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All sources NASA NTRS DOE OSTI

NASA NTRS2017

Magnesium Alloys for Space Hardware Design

There have been advances in magnesium alloy development that NASA has not taken into consideration for space hardware because of a lack of test data. Magnesium alloys offer excellent weight reduction, specific strength, and deep space radiation mitigation. Traditionally, magnesium has been perceived as having too poor of a flammability resistance and corrosion resistance to be used for flight. Recent developments in magnesium alloying has led to the formation of two alloys, WE43 and Elektron 21, which are self-extinguishing and significantly less flammable because of their composition. Likewise, an anodizing process called Tagnite was formulated to deter any concern with galvanic and saltwater corrosion. The Materials Science Branch at Kennedy Space Center is currently researching these new alloys and treatments to better understand how they behave in the harsh environment of space. Successful completion of the proposed testing should result in a more thorough understanding of modern aerospace materials and processes, and possibly the permission to use magnesium alloys in future NASA designs.

microstructure↗

DOE OSTI2013

Characterization and Properties of Micro-arc Composite Ceramic Coatings on Magnesium Alloys

Magnesium alloys are of growing interest for many industrial applications due to their favorable strength-to-weight ratio and excellent cast ability. However, one of the limiting factors in the use of magnesium on production vehicles is its poor corrosion resistance. Micro-arc Composite Ceramic (MCC) coatings on AZ91D magnesium alloys were prepared in combination with Micro-arc Oxidation (MAO) and electrophoresis technologies. The microstructure, corrosion resistance, abrasion resistance, stone impact resistance, thermal shock resistance and adhesion of MCC coating were studied, respectively. The surface and cross-section morphologies of MAO and MCC coating showed that the outer organic coating filled the holes on the surface of the MAO coating. It acted as a shelter on the MAO coating surface when the MCC coatings were exposed to corrosive environments. The corrosion resistance of the MCC coating was characterized by a copper-accelerated acetic acid salt spray test. The testing results showed that the creep back from scribe lines was less than 1mm and completely fit the evaluation standard. The composite structure of the MCC coating vastly improved the corrosion resistance of Mg alloys. According to testing standards, the resistance to abrasion, stone impact resistance, thermal shock resistance and adhesion of MCC coatings completely met the evaluation standard requirements. The MCC coated AZ91D magnesium alloys possessed excellent properties; this is a promising corrosion and wear resistance surface treatment technology on magnesium alloys for production vehicles.

magnesium coatings micro-arc corrosion↗

DOE OSTI2018

Hydrogen sorbing magnesium alloys and composites

The authorsr works studying the hydrogen sorption properties of the magnesium-based materials are reviewed. The objects of the studies were highly dispersed powders of Mg—La—Ni and Mg—Mm—Ni alloys (Mm is misch metal) of the ternary eutectic, composites of magnesium alloys with extended carbon nanostructures, and composites of magnesium hydride with lanthanide oxides. The positive effect of lanthanide oxide additives on the process of hydro-gen desorption from magnesium hydride and the role of carbon nanofibers in these processes carried out at room temperatures are discussed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2019

The Oxidation Mechanism of Pure Magnesium Powder Particles: A Mathematical Approach

In this study, the mechanism of nonisothermal oxidation of magnesium powder was determined using a tension analysis, which was performed by mathematical modeling and the finite element method. The results revealed that phase transformation of magnesium hydroxide to magnesium oxide in the oxide layer plays an important role in this process so that formation of magnesium hydroxide in the early stages of oxidation (< 450 °C) leads to the formation of compressive stresses through the oxide layer, and as a result, the beginning of measurable oxidation is delayed. The results obtained by the mathematical model and finite element method were validated by the experimental results.

36 MATERIALS SCIENCE↗

DOE OSTI2017

A magnesium-induced triplex pre-organizes the SAM-II riboswitch

Our 13C - and 1 H-chemical exchange saturation transfer (CEST) experiments previously revealed a dynamic exchange between partially closed and open conformations of the SAM-II riboswitch in the absence of ligand. Here, all-atom structure-based molecular simulations, with the electrostatic effects of Manning counter-ion condensation and explicit magnesium ions are employed to calculate the folding free energy landscape of the SAM-II riboswitch. We use this analysis to predict that magnesium ions remodel the landscape, shifting the equilibrium away from the extended, partially unfolded state towards a compact, pre-organized conformation that resembles the ligand-bound state. Our CEST and SAXS experiments, at different magnesium ion concentrations, quantitatively confirm our simulation results, demonstrating that magnesium ions induce collapse and pre-organization. Agreement between theory and experiment bolsters microscopic interpretation of our simulations, which shows that triplex formation between helix P2b and loop L1 is highly sensitive to magnesium and plays a key role in pre-organization. Pre-organization of the SAM-II riboswitch allows rapid detection of ligand with high selectivity, which is important for biological function.

Biochemistry & Molecular Biology↗

DOE OSTI2021

Interactions of Aqueous Surface Treatments with Magnesium Alloy

Magnesium, the lightest structural metal, has recently been identified as an important substrate for weight reduction in automotive, aerospace, personal electronics, and many other industries. Magnesium’s unique chemistry, however, makes it challenging to protect from corrosion and incorporate with other materials. Cleaners are the first step in any pretreatment process, and understanding their role in surface preparation for corrosion prevention is crucial to making magnesium substrate a viable solution for lightweighting. In this work, we explore the relationship between cleaner composition, pH, etch rate, and panel morphology post-cleaning to understand how various cleaners interact with magnesium alloy. Our findings broaden the pool of possible bath chemistries that provide safe and effective surface cleaning of magnesium substrate.

Harris, Rachel↗

DOE OSTI2025

Fabrication, oxidation, and combustion of nanoscale magnesium diboride and tetraboride

The difficult ignition of boron decreases the combustion efficiency of boron-loaded, fuel-rich propellants. One approach to solving this problem involves the use of magnesium diboride (MgB2), which ignites easier than boron. Magnesium tetraboride (MgB4) offers greater energy density owing to its higher boron content. However, the effect of B/Mg ratio on the ignition and combustion is unknown. Additionally, while nanoscale MgB₂ particles and quasi-2D structures were recently recognized as promising energetic additives, the oxidation and combustion properties of nanoscale MgB₄ have not been explored. The objectives of the present work included synthesis, purification, and high-energy ball milling of MgB2 and MgB4 powders as well as investigation of their thermal decomposition, oxidation, and combustion. The MgB2 and MgB4 powders were fabricated by combustion synthesis in the chemical oven mode and by heating Mg/B mixtures in a tube furnace. The latter method was superior in the synthesis of MgB4. Oxide impurities in the synthesized powders were removed by acid leaching. Nanoscale powders were obtained by high-energy ball milling. Thermal decomposition and oxidation of the obtained MgB₂ and MgB₄ powders were investigated by conducting non-isothermal thermogravimetric analysis (TGA) at temperatures up to 1550 °C in argon and oxygen flows. Combustion of B, MgB₂, and MgB₄ powders with oxygen at atmospheric pressure was studied in a windowed chamber using laser ignition and high-speed video recording. The TGA has shown multi-step decomposition of both magnesium borides in an argon environment. The maximum oxidation rate of MgB4 in oxygen was observed at a much lower temperature than in the case of MgB2. In the combustion experiments, both magnesium borides burned much faster than submicron boron. Ball milling of the borides further increased their burning rates. It has been concluded that nanoscale magnesium tetraboride is a promising ingredient for fuel-rich propellants owing to its high energy density, efficient oxidation, and rapid combustion.

Molina, Andre [The University of Texas at El Paso]↗

DOE OSTI2023

Activated magnesium boride materials for hydrogen storage

Some embodiments described herein provide for methods for synthesizing magnesium borohydride from hydrogenation of magnesium boride at moderate temperature and pressure in the presence of a modifier. The modifier may be in form of hydrides, liquid hydrogen carriers, ammonia borane, metallic species, croconate anion based materials, ethers, amines or imines, metal carbides, borides, graphene, arenes, magnesium, aluminum, calcium or ionic liquids. Some embodiments provide for charging magnesium boride in presence of a modifier at high pressure hydrogen while simultaneously heating the material. The modification in some instances may lead to an improved magnesium boride product with enhanced properties for application in other hydrogen storage systems.

Severa, Godwin↗

DOE OSTI2014

The analysis of magnesium oxide hydration in three-phase reaction system

In order to investigate the magnesium oxide hydration process in gas–liquid–solid (three-phase) reaction system, magnesium hydroxide was prepared by magnesium oxide hydration in liquid–solid (two-phase) and three-phase reaction systems. A semi-empirical model and the classical shrinking core model were used to fit the experimental data. The fitting result shows that both models describe well the hydration process of three-phase system, while only the semi-empirical model right for the hydration process of two-phase system. The characterization of the hydration product using X-Ray diffraction (XRD) and scanning electron microscope (SEM) was performed. The XRD and SEM show hydration process in the two-phase system follows common dissolution/precipitation mechanism. While in the three-phase system, the hydration process undergo MgO dissolution, Mg(OH){sub 2} precipitation, Mg(OH){sub 2} peeling off from MgO particle and leaving behind fresh MgO surface. - Graphical abstract: There was existence of a peeling-off process in the gas–liquid–solid (three-phase) MgO hydration system. - Highlights: • Magnesium oxide hydration in gas–liquid–solid system was investigated. • The experimental data in three-phase system could be fitted well by two models. • The morphology analysis suggested that there was existence of a peel-off process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2013

Study of second phase in bioabsorbable magnesium alloys: Phase stability evaluation via Dmol{sup 3} calculation

Thermodynamical stabilities of four conventional second phases as well as magnesium matrix in bioabsorbable magnesium alloys were investigated theoretically via computer calculation method. Model of individual phase and systems including phase and four water molecular (phase-4H{sub 2}O) were established to simulate the in vitro and in vivo environment. Local orbital density functional theory approach was applied to calculate the total energy for the individual phase and phase-4H{sub 2}O system. The results demonstrated that all the second phases possessed higher phase stability compared with magnesium matrix, but the phase stability was quite different for different types of second phases or second phase-4H{sub 2}O systems. Furthermore, a schematic process of inflammation reaction caused by magnesium alloy implants was proposed for the further evaluation on biocompatibility of different second phases.

36 MATERIALS SCIENCE↗

DOE OSTI2011

Elastic Properties and Internal Friction of Two Magnesium Alloys at Elevated Temperatures

The elastic properties and internal friction of two magnesium alloys were studied from 25 C to 450 C using Resonant Ultrasound Spectroscopy (RUS). The Young's moduli decrease with increasing temperature. At 200 C, a change in the temperature dependence of the elastic constants is observed. The internal friction increases significantly with increasing temperature above 200 C. The observed changes in the temperature dependence of the elastic constants and the internal friction are the result of anelastic relaxation by grain boundary sliding at elevated temperatures. Elastic properties govern the behavior of a materials subjected to stress over a region of strain where the material behaves elastically. The elastic properties, including the Young's modulus (E), shear modulus (G), bulk modulus (B), and Poisson's ratio (?), are of significant interest to many design and engineering applications. The choice of the most appropriate material for a particular application at elevated temperatures therefore requires knowledge of its elastic properties as a function of temperature. In addition, mechanical vibration can cause significant damage in the automotive, aerospace, and architectural industries and thus, the ability of a material to dissipate elastic strain energy in materials, known as damping or internal friction, is also important property. Internal friction can be the result of a wide range of physical mechanisms, and depends on the material, temperature, and frequency of the loading. When utilized effectively in engineering applications, the damping capacity of a material can remove undesirable noise and vibration as heat to the surroundings. The elastic properties of materials can be determined by static or dynamic methods. Resonant Ultrasound Spectroscopy (RUS), used in this study, is a unique and sophisticated non-destructive dynamic technique for determining the complete elastic tensor of a solid by measuring the resonant spectrum of mechanical resonance for a sample of known geometry, dimensions, and mass. In addition, RUS allows determination of internal friction, or damping, at different frequencies and temperatures. Polycrystalline pure magnesium (Mg) exhibits excellent high damping properties. However, the poor mechanical properties limit the applications of pure Mg. Although alloying can improve the mechanical properties of Mg, the damping properties are reduced with additions of alloying elements. Therefore, it becomes necessary to study and develop Mg-alloys with simultaneous high damping capacity and improved mechanical properties. Moreover, studies involving the high temperature dynamic elastic properties of Mg alloys are limited. In this study, the elastic properties and internal friction of two magnesium alloys were studied at elevated temperatures using RUS. The effect of alloy composition and grain size was investigated. The wrought magnesium alloys AZ31 and ZK60 were employed. Table 1 gives the nominal chemical compositions of these two alloys. The ZK60 alloy is a commercial extruded plate with a T5 temper, i.e. solution-treated at 535 C for two hours, quenched in hot water, and aged at 185 C for 24 hours. The AZ31 alloy is a commercial rolled plate with a H24 temper, i.e. strain hardened and partially annealed.

36 MATERIALS SCIENCE↗

DOE OSTI2022

C−H Activation of Inert Arenes using a Photochemically Activated Guanidinato‐Magnesium(I) Compound

Abstract UV irradiation of solutions of a guanidinate coordinated dimagnesium(I) compound, [{(Priso)Mg} 2 ] 3 (Priso=[(DipN) 2 CNPr i 2 ] − , Dip=2,6‐diisopropylphenyl), in either benzene, toluene, the three isomers of xylene, or mesitylene, leads to facile activation of an aromatic C−H bond of the solvent in all cases, and formation of aryl/hydride bridged magnesium(II) products, [{(Priso)Mg} 2 (μ‐H)(μ‐Ar)] 4 – 9 . In contrast to similar reactions reported for β‐diketiminate coordinated counterparts of 3 , these C−H activations proceed with little regioselectivity, though they are considerably faster. Reaction of 3 with an excess of the pyridine, p ‐NC 5 H 4 Bu t (py Bu t ), gave [(Priso)Mg(py Bu t H)(py Bu t ) 2 ] 10 , presumably via reduction of the pyridine to yield a radical intermediate, [(Priso)Mg(py Bu t ⋅)(py Bu t ) 2 ] 11 , which then abstracts a proton from the reaction solvent or a reactant. DFT calculations suggest two possible pathways to the observed arene C−H activations. One of these involves photochemical cleavage of the Mg−Mg bond of 3 , generating magnesium(I) doublet radicals, (Priso)Mg⋅. These then doubly reduce the arene substrate to give “Birch‐like” products, which subsequently rearrange via C−H activation of the arene. Circumstantial evidence for the photochemical generation of transient magnesium radical species includes the fact that irradiation of a cyclohexane solution of 3 leads to an intramolecular aliphatic C−H activation process and formation of an alkyl‐bridged magnesium(II) species, [{Mg(μ‐Priso −H )} 2 ] 12 . Furthermore, irradiation of a 1 : 1 mixture of 3 and the β‐diketiminato dimagnesium(I) compound, [{( Dip Nacnac)Mg} 2 ] ( Dip Nacnac=[HC(MeCNDip) 2 ] − ), effects a “scrambling” reaction, and the near quantitative formation of an unsymmetrical dimagnesium(I) compound, [(Priso)Mg−Mg( Dip Nacnac)] 13 . Finally, the EPR spectrum (77 K) of a glassed solution of UV irradiated 3 is dominated by a broad featureless signal, indicating the presence of a doublet radical species.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2018

Development of Graphene Nanoplatelet-Reinforced AZ91 Magnesium Alloy by Solidification Processing

It is a challenging task to effectively incorporate graphene nanoplatelets (GNPs) which have recently emerged as potential reinforcement for strengthening metals into magnesium-based matrices by conventional solidification processes due to their large surface areas and poor wettability. A solidification processing which combines mechanical stirring and ultrasonic dispersion of reinforcements in liquid matrix was employed to develop AZ91 magnesium alloy matrix composites reinforced with 0.25 and 0.5 wt.% GNPs. The microstructural studies conducted with scanning and transmission electron microscopes revealed that fairly uniform distribution and dispersion of GNPs through the matrix were achieved due to effective combination of mechanical and ultrasonic stirring. The GNPs embedded into the magnesium matrix led to significant enhancement in the hardness, tensile strength and ductility of the composites compared to those of unreinforced AZ91 alloy. The strength enhancement was predominantly attributed to the grain refinement by the GNP addition and dislocation generation strengthening due to the coefficient of thermal expansion mismatch between the matrix and reinforcement. The improved ductility was attributed to the refinement of β eutectics by transforming from lamellar to the divorced eutectics due to the GNP additions. In addition, the strengthening efficiency of the composite with 0.25 wt.% GNP was found to be higher than those of the composite with 0.5 wt.% GNP as the agglomeration tendency of GNPs is increased with increasing GNP content. These results were compared with those of the GNP-reinforced magnesium composites reported in the literature, indicating the potential of the process introduced in this study in terms of fabricating light and high-performance metal matrix composites.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Microstructure, Texture, and Mechanical Properties of Continuously Extruded and Rolled AZ31 Magnesium Alloy Sheets

It is difficult to fabricate magnesium alloy sheets at room temperature due to their hexagonal close-packed structure. In this paper, we proposed a new process that can be used to fabricate AZ31 magnesium alloy sheets with fine-grained microstructure and good mechanical properties. AZ31 magnesium alloy sheets with dimensions of 160 mm × 8 mm were obtained successfully by a continuous extrusion technique. The extruded sheets were then rolled by two different rolling routes, Route 1: the extruded sheet was heated at 350 °C and then rolled without heating of rolls and Route 2: the sheet was rolled without any previous heating by heating rolls at 280 °C. The microstructure and texture evolution as well as mechanical properties of the continuously extruded and rolled sheets were examined experimentally. The magnesium alloy sheets with relatively fine grains of 4.5-8.3 µm were obtained by continuous extrusion followed by rolling processes. The tensile strength of continuously extruded AZ31 Mg alloy sheets can be effectively increased by rolling using heating rolls (Route 2), while the ductility was enhanced by rolling heated sheets (Route 1). The mixed microstructure, consisting of refined DRX grains and deformed grains, contributes to enhancement in tensile strength of the sheet samples rolled by Route 2 due to grain-boundary strengthening and work hardening. Lower temperature and larger rolling reduction are two main factors for improving the tensile strength of AZ31magnesium alloy sheets.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Effect of pulverized fuel ash and CO{sub 2} curing on the water resistance of magnesium oxychloride cement (MOC)

This paper presents a study on the use of pulverized fuel ash (PFA) to improve the water resistance of magnesium oxychloride cement (MOC). Strength retention coefficients and volume stability were tested to evaluate the water resistance of MOC, in which the addition of PFA resulted in a remarkable improvement. The characterization of hydration products before and after water immersion was carried out using quantitative X-ray diffraction (QXRD), thermogravimetric (TG), Fourier-transformed infrared spectroscopy (FTIR) and scanning electron microscope (SEM). With the Q-XRD analysis, it was shown that the addition of PFA could result in the great increase of the amount of amorphous phase during air curing. This amorphous gel was identified as a mixture of magnesium-chloride-silicate-hydrate gel (M-Cl-S-H gel) and magnesium-chloride-hydrate gel (M-Cl-H gel) by elemental mapping scanning. It suggested that PFA could not only react with MOC to form M-Cl-S-H gel, but also change the morphology of magnesium oxychloride. The generation of insoluble M-Cl-S-H gel and M-Cl-H gel and densification of the microstructure contributed to the improvement of the water resistance of MOC. The MOC mortar expanded during air curing due to the hydration of excess MgO. Water immersion led to more expansion of MOC mortar as a result of the continuously hydration of excess MgO and the formation of Mg(OH){sub 2}. Adding PFA could increase the expansion of MOC mortar during air curing, which may because the amorphous gel could remain more water and benefit to the hydration of MgO. While, the addition of PFA could decrease the expansion of cement mortar during water immersion perhaps due to the reduction of the content of excess MgO and the insoluble amorphous-gel-layer that protect the MgO from hydration. Moreover, CO{sub 2} curing could further improve the performance of the PFA-blended MOC due to the formation of a higher content of amorphous gel.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Development of mechanical properties in a CaO added AZ31 magnesium alloy processed by equal-channel angular pressing

Processing through the application of equal-channel angular pressing (ECAP) is recognized as one of the attractive severe plastic deformation techniques where the processed bulk metals generally achieve ultrafine-grained microstructure leading to improved physical characteristics and mechanical properties. Magnesium has received much attention to date for its lightweight, high strength and excellent elasticity. Mg alloys with addition of CaO is reported to provide the successful casting procedure without usage of greenhouse gas, SF{sub 6}, whereas it is generally used for preventing the oxidation of Mg during casting. In the present investigation, a CaO added AZ31 (AZ31-CaO) magnesium alloy was processed by ECAP at elevated temepratures with a few steps of reduction which result in significant grain refinement to ~ 1.5 μm after 6 passes. Compression testing at room temperature demonstrated the AZ31-CaO alloy after ECAP showed enhanced yield strength more than the as-processed commercial AZ31 alloy while both alloys maintained ductility in spite of significant reduction in grain size. The improved strength in the AZ31-CaO alloy was attributed to the formation of fine Al{sub 2}Ca precipitates which experience breaking-up through ECAP and accelerate the microstructural refinement. Moreover, the preservation of ductility was attributed to the enhancement of strain hardening capability in the AZ31 alloy at room temperature. This study discusses the feasibility of using ECAP to improve both strength and ductility on magnesium alloys by applying the diagram describing the paradox of strength and ductility. - Highlights: • AZ31 and AZ31-CaO magnesium alloys were processed by ECAP up to 6 passes. • AZ31-CaO alloy after ECAP showed improved yield strength without losing ductility. • CaO in AZ31 forms fine Al{sub 2}Ca accelerating microstructural refinement during ECAP. • Feasibility of using ECAP was shown to improve both strength and ductility in Mg.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Magnesium diboride (MgB2): An effective and novel precursor for the synthesis of vertically aligned BNNTs

Highlights: • Discovered Magnesium diboride (MgB{sub 2}) as an effective and novel precursor for the synthesis of BNNTs. • Synthesized vertically aligned BNNTs directly on SiO{sub 2} substrate at 1000{sup °}C. • Magnesium (Mg) from MgB{sub 2} in partially melted form diffuses on SiO{sub 2} substrate. • The adsorbed Boron with Mg reacts with Nitrogen from decomposed ammonia and synthesized vertically aligned BNNTs. - Abstract: Vertically aligned Boron nitride nanotubes (BNNTs) have exceptional electrical, mechanical and thermal properties suitable for its potential applications without any further purification. However, the synthesis of aligned BNNTs via previously reported techniques is not only complicated, lengthy and misleading but also result in useless impurities in the final product. Here, we report Magnesium diboride (MgB{sub 2}) as an effective and novel precursor for the synthesis of vertically aligned BNNTs directly on SiO{sub 2} substrate at 1000 {sup °}C. Magnesium (Mg) from MgB{sub 2} in partially melted form diffuses on SiO{sub 2} substrate whereas the adsorbed Boron with Mg reacts with Nitrogen from decomposed ammonia and synthesized vertically aligned BNNTs. The morphology, alignment, structure and compositions of the as-synthesized BNNTs are studied via field emission scanning electron microscope, high resolution transmission electron microscope, energy dispersive x-ray spectroscopy, x-ray diffraction, Raman spectroscopy and Fourier transform infrared spectroscopy.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2019

Investigation of continuous carbothermal reduction of magnesia by magnesium vapor condensation onto a moving bed of solid particles

Magnesium metal production by carbothermic reduction (CTR) can reduce process emissions and energy requirements relative to silicothermic or electrolytic production, if high magnesium metal yields are achieved. A novel process was investigated where product magnesium gas condensed onto a moving bed of solid particles at high temperatures (≥300 °C) and in vacuum to minimize reversion and promote crystal growth. Using a half-system in which CTR product gases were artificially generated, magnesium continuously condensed onto steel, oxide, or carbide particles at yields >85% for P Mg = 0.5 kPa. Steel particles exhibited the greatest bed retention and ease of separation, so this medium was used for scale-up to a full-system in which MgO CTR in a fixed bed gasifier at 1400 °C–1550 °C produced Mg (g) and CO. The initial reduction resulted in high Mg yield (>80%), but yield decreased as the reaction proceeded. The accumulation of Mg (s) and reversion product in the condenser promoted further reversion. The process yield could likely be improved by using high surface area particles to promote heat and mass transfer, allowing for shorter solid and gas residence times in the condenser. A finite volume model on the reactor tube and pellet bed described the kinetics, heat transfer, and mass transfer phenomena in the reduction reactor. The model predicted that the center of the bed was >50 °C cooler than the furnace, and the product gas pressures were near equilibrium. A wide, directly heated reactor could overcome these heat and mass transfer limitations.

42 ENGINEERING↗