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The production of chlorate, chlorine and sodium hydroxiderelies heavily on electrical energy, so that savings in thisarea are always a pertinent issue. This can be brought aboutthrough increased mass transfer of reacting species to therespective electrodes, and through increased catalytic activityand uniformity of current density distribution at theseelectrodes. This thesis will present studies involvingmathematical modelling and experimental investigations of theseprocesses. They will show the effect that hydrodynamicbehaviour has on the total current density and cell voltages,along with the effects on current density distributions andindividual overpotentials atthe respective electrodes. Primary, secondary and psuedo-tertiary current densitydistribution models of a chlor-alkali anode are presented anddiscussed. It is shown that the secondary model presentsresults rather similar to the pseudo-tertiary model, when thecurrent density distribution is investigated, although thepotential distribution differs rather markedly. Furthermore, itis seen that an adequate description of the hydrodynamicsaround the anode is required if the potential distribution, andthereby the prevalence of side-reactions, is to be reasonablepredicted. A rigorous tertiary current density distribution model ofthe chlorate cell is also presented, which takes into accountthe developing hydrodynamic behaviour along the height of thecell. This shows that an increased flowrate gives more uniformcurrent density distributions. This is due to the fact that theincreased vertical flowrate of electrolyte replenishes ioncontent at the electrode surfaces, thus reducing concentrationoverpotentials. Furthermore, results from the model lead to theconclusion that it is the hypochlorite ion that partakes in themajor oxygen producing side-reaction. A real-scale cross-section of a segmented anode-cathode pairfrom a chlorate cell was designed and built in order to studythe current density distribution in industrial conditions.These experiments showed that increased flowrate brought aboutmore even current density distributions, reduced cell voltageand increased the total current density. An investigation ofthe hydrodynamic effects on the respective electrodeoverpotentials shows the anode reactions being more favoured byincreased flowrate. This leads to the conclusion that theuniform current density distribution, caused by increasedflowrate, occurs primarily through decreasing the concentrationoverpotential at the anode rather than by decreasing thebubble-induced ohmic drop at the cathode. Finally, results from experiments investigating thebubble-induced free convection from a small electrochemicalcell are presented. These experiments show that Laser DopplerVelocimetry is the most effective instrument for investigatingthe velocity profiles in bubble-containing electrochemicalsystems. The results also show that the flow can transform fromlaminar to turbulent behaviour on both the vertical andhorizontal planes, in electrochemical systems where bubbles areevolved.

The present work focuses on mineral reactions and slag formation of LKAB olivine iron ore pellets (MPBO) subjected to reducing conditions in the LKAB experimental blast furnace (EBF). The emphasis is on olivine reactions with surrounding iron oxides. Many factors influence the olivine behaviour. The study was performed by use of micro methods; optical microscopy, micro probe analysis, micro Raman and Mössbuer spectroscopy and thremodynamic modeling. During manufacturing, in oxidising atmosphere at high temperature (1350°C), olivine alterations occur through slag formation and rim reactions with iron oxides and other additives. To be able to describe olivine behaviour in the rather complex blast furnace reduction process one has to consider factors such as reactions kinetics, reduction degree of iron oxides, vertical and horizontal position in the furnace and reactions with alkali. Samples were collected from the EBF both from in shaft probing during operation and from excavation following quenching of the EBF. The initial slag forming olivine consist of primary forsterite – (Mg1.9Fe0.1)SiO4 – with inclusions of hematite and an amorphous silica rich phase, a first corona with lamellae of magnesioferrite, olivine and orthopyroxene, a second corona of amorphous silica and magnesioferrite. During reduction in the upper shaft in the EBF (700-900°C) Fe3+ reduces to Fe2+. The amorphous silica in the second corona absorbs alkali, Al, Fe2+, Mg, and Ca and form glasses of varying compositions. The lamellae in the first corona will merge into a single phase olivine rim. With further reduction the glasses in the second corona will merge with the olivine rim forming an iron rich olivine rim and leaving the elements that do not fit into the olivine crystal lattice as small silicate glass inclusions. Diffusion of magnesium and iron between olivines and iron oxides increase with increasing temperature in the lower shaft of the EBF (750-1100°C). In the cohesive zone of the EBF (1100-1200°C) Fe2+ is not stable any longer and Fe2+ will be expelled from the olivine as metallic iron blebs, and the olivine will form a complex melt with a typical composition of alkali-Al2O3-MgO-SiO2. Alkali plays an important role in this final olivine consumption. The quench time for samples collected with probes and excavation are minutes respectively hours. A study of the quench rate’s effect on the phases showed no differences in the upper shaft. However, in the lower shaft wüstite separates into wüstite and magnetite when wüstite grows out of its stability field during slow cooling of excavated samples. There is also a higher alkali and aluminium deposition in the glass phases surrounding olivines in excavated pellets as a result of alkali and aluminium gas condensing on the burden in the EBF during cooling. Coating applied to olivine pellets was studied in the EBF with the aim to investigate its behaviour, particularly its ability to capture alkali. The coating materials were kaolinite, bauxite, olivine and limestone. No significant reactions were observed in the upper shaft. In the lower shaft a majority of the phases were amorphous and reflecting the original coating compositions. Deposition from the EBF gas phase occurs and kalsilite (KAlSiO4) is found in all samples; coating used for binding alkali is redundant from a quality perspective.

The demand for mixed alcohols has grown since ether compounds were banned as gasoline octane improvers in North America. Molybdenum-based catalysts in sulfide form are an attractive catalyst system for the conversion of synthesis gas to alcohols, due to their excellent resistance to sulfur poisoning and high activity for the water-gas shift reaction. The higher alcohols activity over these catalysts is low, due to the formation of hydrocarbons and CO2. Although a number of catalysts have been developed for this purpose, not any are used commercially at this time. The main objective of this Ph.D. research is to develop a catalyst system that is capable of selectively producing higher alcohols, particularly ethyl alcohols from synthesis gas. In the present series of studies, the investigation of an alkali-promoted trimetallic Co-Rh-Mo catalyst system has led to improvements in product stream composition. The effect of different loadings of active metal (Mo), alkali (K) promoter, and metal promoters (Co and Rh) on higher alcohol synthesis from synthesis gas were investigated using commercially available multi-walled carbon nanotubes (MWCNTs) as the catalyst support. The role of support on higher alcohols synthesis was also studied using different supports, such as ã-Al2O3, activated carbons with different textural characteristics, and MWCNTs. The catalysts were prepared using the incipient wetness impregnation method and extensively characterized in both oxide and sulfide phases using different techniques. Transmission electron microscopy (TEM) results revealed that the metal particles were uniformly distributed inside and outside of the carbon nanotubes, and that metal dispersions were higher on the alkali-promoted trimetallic catalyst supported on MWCNTs. The existence of promoted and un-promoted MoS2 sites was confirmed by diffuse reflectance infrared fourier transform spectroscopy (DRIFTS) studies of adsorbed CO over sulfided catalysts. Temperature programmed reduction (TPR) tests showed that the addition of metal promoters improved the reduction behaviour of the catalysts. XRD patterns showed that alkali-promoted catalysts were less crystalline compared to that of the catalyst not promoted with K. The formation of Co (Rh)-Mo-S species was evident in the XANES spectra of bimetallic and trimetallic alkali-promoted MoS2 catalysts. The activity and selectivity of the catalysts were assessed in a fixed-bed micro-reactor using temperature, pressure, and gas hourly space velocity in the ranges of 275 to 350°C, 800 to 1400 psig (5.529.65 Mpa), and 2.4 to 4.2 m3 (STP)/(kg of cat.)/h, respectively. The Ni-promoted catalyst showed higher activity towards the formation of hydrocarbons over that of alcohols. The total alcohols space time yield (STY) and higher alcohols selectivities are significantly higher over the activated carbon-supported catalysts compared to those supported on alumina. With increased content of K, the formation of alcohols increased and hydrocarbons formation rate was suppressed. The total alcohols STY increased with increased Co content over the Co-promoted MoS2-K/MWCNTs catalysts, whereas, the maximum ethyl alcohol and higher alcohols selectivities were observed on the catalyst promoted with 4.5 wt % Co. Over the Rh-promoted MoS2-K/MWCNTs catalysts, the maximum total alcohol yield, ethanol selectivity, and higher alcohols selectivity were observed on the catalyst with 1.5 wt % Rh. The MWCNT-supported alkali-promoted trimetallic catalyst with 9 wt % K, 4.5 wt % Co, 1.5 wt % Rh, and 15 wt % Mo showed the maximum higher alcohols STY and selectivity compared to other catalysts investigated. The textural properties of the support, such as average pore diameter, pore volume and surface area, could significantly influence the extent of reduction, morphology, adsorption and has direct influence on the synthesis of mixed alcohols from synthesis gas. The optimum higher alcohols STY and selectivity were obtained over the Co-Rh-Mo-K/MWCNT catalyst at 330°C, 1320 psi (9.1 Mpa), 3.8 m3 (STP)/(kg of cat./h) using a H2 to CO molar ratio value of 1.25. To predict the reaction rate for higher alcohols synthesis, the power law model was used for the reaction between CO and H2 on the catalyst surface and the data of this study are well fitted by the model. The activation energies of ethanol and higher alcohols obtained over Co-Rh-Mo-K/MWCNTs were low compared to those values reported in the literature. The sulfided alkali-promoted trimetallic Co-Rh-Mo catalyst supported on MWCNTs was stable over a period of 720 h of continuous reaction.

A combined experimental and analytical program was conducted to investigate the effects of Alkali-Silica Reaction (ASR) and Delayed Ettringite Formation (DEF) on D-regions in reinforced concrete (RC) bridge bents. Four large-scale RC specimens, which represent cantilever and straddle bents in Texas bridges in each specimen, were constructed. The first specimen represented the unexposed control specimen, while the other three were conditioned in the field with supplemental watering to promote ASR/DEF and served as the exposed specimens. The control and two exposed specimens with various levels of ASR/DEF, after eight months and two years of field conditioning, were load tested to failure. The last specimen remains in field with additional exposure to promote ASR/DEF and will be load tested in future studies. The width and length of preload-induced cracks and developing cracks that initiated in the exposed specimens and grew over time, indicating concrete expansion due to ASR/DEF mechanisms, were measured. Petrographic analysis results of concrete cores extracted from the exposed specimens after their load testing confirmed the formation of ASR gel and minimum accumulation of ettringite. The structural testing results showed that the failure mechanism in all three tested specimens was due to a brittle shear failure in the beam-column joint. However, slightly greater stiffness, strength, and ductility were observed in the exposed specimens as a result of the activation of the reinforcing steel in the specimens due to the expansion of the concrete primarily from ASR, which effectively prestressed and confined the core concrete. Sectional analysis and Strut-and-Tie Modeling (STM) of the experimental specimens were applied. Three-dimensional nonlinear Finite Element Analyses (FEA) were also conducted to numerically simulate the overall structural performance, internal response, and out-of-plane behavior of the experimental specimens. The effects of varying constitutive relations of the concrete in tension on models of the specimens were compared with the measured experimental response. A method to mimic ASR/DEF effects on exposed specimens was proposed and incorporated into the FEA approach. As a result, forces that prestress and confine the core concrete were effectively applied through the reinforcing steel prior to subsequent structural loading. The three-dimensional FEA approach was able to simulate the out-of-plane behavior of the beam-column joint and the proposed method yielded comparable results with the measured overall and internal behavior of specimens.

The demand for mixed alcohols has grown since ether compounds were banned as gasoline octane improvers in North America. Molybdenum-based catalysts in sulfide form are an attractive catalyst system for the conversion of synthesis gas to alcohols, due to their excellent resistance to sulfur poisoning and high activity for the water-gas shift reaction. The higher alcohols activity over these catalysts is low, due to the formation of hydrocarbons and CO2. Although a number of catalysts have been developed for this purpose, not any are used commercially at this time. The main objective of this Ph.D. research is to develop a catalyst system that is capable of selectively producing higher alcohols, particularly ethyl alcohols from synthesis gas. In the present series of studies, the investigation of an alkali-promoted trimetallic Co-Rh-Mo catalyst system has led to improvements in product stream composition. The effect of different loadings of active metal (Mo), alkali (K) promoter, and metal promoters (Co and Rh) on higher alcohol synthesis from synthesis gas were investigated using commercially available multi-walled carbon nanotubes (MWCNTs) as the catalyst support. The role of support on higher alcohols synthesis was also studied using different supports, such as ã-Al2O3, activated carbons with different textural characteristics, and MWCNTs. The catalysts were prepared using the incipient wetness impregnation method and extensively characterized in both oxide and sulfide phases using different techniques. Transmission electron microscopy (TEM) results revealed that the metal particles were uniformly distributed inside and outside of the carbon nanotubes, and that metal dispersions were higher on the alkali-promoted trimetallic catalyst supported on MWCNTs. The existence of promoted and un-promoted MoS2 sites was confirmed by diffuse reflectance infrared fourier transform spectroscopy (DRIFTS) studies of adsorbed CO over sulfided catalysts. Temperature programmed reduction (TPR) tests showed that the addition of metal promoters improved the reduction behaviour of the catalysts. XRD patterns showed that alkali-promoted catalysts were less crystalline compared to that of the catalyst not promoted with K. The formation of Co (Rh)-Mo-S species was evident in the XANES spectra of bimetallic and trimetallic alkali-promoted MoS2 catalysts. The activity and selectivity of the catalysts were assessed in a fixed-bed micro-reactor using temperature, pressure, and gas hourly space velocity in the ranges of 275 to 350°C, 800 to 1400 psig (5.529.65 Mpa), and 2.4 to 4.2 m3 (STP)/(kg of cat.)/h, respectively. The Ni-promoted catalyst showed higher activity towards the formation of hydrocarbons over that of alcohols. The total alcohols space time yield (STY) and higher alcohols selectivities are significantly higher over the activated carbon-supported catalysts compared to those supported on alumina. With increased content of K, the formation of alcohols increased and hydrocarbons formation rate was suppressed. The total alcohols STY increased with increased Co content over the Co-promoted MoS2-K/MWCNTs catalysts, whereas, the maximum ethyl alcohol and higher alcohols selectivities were observed on the catalyst promoted with 4.5 wt % Co. Over the Rh-promoted MoS2-K/MWCNTs catalysts, the maximum total alcohol yield, ethanol selectivity, and higher alcohols selectivity were observed on the catalyst with 1.5 wt % Rh. The MWCNT-supported alkali-promoted trimetallic catalyst with 9 wt % K, 4.5 wt % Co, 1.5 wt % Rh, and 15 wt % Mo showed the maximum higher alcohols STY and selectivity compared to other catalysts investigated. The textural properties of the support, such as average pore diameter, pore volume and surface area, could significantly influence the extent of reduction, morphology, adsorption and has direct influence on the synthesis of mixed alcohols from synthesis gas. The optimum higher alcohols STY and selectivity were obtained over the Co-Rh-Mo-K/MWCNT catalyst at 330°C, 1320 psi (9.1 Mpa), 3.8 m3 (STP)/(kg of cat./h) using a H2 to CO molar ratio value of 1.25. To predict the reaction rate for higher alcohols synthesis, the power law model was used for the reaction between CO and H2 on the catalyst surface and the data of this study are well fitted by the model. The activation energies of ethanol and higher alcohols obtained over Co-Rh-Mo-K/MWCNTs were low compared to those values reported in the literature. The sulfided alkali-promoted trimetallic Co-Rh-Mo catalyst supported on MWCNTs was stable over a period of 720 h of continuous reaction.

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No description available.

No description available.

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