3. Electronic Theses and Dissertations (ETDs) - All submissions
Permanent URI for this communityhttps://wiredspace.wits.ac.za/handle/10539/45
Browse
4 results
Search Results
Item Feasible products and cost indicators for vapour-liquid equilibrium separation processes(1996) Jobson, Megan RuthThe aim of process synthesis is to select process equipment and interconnections in order to achieve some performance goal, such as the composition of one or more products, in an optimal manner. This work focuses on the synthesis and optimization of vapour-liquid equilibrium (VLE) separation processes. The regions of feasible products for a range of VLE separation processes (including simple distillation, simple condensation and processes comprised of one or two flash stages and mixing) are determined and analyzed. Binary and ternary systems, both ideal and non-ideal, are considered. It is shows .at the products of VLE separation processes are not inherently restricted; limitations in product composition are therefore introduced by the choice of separation equipment. The products on the boundary of the region of feasible products are often found to be associated with infinite costs. Therefore costs and, product composition should he considered simultaneously in process synthesis. This work introduces a pair of variables which are proposed as cost indicators for VLE separation processes. These variables, which are called "capacity variables", pertain to distillation columns and a wide range of other VLE separation processes, allowing their comparison. The variables incorporate both capital and energy costs of a process and are thus related to total annual costs. They accommodate costs of both boiling and condensing. They ate simple to calculate from the mass balance equations. The capacity variables are analogous to mean residence time, which serves as a cost indicator for processes invoi ving reaction. The capacity variables are evaluated for a range of processes separatins binary and ternary mixtures and a range of thermodynamic systems. The capacity variables reflect the impact of the operating parameters, such as product specifications and reflux ratio, on process costs. In distillation processes, the optimum reflux ratio is found to be close to the beuristic value of 1.2 times the minimum reflux ratio. The capacity variables are proposed as useful tools for the initial stages of process synthesis.Item Synthesis and performance evaluation of Nanocomposite SAPO-34/ceramic membranes for CO₂/N₂ mixture separation(2017) Kgaphola, Kedibone LawrenceGlobal warming, resulting from emission of greenhouse gases (GHGs), is the cause of drastic climate changes that threatens the economy and living conditions on the planet. Currently, recovery and mitigation of these greenhouse gases remains a technological and scientific challenge. Various recovery processes for the mitigation of GHGs have been reported including among others carbon capture and storage (CCS). The most mature and applied technology in CCS process involves the absorption of carbon dioxide on amine based solvents. However, studies have shown that this process has several drawbacks that include low stability and high energy required to strip off the absorbed CO2 and regenerate the solvent. This presents an opportunity for the development of new materials for CO2 capture such as zeolite membranes. Previous studies have shown that the separation of CO2 can be achieved with high selectivity at low temperatures using thin-film SAPO-34 membranes (thin layers on supports). This is because CO2 adsorbs strongly on the membranes compared to other gases found in flue gas. In the thin-film membranes supported on ceramic or sintered stainless steel, thermal expansion mismatch may occur at higher operating temperatures resulting in loss of membrane selectivity due to the formation of cracks. A new method is required to overcome the aforementioned problems, thereby enhancing the separation application of the membranes at higher temperatures. The effective separation and capture of CO2 from the coal-fired power plant flue gas is an essential part in the CCS process (Figueroa et al., 2016; Yang et al., 2008). Currently, the capture stage is a huge contributor to the overall cost of CCS (Yang et al., 2008). This is due to the high-energy intensity and inefficient thermal processes applied in the separation and capture in various industrial applications (Yang et al., 2008). This work presents the use of nanocomposite SAPO-34 zeolite membranes synthesized via the pore-plugging hydrothermal method for the separation of CO2 during post-combustion CO2 capture. The SAPO-34 membranes used were supported on asymmetric α-alumina as membrane supports. The membranes were characterized with a combination of dynamic and static physicochemical techniques such as Basic Desorption Quality Test (BDQT), X-ray diffraction (XRD) spectroscopy, Scanning Electron Microscopy (SEM), Fourier Transform Infrared (FTIR) spectroscopy and thermogravimetric analysis (TGA). The characteristic peaks at 2θ = 21°, 26°, and 32° on the XRD pattern confirmed the presence of SAPO-34 with a rhombohedral crystalline structure. The SEM images showed the formation of the cubic crystalline which were consistent with the reported morphology of SAPO-34. FTIR spectra showed the presence of the essential double-6 membered rings (D6R) and TO4 structural groups in surface chemistry of crystalline materials further confirming the presence SAPO-34. The TGA confirmed that the membranes possessed high thermal stability. To assess the feasibility of the synthesis process, the nanocomposite zeolites were grown within the tubular supports. The SEM images of the cross-section of the membrane confirmed the presence of the zeolites within the pores of the support confirming the fabrication of nanocomposite membranes by the pore-plugging synthesis method. The permeation tests used a dead-end filtration mode to measure the single gas permeance and the ideal selectivity of CO2 and N2 were calculated. The BDQT was essential in the study of the quality of the as-synthesized nanocomposite membranes. The quality of the membranes increased with an increase in the synthesis layers of the membranes. However, with an increase in synthesis layers, the membrane thickness also increases. The membrane thickness affected the gas permeance for CO2 and N2 significantly. The permeance of the N2 gas decreased from 10.73 x10-7 mol.s-1.m2Pa-1 after the first synthesis to 0.31 x10-7 mol.s-1.m2Pa-1 after seven synthesis layers. Alternatively, the more adsorbing gas CO2 decreased from 12.85 x10-7 mol.s-1.m2Pa-1 to 2.44 x10-7 mol.s-1.m2Pa-1. The performance of these zeolite membranes depends significantly on the operating conditions. Hence, we studied extensively the influence of the various operating conditions such as temperature, feed pressure and feed flowrate in this work. Results indicated that the membrane separation performance in this study is largely dependent on the temperature. In addition, the ideal selectivity decreased significantly with an increase in temperature. High temperatures results in less adsorption of the highly adsorbing CO2 gas, the permeance reduces significantly, while the permeance of the less adsorbing N2 increased slightly. The feed flow rate has less effect on the adsorbing gas while the non-absorbing gas increased resulting in a decrease in the ideal selectivity as well. The nanocomposite membranes in this study have a low flux compared to their thin film counterparts. An increase in feed pressure significantly increased the flux significantly as well as the ideal selectivity. Maxwell-Stefan model simulation was done in this study to describe the permeance of pure CO2 single gas permeance as a function of temperature. This model considered explicitly the adsorption-diffusion mechanism, which is the transport phenomenon, involved in the transport of CO2 through the zeolite membrane. The description of the support material was included in the model as well. However, the model was only applied to the CO2 gas permeation well within the experimental data. We then compared the model was with the experimental results and a good correlation was observed. In conclusion, SAPO-34 nanocomposite zeolite membranes were obtained at low temperatures (150 °C) with a short synthesis time (6 h). In addition, the high thermal stability of the as-synthesized SAPO-34 membranes makes them ideal for high temperature CO2 separation such as the intended post-combustion carbon capture. The BDQT revealed that the quality of the membranes was related to the thickness of the membranes. Therefore, better membrane quality was obtained with relatively thicker membranes. The separation performance evaluation was conducted on the membrane with the greatest quality. Our findings demonstrate that the performance of the membranes depends extensively on the operating conditions.Item Investigating particle size segregation in a batch jig(2016) Silwamba, MarthiasParticle size and size range are among the characteristics that affect the segregation of particles in a jig hence they affect the separation efficiency. The effects of these variables on segregation of particles are not fully understood. This work aimed at contributing to knowledge in this area. To better understand how particle size and size range influence segregation, tests were conducted in which the effects of the density and shape of the particles on segregation were minimized by using as the feed material spherical glass beads of uniform shape and density. Batch experiments of two components systems of various particle sizes were conducted under the same set of jigging conditions: the jigging frequency and jigging time were respectively maintained at 60 cycles per minute and 999 seconds (16.65 minutes). The effect of these operating conditions on segregation was not investigated. At the end of each test run, the jig bed was split into horizontal slices and the composition of each slice was determined. The experimental results showed that below a particle size ratio of 1.50:1, the driving force for the segregation of particles, i.e. the particle size difference, was small hence a low degree of segregation was obtained. The degree of segregation increased above this ratio. However, above the size ratio of 2.00:1, interstitial trickling occurred. With the smaller particles tested (8, 6 and 4mm) poor segregation was observed when the size ratios were of 1.50:1 or less along with what is believed to have been remixing due to convective currents within the jig chamber. It was found that the particle size range had a more pronounced effect on size segregation than the particle size. From the results, it can be said that above a size ratio of about 1.50:1, size segregation is very pronounced. This suggests that density separations of real ores, where both the density and size of particles vary, would be impaired if the particle size range of the material fed to the jig exceeds this ratio. However, this needs further confirmation by testing multiple component systems.Item Optimization of dense medium cyclone plant for the beneficiation of low grade iron ore with associated high proportion of near-density material at Sishen Iron Ore Mine(2016) Tom, PhakamileThe research report is premised on three aspects which are critical in the heavy mineral beneficiation. These aspects are classified as (i) understanding the densimetric profile of the available ore body, (ii) understanding the properties of the heavy medium utilised at the plant to beneficiate the ore, and (iii) the automation and modelling of the processing plant in order to maximise plant efficiency. Ore characterisation is mainly focused on understanding the densimetric profile of the ore body, in order to determine the probability of producing a saleable product as well as predicting the expected yields and quality. This is done to utilise the endowment entrusted upon the operating entity by the government and shareholders to treat the mineral resource to its full potential. Understanding of the beneficiation potential of the ore body will assist the mine planning and processing plant to optimise the product tons and quality. This will ensure the marketing plans are in accordance with the expected product as beneficiation will vary depending on the mining block reserves. The mining blocks have potential to produce varying product grades with different recoveries. Ore characterisation was conducted on the GR80 mining block, low-grade stockpiles (i.e. C-grade ore reserves & Jig discard and dense medium separation (DMS) run-of-mine (ROM) material. The GR80 material was characterised as having low proportion of near-density material and would be easy to beneficiate as well as produce high volumes of high grade product. Furthermore, it was revealed that the 2014 DMS ROM had an increased proportion of low-density material; however this material was also had low proportion of near-density material. The low-grade stockpiles was characterised by high proportion of near density material, which necessitate the beneficiation process to operate at high density in excess of 3.8 t/m3. Maintaining a higher operating density requires more dense medium which leads to viscosity problems and impact performance. The characterisation of the FeSi medium was imperative to understand its behaviour and potential influence on beneficiation of low-grade stockpiles and mining blocks with elevated proportion of near-density material. As the proportion of near-density waste material increases in the run-of-mine (ROM), it is necessary to beneficiate the material at elevated operating medium densities. However, when cyclones are operated at high densities, the negative influence of the medium viscosity becomes more apparent and thus influences the separation efficiency. Heavy medium, ferrosilicon (FeSi) characterisation looked at identifying the effects of viscosity on the FeSi stability and whether there would be a need for a viscosity modifier. Thus, the importance of controlling the stability, viscosity, and density of the medium cannot be under-estimated and can very often override the improvements attainable through better designs of cyclones. Furthermore, the slurry mixture of the heavy medium utilised for the purpose of dense medium separation should be non-detrimental to the effectiveness of separation in the DMS Fine cyclone plant. Medium characterisation showed that removal of ultra-fines leads to unstable media as indicated by faster settling rates. This would result in medium segregation in the beneficiation cyclone thereby leading to unacceptable high density differential which will negatively impact the cut-point shift and cause high yield losses to waste. The overall control of the metallurgical processes at Sishen’s Cyclone Plant is still done on manually and thus operation still varies from person-to-person and/or from shift-to-shift. This result in some of the process data and trends not being available online as well as being captured inaccurately. Furthermore, this negatively affects the traceability and reproducibility of the production metallurgical key performance indicators (KPI’s) as well as process stability and efficiency. It has been demonstrated that real-time online measurements are crucial to maintaining processing plant stability and efficiency thereby ensuring that the final product grade and its value is not eroded. Modelling and automation of the key metallurgical parameters for the cyclone plant circuit was achieved by installation of appropriate instrumentation and interlocking to the programmable logic control (PLC). This allowed for the control of the correct medium sump level, cyclone inlet pressure, medium-to-ore ratio as well as online monitoring of density differential as “proxy” for medium rheological characteristics. The benefit of modelling and simulation allows the virtual investigation and optimisation of the processing plant efficiency as well as analysis of the impact of varying ore characteristics, throughput variations and changing operating parameters. Therefore it is imperative that all cyclone operating modules are operated at the same efficiency which can be achieved by optimized process through proper automation and monitoring, thereby improving the total plant profitability. Keywords: dense medium separation; densimetric profile; dynamic modelling; FeSi rheology; iron-ore beneficiation; process automation; process control.