contributes to the advancement of sustainable construction practices emphasizing the importance of local materials and reduced environmental impact in achieving long-term sustainability goals.

A bilateral semi-resolved CFD-DEM approach for cost-effective modelling in a rotary drum

It is of significance to numerically describe particle-flow interphase flow details at a feasible computational cost. Inspired by the semi-resolved Computational Fluid Dynamics-Discrete Element Method (CFD-DEM), an improved bilateral semi-resolved CFD-DEM approach (BSM) approach is developed in this work. Compared with the conventional divided particle volume method (DPVM) and recent semi-resolved CFD-DEM (SM) approach, the BSM approach allows a higher-resolution mesh and achieves higher accuracy as well as applicability when simulating the transient flow with sharp gradients of solid volume fraction and velocity etc. Then the BSM approach is applied to a rotary drum to demonstrate the effectiveness by investigating the internal hydrodynamics details. The typical flow behaviours are detailed; then the effects of the restitution and friction on the internal flow are analysed with details to demonstrate its effectiveness in terms of repose angle, active–passive zone, solid residence time, particle mixing and axial dispersion. The results show a positive correlation of the active depth, mixing degree, and particle dispersion with the friction, while restitution increasing depicts no significant effects on this particulate flow. This work provides an improved numerical tool for understanding the multiphase transient flows involving sharp gradients.

Enhancement of mechanical properties, durability and service life of low carbon cement paste with super low w/c ratio by incorporating carbon fiber

The high strength and durability of cement-based materials are pivotal for energy conservation and carbon emission reduction. By employing solid water mixing technology, a cement-based material with a significantly high compressive strength was developed. However, the concurrent increase in brittleness prompted the exploration of carbon fiber as a potential bridging agent to improve toughness. This paper investigates the role of carbon fiber reinforcement in enhancing the mechanical properties, durability, and service life of cement paste with a super low water-to-cement (w/c) ratio. The results demonstrated that the addition of 0.3 vol% carbon fiber led to an 18.4 % increase in 28-day flexural strength compared to the control group, as well as a 15.3 % increase in flexural compression ratio. Furthermore, under the same carbon fiber content, the drying shrinkage rate after 150-day exhibited a decrease of 20.3 %, and there was a notable decrease of 35.80 % in compressive strength loss rate after 200 freezing-thawing cycles. Service life was significantly improved. It showed that carbon fiber could improve the toughness and durability of hardened cement paste.

Influence of particle stacking modes on the fluidization characteristics of biomass particles in binary particle systems

Spouted bed is widely used in biomass combustion and other industrial production due to the advantages of good heat transfer performance and sufficient gas–solid mixing. In order to achieve higher heat and mass transfer performance and conversion efficiency, inert particles are often added to assist in the fluidization of biomass particles. However, the stacking patterns of different particles in a binary particle system can have some effects on particle flow, distribution, and bed stability. Therefore, in this study, the computational fluid dynamics–discrete element method was used to analyze the particle fluidization characteristics under four different particle stacking modes in a spouted bed. The results show that the average bed height of larger spherocylindrical particles is prioritized in binary particle systems. The void fraction of spherocylindrical particles tends to increase in the near-wall region, whereas spherical particles tend to decrease. When the binary particles are mixed at the initial moment, the change rule of vertical velocity of the two particles remains consistent. In addition, the vertical velocities of two kinds of particles when layered stacking is used are gradually close to each other only after a period of time. In addition, the orientation angle of the spherocylindrical particles in the spouted bed tends to be horizontal for both the single-component spherocylindrical particle system and the wall effect attenuates this phenomenon.

Influence of Dry-Mixing and Solvent Casting Blending Techniques on the Mechanical and Biological Behavior of Novel Biocompatible Poly(ε-caprolactone)/Alumina-Toughened Zirconia Scaffolds Obtained by 3D Printing

This work focuses on the study and comparison of two mixing methods for the dispersion of Alumina-Toughened Zirconia (ATZ) within the polymer matrix of Poly(ε-caprolactone) (PCL). The dry-mixing method using solvent-free impact milling (M) and the solvent casting method with chloroform (SC) were investigated. Samples were produced by 3D printing, and specimens were printed at increasing ATZ loadings (namely, 10, 20, and 40 wt.%). The chemico-physical, mechanical, and cell interaction characteristics of the materials prepared with both mixing methods were studied. Solvent mixing allowed better dispersion of the ATZ in the polymer matrix with respect to dry mixing. In addition, dry mixing affected the molecular weight of the PCL/ATZ composites much more than the solvent casting method. For these reasons, materials obtained by solid mixing exhibited the worst mechanical performance with respect to those obtained by solvent casting, which showed increased Young’s moduli with increasing ATZ amounts. The in vitro biological response elicited in a mesenchymal stem cell model seemed to be influenced by the mixing method, with a preference for the composites obtained through solvent mixing and containing 20 or 40 wt.% of ATZ.

Renewable methyl acetate production from dimethyl ether carbonylation in a fluidized bed reactor

The carbonylation of bio-based dimethyl ether (DME) using ferrierite offers a renewable approach to methyl acetate (MA) production with a potential reduction in carbon emissions. This work showcases the feasibility of employing fluidized-bed reactors in this process, leveraging benefits such as effective solid mixing, uniform temperature distribution, and facile catalyst purge and makeup. Through parametric studies, the impact of operating conditions on the reaction kinetics and reactor hydrodynamics was elucidated. Both physical and chemical catalyst deactivation were found to be dependent on the fluidization regime. Numerical models based on experimental results enabled the prediction of reaction yield and selectivity in the process simulation and optimization. Preliminary techno-economic analysis (TEA) and life cycle assessment (LCA) showed the potential for a 40% reduction in production costs and an 8% reduction in the global warming potential compared to the fossil-based benchmark. Overall, this study highlights the operation simplicity, cost competitiveness, and environmental benefit of MA production from DME carbonylation in a fluidized-bed reactor, providing insights for process scale-up and feedstock sourcing.

Optimization of simulation model adaptability and CFD of particles of Geldart‐B in a gas–solid fluidized bed for silicone monomer synthesis

AbstractThe flow characteristics of gas–solid in fluidized bed reactors constrain or promote the reaction process by affecting gas–solid mixing homogeneity, heat transfer timeliness, and fluidization stability. To improve the production efficiency of silicone monomers, this work shows a comparative analysis of the effects of geometric modelling in different dimensions, flow state, and the interphase exchange coefficient on the characteristics of particles of Geldart‐B in a gas–solid fluidized bed for silicone monomer synthesis based on two‐fluid models (TFM). The results of different dimensional simulations show that the third dimension plays an important role in the bubble behaviour and the particle volume fraction spatial distribution within the fluidization zone, and the three‐dimensional simulation results are closer to the experimental data, and the maximum average error of the simulation results is 4.52% lower than that of the two‐dimensional simulation results. Meanwhile, the flow model has a greater influence on the bubble behaviour during the flow process, whereas the interphase force model has little effect on the flow state of small‐diameter particles. However, for large‐diameter particles, the interphase force model is closely related to the bubble behaviour and the direction and size of the vortex, and the lift model prediction of bubble breakage and coalescence behaviours are higher than the experimental results from the power spectrum results. The inlet velocity has a greater effect on the formation of vortices near the wall; with the same inlet velocity, the more dispersed the particle distribution in the bed, and the more uniform the gas–solid mixing.

Fluid–Solid Mixing Transfer Mechanism and Flow Patterns of the Double-Layered Impeller Stirring Tank by the CFD-DEM Method

The optimization design of the double-layered material tank is essential to improve the material mixing efficiency and quality in chemical engineering and lithium battery production. The draft tube structure and double-layered impellers affect the flow patterns of the fluid–solid transfer process, and its flow pattern recognition faces significant challenges. This paper presents a fluid–solid mixing transfer modeling method using the CFD-DEM coupling solution method to analyze flow pattern evolution regularities. A porous-based interphase coupling technology solved the interphase force and could be used to acquire accurate particle motion trajectories. The effect mechanism of fluid–solid transfer courses in the double-layered mixing tank with a draft tube can be obtained by analyzing key features, including velocity distribution, circulation flows, power, and particle characteristics. The research results illustrate that the draft tube structure creates two major circulations in the mixing transfer process and changes particle and vortex flow patterns. The circulating motion of the double-layered impellers strengthens the overall fluid circulation, enhances the overall mixing efficiency of the fluid medium, and reduces particle deposition. Numerical results can offer technical guidance for the chemical extraction course and lithium battery slurry mixing.

CFD‐ANN coupling model simulation of gas–solid feeding design for ternary biomass mixtures in bubbling fluidized bed gasifier

AbstractThe performance of continuous feeding fluidized bed reactors is significantly influenced by their design. These reactors can effectively operate with a wide range of biomass mixtures. Therefore, it is imperative to carefully design the gas distributor plate and solid tube inlet to ensure stable fluidization and uniform distribution of fluidizing gas and solid particles within the reactor. This study investigated the impact of gas–solid feeder design in bubbling fluidized bed gasifier for biomass mixtures on system hydrodynamics, employing a computational fluid dynamics–artificial neural network (CFD‐ANN) coupling model to achieve more realistic simulations. A 2k factorial experimental design was adopted to inquire the impact of gas and solid feeding systems. The responses under investigation included the gas–solid mixing index and the solid residence time, both of which hold pivotal roles in specific chemical processes related to biomass utilization in fluidized bed technology. All cases were successfully simulated, and the results uncovered that the position and length of the solid inlet tube wielded a significant influence on reactor performance, particularly concerning solid residence time. Furthermore, the designs of the gas distributor were identified as critical factors capable of enhancing system turbulence and mixing. In summary, the results showed the potential for enhancing reactor performance through the optimization of gas–solid feeding systems and underscored the efficacy of the ANN drag model in simulating continuous biomass gasification systems.

Preparation and properties of hybrid specific length carbon fiber thermoplastic composites by suspension method

AbstractCarbon fiber reinforced thermoplastic composites have such advantages as low density, high strength, high temperature resistance, impact resistance, and good ductility, but due to the density difference between carbon fibers and resin fibers, it is difficult to mix them uniformly. Hence, it is difficult to prepare the composites with the uniform properties. In order to solve this problem, a preparation process based on solid phase mixing of carbon and resin fibers by suspension method is proposed in this paper. The carbon fiber reinforced thermoplastic composites (CFRTPs) can be prepared by dispersing carbon fibers of a certain length (~50 mm) and resin fibers in suspension through ultrasound‐assisted and churn‐combing methods. The effects of carbon fiber length, content and molding process on the mechanical properties of the CFRTPs were studied. The results show that the carbon fiber content and length are the main factors affecting the mechanical properties as well as void ratio of CFRTP. The performance of composites is significantly improved with the increase of carbon fiber length. While the length of carbon fiber is 50 mm and the content is 30 wt%, the prepared CFRTP has the best performance, with the tensile strength of 182.1 MPa, the bending strength of 354.3 MPa, the impact strength of 67.2 KJ·m−2, and the material void ratio of 0.65%. The study shows that the suspension method is feasible for the preparation of the CFRTPs. It is beneficial to improve production efficiency and decrease cost of production for the CFRTPs.Highlights Carbon fiber reinforced thermoplastic composites can be prepared by dispersing carbon fibers of a certain length (~50 mm) and resin fibers in suspension through ultrasound‐assisted and churn‐combing methods. Through the cooling‐high pressure molding process, the porosity of CFRTP is reduced and the mechanical properties of CFRTP are improved. The tensile strength, bending strength, and notch‐free impact strength properties of CFRTP are best when the carbon fiber content is 30% and the CF length is 50 mm. The method is characterized by simple process, low cost and high mechanical properties.

Electrical and Electro-Thermal Characteristics of (Carbon Black-Graphite)/LLDPE Composites with PTC Effect.

Electrical properties and electro-thermal behavior were studied in composites with carbon black (CB) or hybrid filler (CB and graphite) and a matrix of linear low-density polyethylene (LLDPE). LLDPE, a (co)polymer with low crystallinity but with high structural regularity, was less studied for Positive Temperature Coefficient (PTC) applications, but it would be of interest due to its higher flexibility as compared to HDPE. Structural characterization by scanning electron microscopy (SEM) confirmed a segregated structure resulted from preparation by solid state powder mixing followed by hot molding. Direct current (DC) conductivity measurements resulted in a percolation threshold of around 8% (w) for CB/LLDPE composites. Increased filler concentrations resulted in increased alternating current (AC) conductivity, electrical permittivity and loss factor. Resistivity-temperature curves indicate the dependence of the temperature at which the maximum of resistivity is reached (Tmax(R)) on the filler concentration, as well as a differentiation in the Tmax(R) from the crystalline transition temperatures determined by DSC. These results suggest that crystallinity is not the only determining factor of the PTC mechanism in this case. This behavior is different from similar high-crystallinity composites, and suggests a specific interaction between the conductive filler and the polymeric matrix. A strong dependence of the PTC effect on filler concentration and an optimal concentration range between 14 and 19% were also found. Graphite has a beneficial effect not only on conductivity, but also on PTC behavior. Temperature vs. time experiments, revealed good temperature self-regulation properties and current and voltage limitation, and irrespective of the applied voltage and composite type, the equilibrium superficial temperature did not exceed 80 °C, while the equilibrium current traversing the sample dropped from 22 mA at 35 V to 5 mA at 150 V, proving the limitation capacities of these materials. The concentration effects revealed in this work could open new perspectives for the compositional control of both the self-limiting and interrupting properties for various low-temperature applications.