Matching Items (12)
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- All Subjects: chemical engineering
- Genre: Masters Thesis
- Creators: Emady, Heather
Description
Granulation is a process within particle technology where a liquid binding agent is added to a powder bed to create larger granules to modify bulk properties for easier processing. Three sets of experiments were conducted to screen for which factors had the greatest effect on granule formation, size distribution, and morphological properties when wet granulating microcrystalline cellulose and water. Previous experiments had identified the different growth regimes within wet granulation, as well as the granule formation mechanisms in single-drop granulation experiments, but little research has been conducted to determine how results extracted from single drop experiments could be used to better understand the first principles that drive high shear granulation. The experiment found that under a liquid solid ratio of 110%, the granule growth rate was linear as opposed to the induction growth regime experienced at higher liquid solid ratios. L/S ratios less than 100% led to a bimodal distribution comprised of large distributions of ungranulated powder and large irregular granules. Insufficient water hampered the growth of granules due to lack of enough water bridges to connect the granules and powder, while the large molecules continued to agglomerate with particles as they rotated around the mixer. The nozzle end was augmented so that drop size as well as drop height could be adjusted and compared to single-drop granulation experiments in proceeding investigations. As individual factors, neither augmentation had significant contributions to granule size, but preliminary screens identified that interaction between increasing L/S ratio and decreasing drop size could lead to narrower distributions of particles as well as greater circularity. Preliminary screening also identified that decreasing the drop height of the nozzle could increase the rate of particle growth during the 110% L/S trials without changing the growth mechanisms, indicating a way to alter the rate of steady-state particle growth. This paper screens for which factors are most pertinent to associating single-drop and wet granulation in order to develop granulation models that can ascertain information from single-drop granulations and predict the shape and size distribution of any wet granulation, without the need to run costly wet granulation experiments.
ContributorsLay, Michael (Author) / Emady, Heather (Thesis advisor) / Muhich, Christopher (Committee member) / Holloway, Julianne (Committee member) / Arizona State University (Publisher)
Created2019
Description
Rotary drums are commonly used for their high heat and mass transfer rates in the manufacture of cement, pharmaceuticals, food, and other particulate products. These processes are difficult to model because the particulate behavior is governed by the process conditions such as particle size, particle size distribution, shape, composition, and operating parameters, such as fill level and rotation rate. More research on heat transfer in rotary drums will increase operating efficiency, leading to significant energy savings on a global scale.
This research utilizes infrared imaging to investigate the effects of fill level and rotation rate on the particle bed hydrodynamics and the average wall-particle heat transfer coefficient. 3 mm silica beads and a stainless steel rotary drum with a diameter of 6 in and a length of 3 in were used at fill levels of 10 %, 17.5 %, and 25 %, and rotation rates of 2 rpm, 6 rpm, and 10 rpm. Two full factorial designs of experiments were completed to understand the effects of these factors in the presence of conduction only (Case 1) and conduction with forced convection (Case 2). Particle-particle friction caused the particle bed to stagnate at elevated temperatures in Case 1, while the inlet air velocity in Case 2 dominated the particle friction effects to maintain the flow profile. The maximum heat transfer coefficient was achieved at a high rotation rate and low fill level in Case 1, and at a high rotation rate and high fill level in Case 2. Heat losses from the system were dominated by natural convection between the hot air in the drum and the external surroundings.
This research utilizes infrared imaging to investigate the effects of fill level and rotation rate on the particle bed hydrodynamics and the average wall-particle heat transfer coefficient. 3 mm silica beads and a stainless steel rotary drum with a diameter of 6 in and a length of 3 in were used at fill levels of 10 %, 17.5 %, and 25 %, and rotation rates of 2 rpm, 6 rpm, and 10 rpm. Two full factorial designs of experiments were completed to understand the effects of these factors in the presence of conduction only (Case 1) and conduction with forced convection (Case 2). Particle-particle friction caused the particle bed to stagnate at elevated temperatures in Case 1, while the inlet air velocity in Case 2 dominated the particle friction effects to maintain the flow profile. The maximum heat transfer coefficient was achieved at a high rotation rate and low fill level in Case 1, and at a high rotation rate and high fill level in Case 2. Heat losses from the system were dominated by natural convection between the hot air in the drum and the external surroundings.
ContributorsBoepple, Brandon (Author) / Emady, Heather (Thesis advisor) / Muhich, Christopher (Committee member) / Holloway, Julianne (Committee member) / Arizona State University (Publisher)
Created2019
Description
While the solution diffusion model and pore flow model dominate pervaporation transport mechanism modeling, a new model combining the solution diffusion and viscous flow models is validated using membranes with large scale defects exceeding 2 nm in diameter. A range of membranes was characterized using scanning electron microscopy and x-ray diffraction (XRD) to determine quality and phase characteristics. MFI zeolite membranes of He/SF6 pure gas permeation ideal selectivities of 25, 15, and 3 for good, medium, and poor quality membranes were subjected to liquid pervaporations with a 5% ethanol in water feed, by weight. Feed pressure was increased from 1 to 5 atm, to validate existence of viscous flow in the defects. Component molar flux is modeled using the solution diffusion model and the viscous flow model, via J_i=F_i (γ_i x_i P_i^sat )+(ρ )/M_W ∅/μ_ij x_i P_h. A negative coefficient of thermal expansion is observed as permeances drop as a function of temperature in all three membranes, where ϕ=((ϵr_p^2)/τ∆x). Experimental parameter ϕ increased as a function of temperature, and increased with decreasing membrane quality. This further proves that zeolitic pores are shrinking in one direction, and pulling intercrystalline voids larger, increasing the (ϵ/τ) ratio. Permiabilities of the bad, medium, and good quality membrane also decreased over time for both ethanol and water, meaning that fundamental membrane characteristics changed as a function of temperature. To conclude, the model reasonably fits empirical data reasonably well.
ContributorsWilliams, Suzanne Jean (Author) / Lin, Jerry Y.S. (Thesis advisor) / Emady, Heather (Committee member) / Mu, Bin (Committee member) / Arizona State University (Publisher)
Created2016
Description
Pseudo-steady state (PSS) flow is an important time-dependent flow regime that
quickly follows the initial transient flow regime in the constant-rate production of
a closed boundary hydrocarbon reservoir. The characterization of the PSS flow
regime is of importance in describing the reservoir pressure distribution as well as the
productivity index (PI) of the flow regime. The PI describes the production potential
of the well and is often used in fracture optimization and production-rate decline
analysis. In 2016, Chen determined the exact analytical solution for PSS flow of a
fully penetrated vertically fractured well with finite fracture conductivity for reservoirs
of elliptical shape. The present work aimed to expand Chen’s exact analytical solution
to commonly encountered reservoirs geometries including rectangular, rhomboid,
and triangular by introducing respective shape factors generated from extensive
computational modeling studies based on an identical drainage area assumption. The
aforementioned shape factors were generated and characterized as functions for use
in spreadsheet calculations as well as graphical format for simplistic in-field look-up
use. Demonstrative use of the shape factors for over 20 additional simulations showed
high fidelity of the shape factor to accurately predict (mean average percentage error
remained under 1.5 %) the true PSS constant by modulating Chen’s solution for
elliptical reservoirs. The methodology of the shape factor generation lays the ground
work for more extensive and specific shape factors to be generated for cases such as
non-concentric wells and other geometries not studied.
quickly follows the initial transient flow regime in the constant-rate production of
a closed boundary hydrocarbon reservoir. The characterization of the PSS flow
regime is of importance in describing the reservoir pressure distribution as well as the
productivity index (PI) of the flow regime. The PI describes the production potential
of the well and is often used in fracture optimization and production-rate decline
analysis. In 2016, Chen determined the exact analytical solution for PSS flow of a
fully penetrated vertically fractured well with finite fracture conductivity for reservoirs
of elliptical shape. The present work aimed to expand Chen’s exact analytical solution
to commonly encountered reservoirs geometries including rectangular, rhomboid,
and triangular by introducing respective shape factors generated from extensive
computational modeling studies based on an identical drainage area assumption. The
aforementioned shape factors were generated and characterized as functions for use
in spreadsheet calculations as well as graphical format for simplistic in-field look-up
use. Demonstrative use of the shape factors for over 20 additional simulations showed
high fidelity of the shape factor to accurately predict (mean average percentage error
remained under 1.5 %) the true PSS constant by modulating Chen’s solution for
elliptical reservoirs. The methodology of the shape factor generation lays the ground
work for more extensive and specific shape factors to be generated for cases such as
non-concentric wells and other geometries not studied.
ContributorsSharma, Ankush, M.S (Author) / Chen, Kang Ping (Thesis advisor) / Green, Matthew D (Thesis advisor) / Emady, Heather (Committee member) / Arizona State University (Publisher)
Created2017
Description
The purpose of this study was to comprehend the global warming potential (GWP), cost variability, and competitiveness of steel with rising carbon taxes. Aluminum, glass fiber composite, and carbon fiber composite were chosen as competing materials. In order to compare the aforementioned factors, the GWP of several processes to produce steel, aluminum, and fiber composites was examined. Cost analyses of various methods were also carried out to determine their viability. Energy consumption data for each of the paths under consideration were taken from the literature for the study. To get the consistent GWP for traditional and decarbonized scenarios, the required energy is multiplied with corresponding energy source (natural gas or electricity). Even after accounting for the carbon tax and the weight-reduction factor, the results show that steel still has the lowest production costs, followed by aluminum, while fiber composites remain the most costly. EAF- steel and secondary aluminum has least GWP followed by H2-DRI (Hydrogen- Direct Reduced Iron)steel and NG-DRI (Natural Gas- Direct Reduced Iron) steel with carbon capture and storage (CCS). The state of art technology for glass fiber reinforced composite also emits less carbon dioxide but the cost of production is still high. Carbon fiber reinforced composite emits most carbon dioxide and is least economical.
ContributorsRajulwar, Vaishnavi Vijay (Author) / Seetharaman, Sridhar (Thesis advisor) / Emady, Heather (Committee member) / Nian, Qiong (Committee member) / Arizona State University (Publisher)
Created2023
Description
This study presents an evaluation of the predicted flow behavior and the minimum outlet diameter in a computationally simulated hopper. The flow pattern in hoppers was simulated to test three size fractions, three moisture levels of microcrystalline cellulose (MCC), and two hopper wall angles in Multiphase Flow with Interphase eXchanges (MFiX). Predictions from MFiX were then compared to current literature. As expected, the smaller size fractions with lower water content were closer to ideal funnel flow than their larger counterparts. The predicted minimum outlet diameter in simulations showed good agreement with close to ideal flowability. These findings illustrate the connection between lab flowability experiments and computational simulations. Lastly, three fluidized bed simulations were also created in MFiX with zeolite 13X to analyze the pressure and velocity within the bed. The application of flowability simulations can improve the transport of solids in processing equipment used during the production of powders.
ContributorsBuchanan, Lidija (Author) / Emady, Heather (Thesis advisor) / Muhich, Christopher (Committee member) / Deng, Shuguang (Committee member) / Arizona State University (Publisher)
Created2023
Description
Adsorption is fundamentally known to be a non-isothermal process; in which temperature increase is largely significant, causing fairly appreciable impacts on the processkinetics. For porous adsorbent particles like metal organic frameworks (MOFs), silica
gel, and zeolite, the resultant relative heat generated is partly distributed within the
particle, and the rest is transferred to the surrounding ambient fluid (air).
For large step changes in adsorbed phase concentration and fast adsorption rates,
especially, the isothermality of adsorption (as in some studies) is an inadequate assumption and inspires rather erroneous diffusivities of porous adsorbents. Isothermal models, in consequence, are insufficient for studying adsorption in porous adsorbents. Non-isothermal models can satisfactorily and exhaustively describe adsorption
in porous adsorbents. However, in many of the analyses done using the models, the
thermal conductivity of the adsorbent is assumed to be infinite; thus, particle temperature is taken to be fairly uniform during the process—a trend not observed for
carbon dioxide (CO2) adsorption on MOFs.
A new and detailed analysis of CO2 adsorption in a single microporous MOF-5
particle, assuming a finite effective thermal conductivity along with comprehensive
parametric studies for the models, is presented herein. A significant average temperature increase of 5K was calculated using the new model, compared to the 0.7K
obtained using the Stremming model. A corresponding increase in diffusivity from
8.17 x 10-13 to 1.72 x 10-11 m2/s was observed, indicating the limitations of both
isothermal models and models that assume constant diffusivity.
ContributorsNkuutu, John (Author) / Lin, Jerry (Thesis advisor) / Emady, Heather (Committee member) / Deng, Shuguang (Committee member) / Arizona State University (Publisher)
Created2023
Description
This thesis investigated the effects of differing diameters and varying moisture content on the flowability properties of granular glass beads through use of a Freeman FT4 Powder Rheometer. These parameters were tested in order to construct an empirical model to predict flowability properties of glass beads at differing size ranges and moisture contents. The final empirical model outputted an average error of 8.73% across all tested diameters and moisture ranges.
Mohr's circles were constructed from experimentally-obtained shear stress values to quantitatively describe flowability of tested materials in terms of a flow function parameter. A high flow function value (>10) was indicative of a good flow.
By testing 120-180 µm, 120-350 µm, 180-250 µm, 250-350 µm, 430-600 µm, and 600-850 µm glass bead diameter ranges, an increase in size was seen to result in higher flow function values. The limitations of testing using the FT4 became apparent as inconsistent flow function values were obtained at 0% moisture with size ranges above 120-180 µm, or at flow function values of >21. Bead sizes larger than 430 µm showed significant standard deviation over all tested trials--when excluding size ranges above that value, the empirical model showed an average error of only 6.45%.
Wet material testing occurred at all tested glass bead size ranges using a deionized water content of 0%, 1%, 5%, 15%, and 20% by weight. The results of such testing showed a decrease in the resulting flow function parameter as more water content was added. However, this trend changed as 20% moisture content was achieved; the wet material became supersaturated, and an increase in flow function values was observed. The empirical model constructed, therefore, neglected the 20% moisture content regime.
Mohr's circles were constructed from experimentally-obtained shear stress values to quantitatively describe flowability of tested materials in terms of a flow function parameter. A high flow function value (>10) was indicative of a good flow.
By testing 120-180 µm, 120-350 µm, 180-250 µm, 250-350 µm, 430-600 µm, and 600-850 µm glass bead diameter ranges, an increase in size was seen to result in higher flow function values. The limitations of testing using the FT4 became apparent as inconsistent flow function values were obtained at 0% moisture with size ranges above 120-180 µm, or at flow function values of >21. Bead sizes larger than 430 µm showed significant standard deviation over all tested trials--when excluding size ranges above that value, the empirical model showed an average error of only 6.45%.
Wet material testing occurred at all tested glass bead size ranges using a deionized water content of 0%, 1%, 5%, 15%, and 20% by weight. The results of such testing showed a decrease in the resulting flow function parameter as more water content was added. However, this trend changed as 20% moisture content was achieved; the wet material became supersaturated, and an increase in flow function values was observed. The empirical model constructed, therefore, neglected the 20% moisture content regime.
ContributorsKleppe, Cameron (Author) / Emady, Heather (Thesis advisor) / Marvi, Hamidreza (Committee member) / Deng, Shuguang (Committee member) / Arizona State University (Publisher)
Created2019
Description
The current research is based on the principles of three-dimensional discrete element method (3D – DEM) through simulations, by using heat transfer models in EDEM, to investigate the effects of fill level, rotation rate and particle size on the steady-state conduction heat transfer in rotary drums. The high heat and mass transfer rates obtained through rotary drums make them very useful for powder mixing and heating processes in metallurgical, cement, mining, pharmaceutical, detergent and other particulate processing applications. However, these complex processes are difficult to model and operate since the particles can have a wide range of properties, and there is currently no way to predict the optimal operating conditions for a given material.
Steady-state heat transfer by conduction forms the basis for understanding other steady-state and unsteady-state heat transfer in a rotary drum – conduction, convection and radiation. Statistical analysis is carried out to determine the effects of these process parameters and find optimal operating conditions, which will thereby improve the heat transfer efficiency in rotary drums. A stainless-steel drum with a diameter of 6 inches and a length of 3 inches was modeled in EDEM with silica beads of sizes 2 mm, 3 mm and 4 mm at fill levels of 10%, 17.5% and 25%, and at rotation rates of 2 rpm, 5 rpm and 10 rpm. It was found that the heating uniformity increased with decreasing particle size, decreasing fill level and increasing rotation rate. This research is the first step towards studying the other heat transfer modes and various other process parameters. Better understanding of the various heat transfer modes, when used in combination for heating the particles, will be beneficial in improving the operating efficiency, reducing material costs and leading to significant energy conservation on a global scale.
Steady-state heat transfer by conduction forms the basis for understanding other steady-state and unsteady-state heat transfer in a rotary drum – conduction, convection and radiation. Statistical analysis is carried out to determine the effects of these process parameters and find optimal operating conditions, which will thereby improve the heat transfer efficiency in rotary drums. A stainless-steel drum with a diameter of 6 inches and a length of 3 inches was modeled in EDEM with silica beads of sizes 2 mm, 3 mm and 4 mm at fill levels of 10%, 17.5% and 25%, and at rotation rates of 2 rpm, 5 rpm and 10 rpm. It was found that the heating uniformity increased with decreasing particle size, decreasing fill level and increasing rotation rate. This research is the first step towards studying the other heat transfer modes and various other process parameters. Better understanding of the various heat transfer modes, when used in combination for heating the particles, will be beneficial in improving the operating efficiency, reducing material costs and leading to significant energy conservation on a global scale.
ContributorsBheda, Bhaumik (Author) / Emady, Heather (Thesis advisor) / Muhich, Christopher (Committee member) / Nielsen, David (Committee member) / Arizona State University (Publisher)
Created2020
Description
The way a granular material is transported and handled plays a huge part in the quality of final product and the overall efficiency of the manufacturing process. Currently, there is a gap in the understanding of the basic relationship between the fundamental variables of granular materials such as moisture content, particle shape and size. This can lead to flowability issues like arching and ratholing, which can lead to unexpected downtimes in the whole manufacturing process and considerable wastage of time, energy, and resources. This study specifically focuses on the development of a model based on the surface mean diameter and the moisture content to predict the flow metric flow function coefficient (FFC) to describe the nature of flow of the material. The investigation involved three parts. The first entailed the characterization of the test materials with respect to their physical properties - density, size, and shape distributions. In the second, flowability tests were conducted with the FT4 Powder Rheometer. Shear cell tests were utilized to calculate each test specimen's flow function parameters. Finally, the physical properties were correlated with the results from the flowability tests to develop a reliable model to predict the nature of flow of the test specimens. The model displayed an average error of -6.5%. Predicted values showed great correlation with values obtained from further shear cell tests on the FT4 Rheometer. Additionally, particle shape factors and other flowability descriptors like Carr Index and Hausner Ratio were also evaluated for the sample materials. All size ranges displayed a decreasing trend in the values of Carr Index, Hausner Ratio, and FFC with increasing moisture percentages except the 5-11 micron glass beads, which showed an increasing trend in FFC. The results from this investigation could be helpful in designing equipment for powder handling and avoiding potential flowability issues.
ContributorsDeb, Anindya (Author) / Emady, Heather (Thesis advisor) / Marvi, Hamidreza (Committee member) / Jiao, Yang (Committee member) / Arizona State University (Publisher)
Created2021