Simulating operational alternatives for future cement production

To support decisions on product and process development options and strategic planning, information on the consequences of planned changes are needed. For this purpose a flexible model for cement manufacturing has been developed. The model predicts the environmental, product and economic performance in a life cycle perspective, simulating different operational alternatives. Interesting future operational alternatives, such as an increase in the use of industrial by-products and wastes as raw materials and fuels have been explored. The results, i.e. the consequences from a life cycle perspective of potential development options, are discussed.The nine simulations show that the use of recovered material and alternative fuel (defined waste) can be increased while maintaining the current requirements on clinker performance. An increase in the use of recovered material and alternative fuel replaces the use of resources. The simulations also show that the emissions of CO₂, NO_X, SO₂, CO, VOC, CH₄ and dust can be reduced between 30 and 80% depending on the use of recovered material and alternative fuel. The transport of recovered material and alternative fuel increases with increased use. However, the environmental benefits of the increase in use of recovered material and alternative fuel are by far greater than the resource use and emissions to air associated with the increase in transport.     

Abrasive jet machining by means of velocity shear instability in plasma

The material removal within different machining process can be performed in distinct modalities. One of the modality is based on the erosion phenomena. In this paper, theoretical model of abrasive jet machining based on erosion phenomenon is discussed. The material is removed from the surface due to erosion. In abrasive jet machining process, the output parameter is achieved by controlling various input parameters. This paper discusses the effects of various input parameters in abrasive jet machining (AJM) on the material removal rate (as the output parameter). The results presented in the paper are obtained from a theoretical study carried out with the help of mathematical model and computational technique. Theoretical investigation indicates that magnetic field, electric field and inhomogeneity in DC electric field have significant effect on metal removal by abrasive jet machining process.     

Process capability study of laser assisted micro milling of a hard-to-machine material

Laser assisted micro milling (LAMM) is capable of generating three-dimensional micro scale features in hard-to-machine materials. This paper compares the process capability of LAMM with conventional micro milling of a hardened tool steel. In particular, the potential advantages of LAMM over micro milling with respect to cutting forces, tool wear, material removal rate, burr formation and surface roughness are investigated when micro milling hardened A2 tool steel (62 HRC). The results show that LAMM has significant advantages over micro milling, especially in terms of cutting forces, material removal rate and tool wear. The average reduction in the resultant cutting force is found to be up to 69% with laser assist. In addition, tool wear is found to be substantially less with laser assist even when the material removal rates are increased by a factor of six over the tool manufacturer recommended cutting conditions.     

催化氧化除锰活性滤料去除地下水中双酚A性能

以催化氧化除锰活性滤料（简称“活性滤料”）为研究对象,考察了地下水中锰污染对于活性滤料去除双酚A效能的影响.结果表明,进水中含有高浓度锰（5mg/L）时,会显著降低活性滤料对于双酚A的去除能力;同时,双酚A也会降低活性滤料对锰的去处能力.双酚A脱附实验结果表明,脱附的双酚A量不足双酚A去除总量的10%,且双酚A去除过程中初期总有机碳（TOC）去除率保持在12%~25%,之后持续保持在0.1%~4%,表明活性滤料去除双酚A存在吸附过程,但是以氧化去除为主.扫描电子显微镜（SEM）和X射线衍射（XRD）分析结果表明,双酚A的去除会导致滤料表面微观形态改变以及新物相的生成;傅里叶变换红外光谱（FTIR）结果表明双酚A的去除会消耗滤料表面羟基基团,且表面残留络合物.本文研究分析提出活性滤料去除双酚A的主要步骤包括双酚A首先吸附到活性滤料表面形成络合物、活性滤料与表面络合物发生氧化反应,部分反应物中间体脱附3个过程.     

废茶活性炭脱硫脱硝性能的应用研究

为探讨废茶活性炭对于SO2和NO脱除作用的制约因素,分别考察了材料孔径结构、石墨化程度及表面结构对其脱硫脱硝性能的影响,同时研究了其吸附机制及动力学过程.结果表明,较高的石墨化程度是影响材料脱硫性能的主要因素,微孔径较小且含氮碱性基团较高时有利于SO2的脱除;发达的中孔结构是制约NO脱除效率的关键因素,含氮碱性基团对NO的脱除具有一定的促进作用;烟气中SO2和NO共存时,材料的脱硫脱硝性能均有所降低,氧气和水蒸气的加入能够改善其脱硫脱硝效率;废茶活性炭在无水环境下对于SO2和NO的吸附作用均以物理吸附为主,水蒸气的存在促进了材料对SO2的化学吸附;通过动力学模型的拟合发现,Bangham吸附模型能够很好地描述材料脱硫脱硝的动力学过程,其R2均高于0.989,材料对于SO2和NO的吸附速率常数均随氧气和水蒸气的加入而减小.     

LED3A土柱淋洗Pb与Zn污染砂土的效果

为探究不同淋洗方式下螯合型表面活性剂LED3A（N-十二酰基乙二胺三乙酸钠盐）对重金属污染土壤的淋洗效果,采用室内土柱淋洗法研究了LED3A在不同流速条件下对Pb、Zn单一污染砂土的淋洗效果,并通过优化的BCR法分析了淋洗前、后土柱中不同深度处Pb、Zn的形态变化特征.结果表明:LED3A对Pb、Zn单一污染砂土的淋洗规律基本类似,淋出液中ρ（Pb）、ρ（Zn）随淋洗液累积孔隙体积数目的增加呈现急剧增大、达到峰值后逐渐降低的趋势;Pb、Zn的淋洗曲线中均存在不同程度的拖尾现象,且对称性较差;淋出液中ρ（Pb）、ρ（Zn）峰值和Pb、Zn最大累积去除率均随流速的增大而减小.随着淋洗深度和流速的增加,各形态Pb、Zn的去除率均呈现减小的趋势,LED3A对酸可提取态Pb、Zn的去除效果最为显著,去除率均大于50%;对氧化物结合态、有机结合态和残渣态Pb、Zn的去除率大小顺序与淋洗深度和流速有关;对比淋洗前、后土柱中重金属的形态分布可知,最易释放和被生物利用的酸可提取态的占比明显减少,不易或不能被生物利用的氧化物结合态、有机结合态和残渣态的占比明显增加.研究显示,LED3A低流速淋洗不仅能够去除一定量的土壤重金属,同时可有效降低残留重金属对环境的潜在风险.      

AFM probe based nano mechanical scribing of soda-lime glass

In recent years, demands for miniature components have increased due to their reduced size, weight and energy consumption. In particular, brittle materials such as glass can provide high stiffness, hardness, corrosion resistance and high-temperature strength for various biomedical and high-temperature applications. In this study, cutting properties and the effects of machining parameters on the ductile cutting of soda-lime glass are investigated through the nano-scale scratching process. In order to understand the fundamentals of the material removal mechanism at the atomic scale, such as machined surface quality, cutting forces and the apparent friction, theoretical investigation along with experimental study are needed. Scribing tests have been performed using a single crystal diamond atomic force microscope (AFM) probe as the scratching tool, in order to find the cutting mechanism of soda-lime glass in the nano-scale. The extended lateral force calibration method is proposed to acquire accurate lateral forces. The experimental thrust and cutting forces are obtained and apparent friction coefficients are deduced. The effects of feed rates and the ploughing to shearing transition of soda-lime glass have been investigated.     

高效除砷分子筛新型材料制备及其吸附特性研究

为提高4A分子筛(MS)对水溶液中砷的吸附性能,以MS为载体,采用浸渍法制备载铁分子筛(FMS)和铁锰分子筛(FMMS)作为除砷吸附剂,利用扫描电镜(SEM)、傅里叶红外光谱(FT-IR)、比表面积测试法(BET)等手段对MS和FMS微观结构特点进行表征,并开展批次试验考察FMS和FMMS对水中五价砷(As5+)和三价砷(As3+)的吸附效果,对FMS吸附As5+过程进行吸附动力学、等温吸附试验和吸附热力学等拟合.结果表明:①铁盐浸渍改性能有效提高MS比表面积、改善其表面结构,改性后FMS是一种窄孔径、尺寸均匀的介孔材料,比表面积和孔体积分别从27.38 m2/g和0.068 cm3/g增至281.25 m2/g和0.16 cm3/g,平均孔径由9.93 nm减至2.21 nm;MS微观结构由密实粗糙颗粒转变为疏松多孔隙结构.②FT-IR表明,铁盐浸渍形成的铁氧化物主要与MS结构中O—H、Al—O和Si—O结合;批次试验设定ρ(As5+)为4 mg/L,与MS相比FMS对As5+的去除率约提高70%.③吸附动力学结果显示,FMS对As5+的吸附过程符合准二级动力学模型,相关系数(R2)达0.99,反应过程中化学吸附起主要作用.④等温吸附试验表明,FMS对As5+吸附过程与Freundlich等温吸附模型拟合程度较高,相关系数(R2)达0.98,计算最大吸附容量为9.9 mg/g.⑤热力学参数ΔG、ΔH和ΔS计算表明,温度升高有利于FMS吸附砷,反应过程中FMS表面固体与溶液的混乱度上升.⑥与FMS相比,FMMS对As3+吸附性能有效提高,ρ(As3+/As5+)(As3+与As5+共存条件下溶液质量浓度)分别为2.0、4.0、6.0 mg/L下,FMMS去除率分别约提高26.34%、28.06%和28.09%.研究显示,利用铁盐浸渍法对MS改性可有效提升其对As5+和As3+的吸附容量,发挥材料的实际运用价值.      

A new semi-dry desulfurization process using a powder-particle spouted bed

A new semi-dry desulfurization process was tested in this study. The process uses the so-called powder-particle spouted bed (PPSB) as the reactor in which coarse medium particles, usually silica sand of several hundred micrometers in size, are fluidized with hot flue gas. A slurry of fine SO_x sorbent, such as slaked lime or other alkaline powder, is continuously supplied into the bed of coarse particles. As a consequence, both the desulfurization reaction and slurry drying take place simultaneously in the single reactor. By using a model flue gas, SO₂–air, and the sorbent Ca(OH)₂ in a laboratory-scale reactor, the removal efficiency of this process was examined with respect to major operating parameters in this study. It was demonstrated that SO₂ removal in excess of 95% can be achieved at Ca/S=1.2, while spent sorbent appears in the form of dry powder. The optimal temperature of flue gas treated with this technique was shown to be approximately 420 K. In comparison with wet desulfurization scrubbers, this PPSB semi-dry process appears to have lower cost, less complicated configuration and simpler disposal of used sorbent.     

An experimental investigation into micro ball end-milling of silicon

Silicon is a representative operational material for semiconductor and micro-electronics. In certain MEMS applications, it is required to fabricate three dimensional channels and complex pattern on silicon substrate. Such features are typically fabricated by photolithography and chemical etching. These processes have low productivity and have certain other limitations. Therefore, a viable switch-over from non-traditional fabrication processes to traditional machining is highly desired for improved productivity in high-mix low-volume production. However, machining of silicon by traditional process is extremely difficult due to its high brittleness. Even very small forces produced during machining can cause brittle fracture on silicon surface resulting in deteriorated surface quality. The fundamental principle in machining of a brittle material such as silicon is to achieve material removal through plastic deformation rather than crack propagation. This paper presents the experimental results of ductile-mode machining of silicon by micro ball end-milling. The workpiece surface was inclined to the rotational axes of the cutter to improve the surface finish. It was established experimentally that 15-μm deep, fracture-free slots can be machined on silicon wafer by micro ball end-milling if the feed rate is below a certain threshold. The influence of several machining parameters on the roughness of machined-surface was also investigated. Cubic boron nitride (CBN) is presented as much economical alternative tool-material to single-crystal diamond for machining silicon in ductile-mode.     

Removal of Cd2+ from water by Friedel’s salt (FS: 3CaO.Al2O3·CaCl2·10H2O): Sorption characteristics and mechanisms

The development of low-cost and efficient new mineral adsorbents has been a hot topic in recent years. In this study, Friedel’s salt (FS:3CaO·A12O3 ·CaCl2 ·10H2O), a hexagonal layered inorganic absorbent, was synthesized to remove Cd2+ from water. The adsorption process was simulated by Langmuir and Freundlich models. The adsorption mechanism was further analyzed with TEM, XRD, FT-IR analysis and monitoring of metal cations released and solution pH variation. The results indicated the adsorbent FS had an outstanding ability for Cd(Ⅱ) adsorption. The maximum adsorption capacity of the FS for Cd(Ⅱ) removal can reach up to 671.14 mg/g. The nearly equal numbers of Cd2+ adsorbed and Ca2+ released demonstrated that ion-exchange (both surface and inner) of the FS for Cd(Ⅱ) played an important role during the adsorption process. Furthermore, the surface of the FS after adsorption was microscopically disintegrated while the inner lamellar structure was almost unchanged. The behavior of Cd(Ⅱ) adsorption by FS was significantly affected by surface reactions. The mechanisms of Cd2+ adsorption by the FS mainly included surface complexation and surface precipitation. In the present study, the adsorption process was fitted better by the Langmuir isotherm model (R2 = 0.9999) than the Freundlich isotherm model (R2 = 0.8122). Finally, due to the high capacity for ion-exchange on the FS surface, FS is a promising layered inorganic adsorbent for the removal of Cd(Ⅱ) from water.     

Preparation and characterization of boron-doped corn straw biochar: Fe (Ⅱ) removal equilibrium and kinetics

Nowadays, iron ions as a ubiquitous heavy metal pollutant are gradually concerned and the convenient and quick removal of excessive iron ions in groundwater has become a major challenge for the safety of drinking water. In this study, boron-doped biochar (B-BC) was successfully prepared at various preparation conditions with the addition of boric acid. The as-prepared material has a more developed pore structure and a larger specific surface area (up to 897.97 m²/g). A series of characterization results shows that boric acid effectively activates biochar, and boron atoms are successfully doped on biochar. Compared with the ratio of raw materials, the pyrolysis temperature has a greater influence on the amount of boron doping. Based on Langmuir model, the maximum adsorption capacity of 800B-BC_1:2 at 25 °C, 40 °C, 55 °C are 50.02 mg/g, 95.09 mg/g, 132.78 mg/g, respectively. Pseudo-second-order kinetic model can better describe the adsorption process, the adsorption process is mainly chemical adsorption. Chemical complexation, ions exchange, and co-precipitation may be the main mechanisms for Fe²⁺ removal.     

Removal of tetracycline from water by Fe-Mn binary oxide

Significant concerns have been raised over the presence of antibiotics including tetracyclines in aquatic environments. A series of Fe-Mn binary oxide with different Fe:Mn molar ratios was synthesized by a simultaneous oxidation and coprecipitation process for TC removal. Results showed that Fe-Mn binary oxide had higher removal efficiency than that of hydrous iron oxide and hydrous manganese oxide, and that the oxide with a Fe:Mn molar ratio of 5:1 was the best in removal than other molar ratios. The tetracycline removal was highly pH dependent. The removal of tetracycline decreased with the increase of initial concentration, but the absolute removal quantity was more at high concentration. The presence of cations and anions such as Ca²⁺, Mg²⁺, CO₃^2- and SO₄^2- had no significant effect on the tetracycline removal in our experimental conditions, while SiO₃^2- and PO₄^3- had hindered the adsorption of tetracycline. The mechanism investigation found that tetracycline removal was mainly achieved by the replacement of surface hydroxyl groups by the tetracycline species and formation of surface complexes at the water/oxide interface. This primary study suggests that Fe-Mn binary oxide with a proper Fe:Mn molar ratio will be a very promising material for the removal of tetracycline from aqueous solutions.     

病死猪热解炭化物的特性及其对水中Cu2+的去除

研究了病死猪热解炭化物对水中Cu~(2+)的去除效果,并借助扫描电子显微镜、X射线光谱仪及傅里叶红外光谱仪等分析手段对病死猪热解得到的炭化物理化学性质进行了表征,分析了其微观结构及官能团.结果发现,病死猪热解炭化物内部具有大量孔状结构,表面出现了PO3-4等结构.最后,利用热解得到的炭化物对水中的Cu~(2+)进行处理研究,考察了初始p H值、反应温度、吸附时间等对水中Cu~(2+)去除效果的影响.结果表明,病死猪热解炭化物对水中Cu~(2+)的吸附效果较好,最佳初始p H值为5.0,温度的升高有利于热解炭化物对Cu~(2+)的去除.通过对实验数据进行动力学及吸附等温线分析,发现实验中使用的病死猪热解炭化物对Cu~(2+)的吸附动力学数据符合准二级吸附动力学方程,Langmuir模型能较好地描述Cu~(2+)在猪热解炭化物上的吸附行为.     

一种新型水与废水吸附过滤技术的研究

以普通的石英砂(20～40目)滤料为基本原料,表面改性制备了一种投资省的多功能水与废水吸附过滤材料。首先考察了吸附过滤材料的表面特性,然后以人工配水为处理对象,通过动态试验装置,较系统地研究了此材料对可溶性磷酸盐和Cr3、Cu2等重金属离子的去除性能。试验结果表明,此吸附过滤材料不仅可以有效去除磷酸盐,而且对Cr3、Cu2等的去除率均在90％以上,再生率分别达94％及50％以上。      

磁铁锆改性牡蛎壳对水体磷的控释行为研究

通过磁化和添加溶解性锆盐,制成一种磁铁锆改性牡蛎壳粉材料,对其性质及除磷效果进行研究.结果表明,经磁铁锆改性,牡蛎壳具备磁性且比表面积和孔隙度均得到了显著提升,磷吸附量由4.5 mg·g^-1提高到了46.5 mg·g^-1,同时通过外加磁场可成功实现改性牡蛎壳粉的回收,而吸附动力学研究则证明整个磷吸附过程包括快速吸附和平衡吸附两个阶段.另外,改性牡蛎壳粉末对于水体中磷的吸附主要以溶解性磷酸盐（SRP）为主,相较于底泥间隙水,改性牡蛎壳粉对底泥上覆水的释磷行为具有更好的抑制效果,同时该材料还会促进底泥磷形态中易释放的铁结合态磷（Fe-P）向难释放的闭蓄态磷（Oc-P）转化,并降低易释放交换态磷（Ex-P）的含量.上述结果说明磁铁锆改性牡蛎壳适合作为一种高效除磷吸附剂用于控制富营养化水体中磷过量现象.     

A~2O-人工湿地组合工艺对污水中油类物质的去除研究

以河源市城南生活污水处理厂为平台,研究了A2O-人工湿地组合工艺对污水中油类物质的去除效果。结果表明:经过A2O-人工湿地组合工艺处理后,污水中油类物质的去除可达96.5%以上,出水水质基本达GB 8978—1996《污水综合排放标准》中的二类污染物一级排放标准;同时探讨了该组合工艺对城市含油污水的净化机制以及系统运行的限制性因素,系统内部油类物质被降解和去除的过程,确立可推广应用的A2O-人工湿地组合工艺对含油废水的深度处理系统。     

Laser tempering based turning process for efficient machining of hardened AISI 52100 steel

Cost-effective machining of hardened steel components such as a large wind turbine bearing has traditionally posed a significant challenge. This paper presents an approach to machine hardened steel parts efficiently at higher material removal rates and lower tooling cost. The approach involves a two-step process consisting of laser tempering of the hardened workpiece surface followed by conventional machining at higher material removal rates with lower cost ceramic tools to efficiently remove the tempered material. The laser scanning parameters that yield the highest depth of tempered layer are obtained from a kinetic phase change model. Machining experiments are performed to demonstrate the possibility of higher material removal rates and improved tool wear behavior compared to the conventional hard turning process. Tool wear performance, cutting forces, and surface finish of Cubic Boron Nitride (CBN) tools as well as low cost ceramic tools are compared in machining of hardened AISI 52100 steel (~63 HRC). In addition, cutting forces and surface finish are compared for the laser tempering based turning and conventional hard turning processes. Experimental results show the potential benefits of the laser tempering based turning process over the conventional hard turning process.     

A method for double-sided friction stir spot welding

A rotating anvil similar to a pinless friction stir welding (FSW) tool can be applied to friction stir spot welding (FSSW) of thin metal plates. FSSW is a solid-state joining process that is currently being used by automotive manufacturers as an alternative to rivets and traditional resistance spot welding. The principal detractor of this process is the keyhole left by pin extraction, which can be detrimental to the weld strength. A pinless tool can be used to eliminate the keyhole. However, this approach is limited to joining thin sheet (≤1 mm). Using a rotating anvil with the FSSW process permits the joining of thicker cross sections, improves the mechanical strength of the spot weld and reduces the reaction forces on the spot welding frame. A numerical model of the process, tensile shear tests and macrosection analysis are used to evaluate the spot welds.Macrosection and numerical analysis reveals that the material flow between the pinless tool and rotating anvil is complex and unique to this process. It has been found that the use of a rotating anvil for FSSW is a viable means to create quality spot welds in thicker weldments.     

Comparison between numerical simulations and experiments for single-point diamond turning of single-crystal silicon carbide

Single-point diamond turning (SPDT) experiments conducted on single-crystal 6-H silicon carbide (SiC) have shown chip formation similar to that seen in the machining of metals. The ductile nature of SiC is believed to be the result of a high-pressure phase transformation (HPPT), which generates a plastic zone of material that behaves in a metallic manner. This metallic behavior is the basis for using AdvantEdge, a metal machining simulation software, for comparison to experimental results.Simulations (2D) were carried out by matching the SPDT experimental conditions, which were conducted at nanometer (nm) depths of cut and varying tool rake angles. The experiments were performed by machining the circumference of the single-crystal wafer, thereby conforming to a 2D orthogonal cut (plunge cuts, or an infeed, achieved the depth of cut, and no cross feed was incorporated).The cutting and thrust forces generated from the experiments under ductile cutting conditions compared favorably with the simulation. As the depth of cut is decreased (250 nm, 100 nm, and 50 nm), the experimental conditions transition from a brittle to ductile behavior, with the 50 nm cuts being dominated by the ductile regime. Thus, the forces from the experiment and the simulations are in much better agreement for the smaller depths of cut, that is, below the critical depth of cut that establishes the ductile-to-brittle transition, as ductile conditions exist in both the simulation and experiments. The differences in the results that do arise are assumed to be primarily due to a springback of the material leading to increased rubbing on the flank face.