The conventional cement grinding system, the ball mill, has very poor efficiencies in spite of innovative improvements. For this purpose, development of new techniques, which allow proper size reduction and uniform particle size distribution with less specific energy consumptions, have become a necessity. The aim of this study is to make a comparative analysis of the fairly new cement grinding technologies, COMFLEX&reg / Grinding System, Roller Press and HOROMILL&reg / , at the same cement production plant with the same raw materials. In this context, CEM I 42.5 R type cement was produced with a fixed Blaine fineness of 3600 (&plusmn / 100) cm2/g at three different grinding units. The same raw materials, clinker and gypsum, and identical feeding ratios, 95% and 5%, were used to produce cement. Accordingly, these different grinding techniques were inspected with respect to the microstructural properties of cement particles, and the relative chemical, physical and mechanical properties of products. It was found that the main cement grinding parameters, specific surface area and sieve residue, do not show expected relation and change with each grinding system due to differences in the size reduction technique. Moreover, strength and other hardened mortar properties are directly affected by the liberation conditions of reactive grains at grinding stages.High capacity and low specific energy consumption i.e. the breaking and cracking efficiency of the roller press and higher grinding performance of the ball mill promoted the COMFLEX&reg / system. On the other hand, the roller press was clearly advantageous at early strength performances with moderate specific energy usages during grinding. Nonetheless, it also had drawbacks like higher water demand and earlier setting times (which mean higher hydration temperatures). When the wideness and sharpness of classification results were considered, HOROMILL&reg / gave better results with high circulation and efficient air classification design / although there were weaknesses of the system such as lower capacity and higher specific energy consumption rate.

The aim of this research was to determine the effects of the fineness of different mineral additives on loss on ignition, heat of hydration, physical, mechanical and chemical properties of blended cements. For that purpose, portland cement clinker was replaced with granulated blast furnace slag (GBFS), natural pozzolan (NP) and limestone (L) at 6%, 20% and 35% replacement levels. Blended cements containing GBFS and NP were ground to a fineness of 3000, 5000 and 6000 cm2/g. Cements containing L were ground to 3000 cm2/g, 4000 cm2/g and 4500 cm2/g. All of the blended cement types mentioned above were both interground and separately ground to the specified fineness levels. Therefore, a total of 57 different cements were produced. Loss on ignition, heat of hydration, chemical, mechanical and physical analyses were performed on the produced cements. Moreover, the chemical analyses of the cements were obtained for cement particles finer (-45&mu / m) and coarser (+45&mu / m) than 45 &mu / m in order to determine the ingredients of -45 &mu / m, which is known to be more reactive. As a result it was shown that the grindability differences of the cement ingredients affect the properties of blended cements. An increase in the specific surface area increases both the compressive strength and heat of hydration values and adversely affects the loss on ignition values. The results also showed that if the cement particles were ground finer, it was more prone to moisture which resulted in higher loss on ignition values after longer periods.

Back grinding (BG) wastewater consists mainly of high-purity water and high concentrations of inorganic particles. If the BG wastewater could be treated and recycled efficiently, it should be sort of economic benefit. In this study, appropriate pre-treatment technologies are evaluated to obtain the feasible recycle system. From the chemical coagulation experiment, the addition of PAC or FeCl3, both of them can obviously reduce the turbidity and suspended solid concentrations (SS). In addition, polymer can advance the sedimentation process. Considering the cost of practical operation, the turbidity of BG waste water could be removed up to 97% by using polyaluminum chloride as the coagulant (2.2 mg/L) and polymer as the coagulant aid (0.5 mg/L) in the pH=7 condition . In sand filtration experiment, the turbidity and SS can¡¦t be effectively removed if the coagulation isn¡¦t used on BG wastewater. It demonstrates that BG wastewater contains high concentration of nano-scale particles. The rate of removable turbidity can reach 99% under applying coagulation, sedimentation, and sand filtration. In ultra-filtration experiment, both of spiral-wound (SW) and hollow-fiber (HF) can remove more than 99.9% of turbidity. For the flux of behavior, the performance of pre-treatment water is better than non-treatment water. Thus, it reveals that appropriate pre-treatment can lower the load of membrane filtration system. For the obtained recycle water, the grade of standard can achieve the grade of the cooling tower required. However, due to its high particle-containing characteristics, the commonly used reverse-osmoses (RO) membrane filtration technology can not be directly applied for purification process because the fouling/clogging problem would cause the frequent membrane replacement. In this lab-scale feasibility study, pre-treatment technologies (e.g., sand filtration, chemical coagulation, ultra-filtration) were applied to reduce the turbidity and particle concentrations of the BG wastewater (collected from a semiconductor manufacturing plant) before RO filtration unit. The BG wastewater contained turbidity and suspended solid concentrations of 3,200 NTU and 96 mg/L, respectively. The measured pH and conductivity of the BG wastewater were in the ranges of 6.8 to 7.2 and 14 to 18 £gS/cm, respectively. Moreover, the particle sizes of the solids varied from 300 to 700 nm. Thus, applying conventional sand filtration along could not effectively remove the nano-scale particles. Results from the chemical coagulation experiment reveal that the turbidity and particles of the BG wastewater could be significantly removed (up to 95% of turbidity and particle removal) by the coagulation/sedimentation process using polyaluminum chloride as the coagulant (2.2 mg/L) and polymer as the coagulant aid (0.5 mg/L). Results also indicate that up to 99% of turbidity and particle removal could be obtained with the application of ultra-filtration unit after the coagulation/sedimentation process. Results from this study indicate that applying appropriate pre-treatment technologies (coagulation and ultra-filtration) would lower the fouling rate and extend the life of RO membrane used for BG wastewater purification.

The cutting action of a single abrasive grain was investigated using a combination of high-speed scratch tests and finite element models. The high-speed scratch tests were unique in that the cutting conditions of a grinding operation were closely replicated. Two geometries were tested: a round-nosed stylus to approximate a 15-grit abrasive grain and a flat-nosed stylus to approximate a worn 46-grit abrasive grain. The three-dimensional finite element model was unique in that a hybrid Euler-Lagrange method was implemented to efficiently model the interaction between an abrasive grain and a workpiece. The finite element model was initially validated using indentation tests to remove the complexities of relative motion from the validation process. The validation was completed through comparisons to the experimental scratch tests. The results of the analysis revealed several key findings. Rubbing, plowing, and cutting do not display distinct transitions; rather, they coexist with different weightings depending on the scratching speed and the depth of cut. The normal forces increased for a given depth of cut as the scratching speed was increased due to strain-rate hardening of the workpiece. The tangential forces decreased for a given depth of cut as the scratching speed was increased due to a reduction in the coefficient of friction and a change in the cutting mechanics from plowing to cutting. The change in the cutting mechanics was investigated by analyzing the evolution of the scratch profiles as the depth of cut and scratching speed were changed. It was found that higher scratching speeds produced less material pile-up and this was attributed to a change in the cutting mechanics. Due to the change in the cutting mechanics, the specific energy decreased as the depth of cut and scratching speed were increased. A numerical case study revealed that reducing the grain size resulted in: lower forces, lower specific energies, and smaller volumes of subsurface stresses. The finite element model was adapted to work in conjunction with the flat-nosed stylus creating the first model capable of simulating the cutting of an abrasive grain in three dimensions.

A novel method was developed to design and fabricate nozzles capable of producing low-divergence fluid jets. Nozzle apertures were elliptical, and jets exhibited elliptical cross-sections with divergence varying predictably between 0 and 13°. Nozzle aperture aspect ratios varied from 1.00 to 2.45, area was equivalent to that of a 6mm diameter circle. An elliptical jet was developed with 0.4° and 0.9° divergence in the major and minor axes, respectively. Performance of this elliptical nozzle was compared to that of a circular nozzle via profiled creep-feed grinding trials. Results indicate the circular nozzle performs similarly to the horizontal ellipse; the vertical ellipse frequently caused wheel breakdown. Optimized cutting parameters: wheel speed 23m/s, cut depth 1.78mm, feed rate 200mm/min, jet pressure 3.21MPa or greater. Experiments were performed on a Blohm Planomat 408 CNC grinding machine using CimTech 310 cutting fluid. Nozzle experiments used a Brix concentration of 6.1%, grinding experiments used 3.1%.

No description available.

Nanometer-scale silicon shows extraordinary electronic and optical properties that are not available for bulk silicon, and many investigations toward applications in optoelectronic devices are being pursued. Silicon nanoparticle films made from solution are a promising candidate for low-cost solar cells. However, controlling the properties of silicon nanoparticles is quite a challenge, in particular shape and size distribution, which effect device performance. At present, none of the solar cells made from silicon nanoparticle films have an efficiency exceeding the efficiency of those based on crystalline silicon. To address the challenge of controlling silicon nanoparticle properties, both theoretical and experimental investigations are needed. In this thesis, we investigate silicon nanoparticle properties via quantum mechanical modeling of silicon nanoparticles and synthesis of silicon nanoparticle films via colloidal grinding. Silicon nanoparticles with shapes including cubic, rectangular, ellipsoidal and flat disk are modeled using semi-empirical methods and configuration interaction. Their electronic properties with different surface passivation were also studied. The results showed that silicon nanoparticles with hydrogen passivation have higher HOMOLUMO gaps, and also the HOMO-LUMO gap depends on the size and the shape of the particle. In contrast, silicon nanoparticles with oxygen passivation have a lower HOMO-LUMO gap. Raman spectroscopy calculation of silicon nanoparticles show peak shift and asymmetric broadening similar to what has been observed in experiment. Silicon nanoparticle synthesis via colloidal grinding was demonstrated as a straightforward and inexpensive approach for thin film solar cells. Data analysis of silicon particles via SEM images demonstrated that colloidal grinding is effective in reducing the Si particle size to sub-micron in a short grinding time. Further increases in grinding time, followed by filtration demonstrated a narrowing of the Si particle size and size-distribution to an average size of 70 nm. Raman spectroscopy and EDS data demonstrated that the Si nanoparticles contain oxygen due to exposure to air during grinding. I-V characterization of the milled Si nanoparticles showed an ohmic behaviour with low current at low biases then Schottky diode behaviour or a symmetric curve at large biases. / Graduate / 0794 / 0544 / zahraalbu@hotmail.com

Nanometer-scale silicon shows extraordinary electronic and optical properties that are not available for bulk silicon, and many investigations toward applications in optoelectronic devices are being pursued. Silicon nanoparticle films made from solution are a promising candidate for low-cost solar cells. However, controlling the properties of silicon nanoparticles is quite a challenge, in particular shape and size distribution, which effect device performance. At present, none of the solar cells made from silicon nanoparticle films have an efficiency exceeding the efficiency of those based on crystalline silicon. To address the challenge of controlling silicon nanoparticle properties, both theoretical and experimental investigations are needed. In this thesis, we investigate silicon nanoparticle properties via quantum mechanical modeling of silicon nanoparticles and synthesis of silicon nanoparticle films via colloidal grinding. Silicon nanoparticles with shapes including cubic, rectangular, ellipsoidal and flat disk are modeled using semi-empirical methods and configuration interaction. Their electronic properties with different surface passivation were also studied. The results showed that silicon nanoparticles with hydrogen passivation have higher HOMOLUMO gaps, and also the HOMO-LUMO gap depends on the size and the shape of the particle. In contrast, silicon nanoparticles with oxygen passivation have a lower HOMO-LUMO gap. Raman spectroscopy calculation of silicon nanoparticles show peak shift and asymmetric broadening similar to what has been observed in experiment. Silicon nanoparticle synthesis via colloidal grinding was demonstrated as a straightforward and inexpensive approach for thin film solar cells. Data analysis of silicon particles via SEM images demonstrated that colloidal grinding is effective in reducing the Si particle size to sub-micron in a short grinding time. Further increases in grinding time, followed by filtration demonstrated a narrowing of the Si particle size and size-distribution to an average size of 70 nm. Raman spectroscopy and EDS data demonstrated that the Si nanoparticles contain oxygen due to exposure to air during grinding. I-V characterization of the milled Si nanoparticles showed an ohmic behaviour with low current at low biases then Schottky diode behaviour or a symmetric curve at large biases. / Graduate / 0794 / 0544 / zahraalbu@hotmail.com

A survey of the literature of grinding and surface texture shows the influence of dressing and wear on surfaces involved in the process and the advantages of stylus profilometry for data collection from both grinding wheels and ground surfaces. Statistical analysis is favoured for surface profile characterization and, of the various parameters used, power spectral density alone offers some prospect of effective comparison between these surfaces. Work on grinding with single crystals of natural corundum was eventually discontinued in favour of experiments with conventional bonded grinding wheels subjected to a dressing operation and some wear in grinding steel surfaces. Statistical parameters representing the surfaces are computed using data obtained from profilograms. Results in terms of power spectral density are presented showing progressive improvement following upon developments in apparatus and methods which facilitated the use of larger surface profile samples. Transfer functions are used to relate power spectra representing corresponding pairs of surfaces. The significance of power spectral density applied to surface profile characterization is discussed and, in this context, it is suggested that these should be described as variance spectra. Attention is drawn to certain disadvantages of variance spectra applied to grinding wheel and ground surface profiles. Methods designed to improve presentation of variance spectra lead to development of a proposed new and more suitable spectrum in which density of standard deviation of surface profile ordinates with respect to frequency is plotted against frequency. Transfer functions calculated from related pairs of these standard deviation spectra show a strong linear correlation with frequency and offer prospects of convenient comparison between the profiles of the various surfaces involved in grinding.

Perlite is a glassy volcanic rock that contains approximately 70-75% silica and 12-18% alumina. There are very large perlite reserves in the world (~6700 million tons) and approximately two thirds of these is in Turkey. Due to its high amounts of silica and alumina, at the beginning of such a study, it seemed that it would be worth first to find out whether perlite possesses sufficient pozzolanic property when it is a finely divided form and then to investigate whether it could be used as a pozzolanic addition in producing blended cements. In this study, perlites from two different regions (izmir and Erzincan) were tested for their pozzolanic properties. After obtaining satisfactory results, grindability properties of the clinker, perlites and their different combinations were investigated. Several blended cements with different fineness values and different perlite amounts were produced by either intergrinding or separate grinding methods. The tests performed on the cement pastes and mortars containing the blended cements produced were as follows: Water requirement, normal consistency, setting time, soundness, compressive strength, rapid chloride permeability, resistance to sulfate attack and resistance to alkali-silica reactions. The results showed that Turkish perlites possess sufficient pozzolanic characteristics to be used in cement and concrete industry. Moreover, the properties tested in this study satisfied the requirements stated in the standards for blended cements. The durability of the mortars was found to be improved by 20% or more perlite incorporation.