This study was aimed at understanding the environmental performance of two abrasives, coal slag and garnet which are commonly used by shipyards and many other industries in surface preparation of metallic surfaces. Environmental performance evaluated in this study included, (1) productivity (ft2/hr), (2) consumption and or used-abrasive generation rate (ton/2000 ft2; lb/ ft2), (3) particulate emission factors (mg/ft2; mg/lb; lb/lb; lb/kg; lb/ton). In order to achieve the study objectives, an emission test facility was built and necessary equipment and materials were procured. Blasting was performed on rusted steel panels inside the test facility and emissions were measured using EPA Source Test Method to quantify particulate emissions. By measuring the area cleaned, blasting time, and the abrasive consumed, environmental performance of coal slag and garnet was evaluated. Simple mathematical models were developed to predict performance based on feed rate and blast pressure. Garnet was observed to be more productive, less consuming, and more environmentally-friendly compared to coal slag. These study findings will valuable in reducing costs, improving productivity, and protecting the environment.

Dry abrasive blasting is one of the most widely used methods of surface preparation. Air emissions from this process include particulate matter (PM) and metals. Spent abrasive generated from this process may be hazardous in nature. With increasing concern on health effects due to silica emissions from sand, use of alternative materials is suggested by health and regulatory agencies. The objective of this research was to evaluate performance of expendable abrasives and determine PM emission factors. Dry abrasive blasting was performed in an enclosed chamber and total PM samples were collected. Three commonly used expendable abrasives, coal slag, copper slag and specialty sand, were used to evaluate cleaner alternatives. Blast pressure and abrasive feed rate, two important process conditions were varied to study their effect on performance of an abrasive. Productivity, consumption and emission factors (performance parameters) were calculated and their variation with pressure and feed rate was evaluated. Two dimensional and three dimensional predicted models were developed to estimate the performance at intermediate blast pressure and feed rate conditions. Performance of the three abrasives was compared with respect to emission potential, productivity and consumption. Emission factors developed in this research will help in accurate estimation of total PM emissions and to select cleaner abrasives and optimum process conditions that will results in minimum emissions and reduced health risk. The productivity and consumption models will help is estimating life cycle costs including material cost, equipment cost, energy cost, labor costs, waste disposal cost, and compliance costs. Consumption models will also help in determining the quantity of spent abrasive generated, identify abrasives with lower material consumption, and identify process conditions that generate minimum spent abrasives. In addition, these models will help industries in making environmentally preferable purchasing (EPP), which results in pollution prevention and cost reduction.

Thesis (PhD.(Metallurgy)--University of Pretoria, 2008. / Includes bibliographical references.

To meet the requirements of precise temperature monitoring at high temperatures in extremely corrosive environments, such as in coal gasifiers, a new sensor technology has been developed. This optical, ultra high temperature measurement system utilizes single crystal sapphire as a sensing element. A series of experiments was performed to determine the corrosion resistance of single crystal sapphire and single crystal fully stabilized cubic zirconia at high temperatures in coal slag and soda lime glass. The amount of corrosion of sapphire and zirconia in corrosive slags was measured at 1200°C, 1300°C, and 1400°C for different exposure times. The microstructural features at the interface of sapphire and zirconia were investigated using SEM and EDX analysis. The experimental measurements as well as SEM micrographs show very little or no degradation of sapphire and zirconia samples in corrosive slags. An interesting phenomenon was observed in the EDX scans of sapphire in the coal slag: the iron from the slag appears to have completely separated from the silicon and deposited at the sapphire surface. This interesting observation can be further explored to study whether this iron layer can be used to control the corrosion of sapphire. / Master of Science

The basic objective of this study was to evaluate the environmental performance of two abrasives Copper Slag and Barshot in terms of productivity (in terms of area cleaned- ft2/hr), consumption and or used-abrasive generation rate (of the abrasive- ton/2000ft2; lb/ft2) and particulate emissions (mg/ft2; mg/lb; lb/lb; lb/kg; lb/ton). This would help in evaluating the clean technologies for dry abrasive blasting and would help shipyards to optimize the productivity and minimize the emissions by choosing the best combinations reported in this study to their conditions appropriately. This project is a joint effort between the Gulf Coast Region Maritime technology Center (GCRMTC) and USEPA. It was undertaken to simulate actual blasting operations conducted at shipyards under enclosed, un-controlled conditions on plates similar to steel plates commonly blasted at shipyards.

科学研究費補助金 研究種目:基盤研究(B)(2) 課題番号:10480145 研究代表者:松田 仁樹 研究期間:1998-1999年度