capstone presentation: high-temperature microporous insulation
DESCRIPTION
My capstone presentation for materials engineering at McMaster. Work done with Steven Chortos, Darnelle Jones, Jeff Kay, for Advanced Ceramics Corp.TRANSCRIPT
Jones and Co. Consulting
Advanced Ceramics CorpAdvancement of microporous insulation
Presented by: Darnelle Jones, Jeff Kay, Alex Melvin and Steven ChortosMentors: Ritch Mathews and Dr. ZhitomirskyApril 2nd, 2013
2
Background Procedure and error Linear change results SEM and XRD Sustainability Gantt chart Future direction Conclusion
Contents
3
Investigation done in 2011-2012 on AC80
Assumed by both parties that the properties were the same
AC80i vs AC80
4
Background
5
AC80i assumptions
Thermally resistant (1000 °C) Made of:
Amorphous fumed silica Rutile titania (mixture) Silica fibres
Process: Mixed together Pressed by 75 ton force Not fired (reduced cost)
6
Degradation of thermal properties at 1000°C Onset of sintering
Shrinkage (densification) Cracking
What’s the problem?
7
The overall goal of this project is to increase the operating temperature of AC80i by 100°C while keeping it economically viable.
Problem statement
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Testing methods
Fibre coating Reduce fibre-fibre contact (conduction) SEM
Addition of fumed alumina Inhibit sintering and phase change Linear shrinkage SEM XRD
9
Procedure and error
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Total days spent testing = 36
Total hours of furnace operation = 966
Total samples tested = 145 Usable samples = 90
Testing overview
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Preparation
Fumed silica, TiO2 and silica fibres weighed and mixed in shear mixer
Alumina addition and final mixing The Al2O3 was weighed and added to the
bucket
Materials were mixed for approx 5 mins using a drill with a paint mixer attached to the end Error in homogeneity of mix
12
Testing
Samples tested using a modified version of the ASTM C356-10 testing procedure Samples were placed in furnace and held at
temperature for 24 hours
Measurements Initial samples were measured in each dimension
Significant error due to inconsistent measuring practice
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Radiation Shields
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Ladle example
Feb 12th-19th
Shield #1
3
16
Feb 25th-March 3rd
Shield #2
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March 4th-12th
Shield #3
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March 12th-April 1st (Morgan Thermal Ceramics
– insulating fire bricks)
Shield #4
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Linear change results
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Alumina added
0 wt% (AC80i) 6 wt% 9.5 wt% 12.5 wt% 19 wt%
Final brick design Cost vs linear shrinkage 12.5 wt%
Design compositions
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Importance of testing direction
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Morgan radiation shield
1 2 3 4 5 6 71000
1025
1050
1075
1100
6% Worst Case Scenario
0%6%5% linear change
Linear Change (%)
Tem
pera
ture
(°C
)
1 2 3 4 5 61000
1025
1050
1075
1100
9.5% Worst Case Scenario
0%9.5%5% linear change
Linear Change (%)
Tem
pera
ture
(°C
)
1 2 3 4 5 61000
1025
1050
1075
1100
12.5% Worst Case Scenario
0%12.5%5% linear change
Linear Change (%)
Tem
pera
ture
(°C
)
1 2 3 4 5 61000
1025
1050
1075
1100
19% Worst Case Scenario
0%19%5% linear change
Linear Change (%)
Tem
pera
ture
(°C
)
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Final brick
4 5 61000
1025
1050
1075
1100
1125
1150
ASTM Worst Case
0%FB5% linear change
Linear Change (%)
Tem
pera
ture
(°C
)
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SEM and XRD
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Distribution of titania particles
Hard/soft fracture
Open/closed pores
Coating of silica fibres
Went in looking for:
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Titania Particles
Titania acts as an opacifier, reducing the effects of radiation
Even distribution ensures effective scattering
Titania does appear to be distributed evenly
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3% alumina @ 1025 °C
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Sharp/soft fracture
Looking for: Sharp structures in the 1100 °C heated sample Rounder edges in pre-densified samples
Some differences noted, but results were not definitive
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3% alumina @ 1100 °C
3% alumina @ 1025 °C
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Open/closed pores
Unable to effectively image the pores using SEM
If the samples were mounted and polished rather than crushed, results may have been more informative
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Coating of silica fibres
Compressive shear mixing was proposed to coat the silica fibres in a layer of fumed silica
Munson Machinery was investigated to mix, but communication fell through
Devised our own shear mixing method, but did not achieve fibre coating
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Centrifugal compressive-shear mill
Tomato strainer
33Coated fibres
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XRD Analysis
Went in looking for cristobalite in our samples
Alumina was originally added as a phase change and sintering suppressant
No cristobalite was found, even in the 0% alumina samples Due to the difference in titania content
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Results
2Th Degrees7472706866646260585654525048464442403836343230282624222018161412108
Co
un
ts
11,000
10,500
10,000
9,500
9,000
8,500
8,000
7,500
7,000
6,500
6,000
5,500
5,000
4,500
4,000
3,500
3,000
2,500
2,000
1,500
1,000
0-1000C.raw0-1025C.raw0-1075C.raw0-1100C.raw
2Th Degrees7472706866646260585654525048464442403836343230282624222018161412108
Co
un
ts
16,500
16,000
15,500
15,000
14,500
14,000
13,500
13,000
12,500
12,000
11,500
11,000
10,500
10,000
9,500
9,000
8,500
8,000
7,500
7,000
6,500
6,000
5,500
5,000
4,500
4,000
3,500
10-1025C.raw10-1050C.raw10-1075C.raw10-1100C.raw
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Sustainability
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No increase in health risks to workers or
users
No change in the environmental impact
Environmental
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New markets
No new processing machines needed
Economical
53%
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Gantt chart
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Meeting with Ritch Mathews
Preliminary research
Indepth research of proposed solutions
Meeting with Dr. Zhitomirsky
Problem statement presentation
Meeting with Dr. Malakhov
Proposal presentation preparation
Proposal presentation
Written proposal
Testing preperation and testing
Progress presentation #2
Progress presentation #3
Final presentation preparation
Final presentation
Final written report
9/20/12 11/9/12 12/29/12 2/17/13 4/8/13Proposed Gantt Chart
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Meeting with Ritch Mathews
Preliminary research
Indepth research of proposed solutions
Meeting with Dr. Zhitomirsky
Problem statement presentation
Meeting with Dr. Malakhov
Proposal presentation preparation
Proposal presentation
Written proposal
Initial contact with Munson
Contacting and ordering Al2O3
Contacting for TiO2
Correspondance with Munson
Industry pick-up
Industry visit (sample prep)
Progress presentation #2
Furnace testing (JHE
Correspondance with CANMet
Progress presentation #3
SEM analysis
XRD analysis
Final report
Final presentation preparation
Final presentation
9/20/12 11/9/12 12/29/12 2/17/13 4/8/13
Final Gantt Chart
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Future direction
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General Heat Equation
q” = kΔT + hΔT + ϵσΔT4
ConductionConvection
Radiation
k: thermal conductivityh: convective heat transfer coefficientϵ: emissivityσ: Stefan-Boltzmann constant
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Optimize particle size / opacifier material
Optimized opacifier = less radiant heat transfer
Evidence through radiation shields
Radiation shield in industry
Recommendations
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AC80i radiation shield
0 5 101000
1025
1050
1075
1100
Densification Results (AC80i Shield)
6%9.5%12.5%19%5% linear change
Linear Change (%)
Tem
pera
ture
(°C
)
46
Morgan radiation shield
1 2 3 4 5 6 71000
1025
1050
1075
1100Worst Case Densification Results
6%
9.5%
12.5%
19%
0%
5% linear change
Linear Change (%)
Tem
pera
ture
(°C
)
47
Design a solid radiation shield
Easy loading and unloading Consistent heating Accurate and reproducible results
Homogenous mix Consistent mixing procedure Reduction in error
Sample orientation Consistent orientation of samples
Suggestions
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AC 80i – Best option up to 1100 °C Less linear shrinkage Cheaper
Conclusion
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Thank you• Ritch Mathews• Dr. Zhitomirsky• All of the MSE faculty
Acknowledgements
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Questions?