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Presentation Outline 1. What is spray drying? 2. How can spray drying be utilized for high explosives processing? 3. Literature overview. 4. Examples of current spray drying research done in Q-5. 5. Future plans and outlook for spray drying high explosives.
Reaction Engineering International (REI) has managed a team of experts from the University of Utah, Southeast University (SEU) in Nanjing, China, Electric Power Research Institute (EPRI), Corrosion Management Ltd. (C-M), Praxair, and Brigham Young University (BYU) to investigate dry pulverized coal feeding for pressurized oxy-coal combustion. Dry feed firing systems for entrained flow, pressurized, oxy-coal combustors have not been well developed, although related technologies have been used in the Shell Gasification Process and for pressurized fluid bed combustion. DOE-funded research recently completed at REI and the University of Utah focused on characterizing impacts of high temperatures and pressures in oxy-coal combustion systems. For high pressure combustion, that research used a coal slurry feed into a 17 bar pressurized combustor. As a consequence of that research, it was identified that fuel feeding and firing system flexibility are challenges that require attention. Based on that experience, the approach of using a coal slurry feed system leads to challenges in producing consistent atomization of the slurry, which causes burnout problems, especially at high pressures. In addition, slurry atomization processes may be difficult to scale to sizes appropriate for practical commercial use. Dry pressurized coal burner systems, on the other hand, have the potential to yield efficiency gains, improve flexibility and facilitate applications at larger scales. Experimental work was conducted at the University of Utah Industrial Combustion and Gasification Research Facility as well as the 100 kW pressurized oxy-coal combustor (POC) facility at Brigham Young University. Mechanism development and CFD-based combustion and dense-phase flow modeling were performed at REI. Successful completion of the project objectives has resulted in the following key deliverables: 1) Design and prototype of a pressurized pulverized coal feeding and oxy-firing system 2) Data from a 100kW, pressurized (15 bar) entrained flow reactor with a dry feeding delivery and burner system that describes flame characteristics, radiative heat flux profiles, carbon burnout, along with characteristics of ash aerosols, fouling, and slagging. 3) Validated and transportable models that describe the relevant conditions in pressurized oxy-combustion systems and that can be used for scale-up and optimization. 4) Principles to guide design of high pressure, pilot-scale and full-scale coal oxy-firing systems. 5) Assessment of pressurized oxy-combustion impacts on key parameters relevant to oxy-coal fired utility boilers such as coal devolatilization, char oxidation, mineral matter transformation, deposition, and corrosion. The experimental data, pressurized oxy-firing system principles, and process mechanisms provided by this work can be used by electric utilities, boiler OEMs, equipment suppliers, design firms, software vendors, consultants and government agencies to assess the use of high temperature and high pressure oxy-combustion in current research and to guide development of new oxy-coal boiler designs.
Reaction Engineering International (REI) has managed a team of experts from the University of Utah, Southeast University (SEU) in Nanjing, China, Electric Power Research Institute (EPRI), Corrosion Management Ltd. (C-M), Praxair, and Brigham Young University (BYU) to investigate dry pulverized coal feeding for pressurized oxy-coal combustion. Dry feed firing systems for entrained flow, pressurized, oxy-coal combustors have not been well developed, although related technologies have been used in the Shell Gasification Process and for pressurized fluid bed combustion. DOE-funded research recently completed at REI and the University of Utah focused on characterizing impacts of high temperatures and pressures in oxy-coal combustion systems. For high pressure combustion, that research used a coal slurry feed into a 17 bar pressurized combustor. As a consequence of that research, it was identified that fuel feeding and firing system flexibility are challenges that require attention. Based on that experience, the approach of using a coal slurry feed system leads to challenges in producing consistent atomization of the slurry, which causes burnout problems, especially at high pressures. In addition, slurry atomization processes may be difficult to scale to sizes appropriate for practical commercial use. Dry pressurized coal burner systems, on the other hand, have the potential to yield efficiency gains, improve flexibility and facilitate applications at larger scales. Experimental work was conducted at the University of Utah Industrial Combustion and Gasification Research Facility as well as the 100 kW pressurized oxy-coal combustor (POC) facility at Brigham Young University. Mechanism development and CFD-based combustion and dense-phase flow modeling were performed at REI. Successful completion of the project objectives has resulted in the following key deliverables: 1) Design and prototype of a pressurized pulverized coal feeding and oxy-firing system 2) Data from a 100kW, pressurized (15 bar) entrained flow reactor with a dry feeding delivery and burner system that describes flame characteristics, radiative heat flux profiles, carbon burnout, along with characteristics of ash aerosols, fouling, and slagging. 3) Validated and transportable models that describe the relevant conditions in pressurized oxy-combustion systems and that can be used for scale-up and optimization. 4) Principles to guide design of high pressure, pilot-scale and full-scale coal oxy-firing systems. 5) Assessment of pressurized oxy-combustion impacts on key parameters relevant to oxy-coal fired utility boilers such as coal devolatilization, char oxidation, mineral matter transformation, deposition, and corrosion. The experimental data, pressurized oxy-firing system principles, and process mechanisms provided by this work can be used by electric utilities, boiler OEMs, equipment suppliers, design firms, software vendors, consultants and government agencies to assess the use of high temperature and high pressure oxy-combustion in current research and to guide development of new oxy-coal boiler designs.
Reaction Engineering International (REI) has managed a team of experts from the University of Utah, Southeast University (SEU) in Nanjing, China, Electric Power Research Institute (EPRI), Corrosion Management Ltd. (C-M), Praxair, and Brigham Young University (BYU) to investigate dry pulverized coal feeding for pressurized oxy-coal combustion. Dry feed firing systems for entrained flow, pressurized, oxy-coal combustors have not been well developed, although related technologies have been used in the Shell Gasification Process and for pressurized fluid bed combustion. DOE-funded research recently completed at REI and the University of Utah focused on characterizing impacts of high temperatures and pressures in oxy-coal combustion systems. For high pressure combustion, that research used a coal slurry feed into a 17 bar pressurized combustor. As a consequence of that research, it was identified that fuel feeding and firing system flexibility are challenges that require attention. Based on that experience, the approach of using a coal slurry feed system leads to challenges in producing consistent atomization of the slurry, which causes burnout problems, especially at high pressures. In addition, slurry atomization processes may be difficult to scale to sizes appropriate for practical commercial use. Dry pressurized coal burner systems, on the other hand, have the potential to yield efficiency gains, improve flexibility and facilitate applications at larger scales. Experimental work was conducted at the University of Utah Industrial Combustion and Gasification Research Facility as well as the 100 kW pressurized oxy-coal combustor (POC) facility at Brigham Young University. Mechanism development and CFD-based combustion and dense-phase flow modeling were performed at REI. Successful completion of the project objectives has resulted in the following key deliverables: 1) Design and prototype of a pressurized pulverized coal feeding and oxy-firing system 2) Data from a 100kW, pressurized (15 bar) entrained flow reactor with a dry feeding delivery and burner system that describes flame characteristics, radiative heat flux profiles, carbon burnout, along with characteristics of ash aerosols, fouling, and slagging. 3) Validated and transportable models that describe the relevant conditions in pressurized oxy-combustion systems and that can be used for scale-up and optimization. 4) Principles to guide design of high pressure, pilot-scale and full-scale coal oxy-firing systems. 5) Assessment of pressurized oxy-combustion impacts on key parameters relevant to oxy-coal fired utility boilers such as coal devolatilization, char oxidation, mineral matter transformation, deposition, and corrosion. The experimental data, pressurized oxy-firing system principles, and process mechanisms provided by this work can be used by electric utilities, boiler OEMs, equipment suppliers, design firms, software vendors, consultants and government agencies to assess the use of high temperature and high pressure oxy-combustion in current research and to guide development of new oxy-coal boiler designs.
Drying processes are one of the most energy intensive operations. Drying accounts for anywhere from 12 to 20% of the energy consumption in the industrial sector. While many different drying processes and thus technologies exist and each is appropriate for particular applications, convective heated-air dryers account for about 85% of all industrial dryers, where air is heated by the combustion of fossil fuels prior to being forced through the product. The electric-field dewetting concept evaluated has the potential to increase heat pumping efficiency by 30% assuming a typical sensible heat ratio of 70%. At full deployment, this can reduce drying energy by 25%. Further, the technology can benefit the performance of air-source heat pumps in general and broaden their application base resulting in greater energy reductions.
During maximum braking the average ratio of drag-force friction coefficient developed by the antiskid system to maximum drag-force friction coefficient available at the tire/runway interface was higher on dry surfaces than on wet surfaces. The gross stopping power generated by the brake system on the dry surface was more than twice that obtained on the wet surfaces. With maximum braking applied, the average ratio of side-force friction coefficient developed by the tire under antiskid control to maximum side-force friction available at the tire/runway interface of a free-rolling yawed tire was shown to decrease with increasing yaw angle. Braking reduced the side-force friction coefficient on a dry surface by 75 percent as the wheel slip ratio was increased to 0.3; on a flooded surface the coefficient dropped to near zero for the same slip ratio. Locked wheel skids were observed when the tire encountered a runway surface transition from dry to flooded, due in part to the response time required for the system to sense abrupt changes in the runway friction; however, the antiskid system quickly responded by reducing brake pressure and cycling normally during the remainder of the run on the flooded surface.
The dry-heat resistance characteristics of spores of psychrophilic organisms isolated from soil samples from the Viking spacecraft assembly areas at Cape Kennedy Space Flight Center, Cape Canaveral, Fla., were studied. Spore suspensions were produced, and dry-heat D values were determined for the microorganisms that demonstrated growth or survival under a simulated Martian environment. The dry-heat tests were carried out by using the planchet-boat-hot plate system at 110 and 125 C with an ambient relative humidity of 50% at 22 C. The spores evaluated had a relatively low resistance to dry heat. D (110 C) values ranged from 7.5 to 122 min, whereas the D (125 C) values ranged from less than 1.0 to 9.8 min.
The effectiveness of dry chemical in extinguishing and delaying reignition of fires resulting from hydrocarbon fuel leaking onto heated surfaces such as can occur in jet engine nacelles is studied. The commercial fire extinguishant dry chemical tried are sodium and potassium bicarbonate, carbonate, chloride, carbamate (Monnex), metal halogen, and metal hydroxycarbonate compounds. Synthetic and preparative procedures for new materials developed, a new concept of fire control by dry chemical agents, descriptions of experiment assemblages to test dry chemical fire extinguishant efficiencies in controlling fuel fires initiated by hot surfaces, comparative testing data for more than 25 chemical systems in a 'static' assemblage with no air flow across the heated surface, and similar comparative data for more than ten compounds in a dynamic system with air flows up to 350 ft/sec are presented.
The feasibility of using a freeze-drying (solvent removal by sublimation) approach for controlling the morphology of a high-performance semi-IPN is assessed. A high-performance thermoplastic polyimide and commercially available 4,4'-bismaleimide diphenylenemethane were dissolved in a solvent, 1,3,5-trioxane. The solvent was removed from the constituents by freeze-drying. For purposes of comparison, the constituents were dissolved in a high-boiling-point solvent, N,N-dimethylformamide. The solvent was removed from the solution by evaporation. The physical and mechanical properties and phase morphology of the neat resins and composites prepared by freeze-drying and traditional solution methods are presented and compared. It is concluded that the TG is higher and that the magnitude of minor constituent separation is less in the freeze-dry processed materials than for the processed solution.
Field research conducted in the Antarctic has been providing insights about the nature of Mars in the science disciplines of exobiology and geology. Located in the McMurdo Dry Valleys of southern Victoria Land (160 deg and 164 deg E longitude and 76 deg 30 min and 78 deg 30 min S latitude), research outposts are inhabited by teams of 4-6 scientists. It is proposed that the design of these outposts be expanded to enable meaningful tests of many of the systems that will be needed for the successful conduct of exploration activities on Mars. Although there are some important differences between the environment in the Antarctic dry valleys and on Mars, the many similarities and particularly the field science activities, make the dry valleys a useful terrestrial analog to conditions on Mars. Three areas have been identified for testing at a small science outpost in the dry valleys: (1) studying human factors and physiology in an isolated environment; (2) testing emerging technologies (e.g. innovative power management systems, advanced life support facilities including partial bioregenerative life support systems for water recycling and food growth, telerobotics, etc.); and (3) conducting basic scientific research that will enhance understanding of Mars while contributing to the planning for human exploration. It is suggested that an important early result of a Mars habitat program will be the experience gained by interfacing humans and their supporting technology in a remote and stressful environment.
McDonnell Douglas came up with a new method of drying agricultural crops derived from vacuum chamber technology called MIVAC, a compression of microwave vacuum drying system. A distant cousin of the home microwave oven, MIVAC dries by means of electrically- generated microwaves introduced to a crop-containing vacuum chamber. Microwaves remove moisture quickly and the very low pressure atmosphere in the chamber permits effective drying at much lower than customary temperatures. Thus energy demand is doubly reduced by lower heat requirement and by the shorter time electric power is needed.
Future generation aerospace vehicles will require specialized hybrid material forms for component structure fabrication. For this reason, high temperature composite prepregs in both dry and wet forms are being developed at NASA Langley Research Center (LaRC). In an attempt to improve compressive properties of carbon fiber reinforced composites, a hybrid carbon-boron tape was developed and used to fabricate composite laminates which were subsequently cut into flexural and compression specimens and tested. The hybrid material, given the designation HYCARB, was fabricated by modifying a previously developed process for the manufacture of dry polymer matrix composite (PMC) tape at LaRC. In this work, boron fibers were processed with IM7/LaRC(TradeMark)IAX poly(amide acid) solution-coated prepreg to form a dry hybrid tape for Automated Tow Placement (ATP). Boron fibers were encapsulated between two (2) layers of reduced volatile, low fiber areal weight poly(amide acid) solution-coated prepreg. The hybrid prepreg was then fully imidized and consolidated into a dry tape suitable for ATP. The fabrication of a hybrid boron material form for tow placement aids in the reduction of the overall manufacturing cost of boron reinforced composites, while realizing the improved compression strengths. Composite specimens were press-molded from the hybrid material and exhibited excellent mechanical properties.
One component of a proposed life support system is the use of zeoponic substrates, which slowly release NH4+ into "soil" solution, for the production of plants. Nitrifying bacteria that convert NH4+ to NO3- are among the important microbial components of these systems. Survival of nitrifying bacteria in dry zeoponic substrates is needed, because the substrate would likely be stored in an air-dry state between croppings. Substrate was enriched for nitrifying bacteria and allowed to air-dry in a laminar flow hood. Stored substrate was analyzed for nitrifier survivability by measuring nitrifier activity at the beginning, 3 days, 1, 2, and 3 weeks. After rewetting, activity was approximately 9 micrograms N g-1 h-1 regardless of storage time. Nitrification rates did not decrease during storage. It seems unlikely that drying between plantings would result in practical reductions in nitrification, and reinoculation with nitrifying bacteria would not be necessary.
The Antarctic Dry Valleys (ADVs) located in the Transantarctic Mountains are the coldest and driest locations on Earth. The mean annual air temperature is -20 C or less and the ADVs receive 100mm or less of precipitation annually in the form of snow. The cold and dry climate in the ADVs is one of the best terrestrial analogs for the climatic conditions on Mars [2]. The soils in the ADVs have been categorized into three soil moisture zones: subxerous, xerous and ultraxerous. The subxerous zone is a coastal region in which soils have ice-cemented permafrost relatively close to the surface. Moisture is available in relatively large amounts and soil temperatures are above freezing throughout the soil profile (above ice permafrost) in summer months. The xerous zone, the most widespread of the three zones, is an inland region with a climate midway between the subxerous and ultraxerous. The soils from this zone have dry permafrost at moderate depths (30-75cm) but have sufficient water in the upper soil horizons to allow leaching of soluble materials. The ultraxerous zone is a high elevation zone, where both temperature and precipitation amounts are very low resulting in dry permafrost throughout the soil profile. The three moisture regime regions are similar to the three microclimatic zones (coastal thaw, inland mixed, stable upland) defined by Marchant and Head.
Terrestrial weathering processes in cold-desert climates such as the Dry Valleys of Antarctica may provide an excellent analog to chemical weathering and diagenesis of soils on Mars. Detailed studies of soil development and the chemical and mineralogical alterations occurring within soil columns in Wright Valley, Antarctica show incredible complexity in the upper meter of soil. Previous workers noted the ice-free Dry Valleys are the best terrestrial approximations to contemporary Mars. Images returned from the Pathfinder and Spirit landers show similarities to surfaces observed within the Dry Valleys. Similarities to Mars that exist in these valleys are: mean temperatures always below freezing (-20 C), no rainfall, sparse snowfall-rapidly removed by sublimation, desiccating winds, diurnal freeze-thaw cycles (even during daylight hours), low humidity, oxidative environment, relatively high solar radiation and low magnetic fields . The Dry Valley soils contain irregular distributions and low abundances of soil microorganisms that are somewhat unusual on Earth. Physical processes-such as sand abrasion-are dominant mechanisms of rock weathering in Antarctica. However, chemical weathering is also an important process even in such extreme climates. For example, ionic migration occurs even in frozen soils along liquid films on individual soil particles. It has also been shown that water with liquid-like properties is present in soils at temperatures on the order of approx.-80 C and it has been observed that the percentage of oxidized iron increases with increasing soil age and enrichments in oxidized iron occurs toward the surface. The presence of evaporates is evident and appear similar to "evaporite sites" within the Pathfinder and Spirit sites. Evaporites indicate ionic migration and chemical activity even in the permanently frozen zone. The presence of evaporates indicates that chemical weathering of rocks and possibly soils has been active. Authogenic zeolites have been identified within the soil columns because they are fragile; i.e. they are euhedral, unabraded, and unfractured, strongly suggesting in situ formation. Their presence in Antarctic samples is another indication that diagenic processes are active in cold-desert environments. The presence of zeolites, and other clays along with halites, sulfates, carbonates, and hydrates are to be expected within the soil columns on Mars at the Gusev and Isidis Planitia regions. The presence of such water-bearing minerals beneath the surface supplies one of the requirements to support biological activity on Mars.
The distribution of water-soluble ions, major and minor elements, and other parameters were examined to determine the extent and effects of chemical weathering on cold desert soils. Patterns at the study sites support theories of multiple salt forming processes, including marine aerosols and chemical weathering of mafic minerals. Periodic solar-mediated ionization of atmospheric nitrogen might also produce high nitrate concentrations found in older sediments. Chemical weathering, however, was the major contributor of salts in Antarctic Dry Valleys. The Antarctic Dry Valleys represent a unique analog for Mars, as they are extremely cold and dry desert environments. Similarities in the climate, surface geology, and chemical properties of the Dry Valleys to that of Mars imply the possible presence of these soil formation mechanisms on Mars, other planets and icy satellites.
Climate change impacts on dry season streamflow in the Mekong River are relatively understudied, despite the fact that water availability during this time is critically important for agricultural and ecological systems. Analyses of two gauging stations (Vientiane and Kratie) in the Lower Mekong Basin (LMB) show significant positive correlations between dry season (March through May, MAM) discharge and upper basin snow cover and local precipitation. Using snow cover, precipitation, and upstream discharge as predictors, we develop skillful regression models for MAM streamflow at Vientiane and Kratie, and force these models with output from a suite of general circulation model (GCM) experiments for the twentieth and twenty-first centuries. The GCM simulations predict divergent trends in snow cover (decreasing) and precipitation (increasing) over the twenty-first century, driving overall negligible long-term trends in dry season streamflow. Our study demonstrates how future changes in dry season streamflow in the LMB will depend on changes in snow cover and precipitation, factors that will need to be considered when assessing the full basin response to other climatic and non-climatic drivers.
Removal of carbon dioxide (CO2) is a necessary step in air revitalization and is often accomplished with sorbent materials. Since moisture competes with CO2 in sorbent materials, it is necessary to remove the water first. This is typically accomplished in two stages: bulk removal and residual drying. Silica gel is used as the bulk drying material in the Carbon Dioxide Removal Assembly (CDRA) in operation on ISS. There has been some speculation that silica gel may also be capable of serving as the residual drying material. This paper will describe test apparatus and procedures for determining the performance of silica gel in residual air drying.