The aim of the project was to establish the rate and mechanisms of solid stage reduction of titania and ilmenite ores. The project examined carbothermal reduction of titania and various types of ilmenite ores in argon, helium, hydrogen, and their mixtures. Effect of CO in the gas atmosphere on reduction behavior of titania and primary ilmenite ore was also studied. Isothermal and non-isothermal reduction experiments were conducted in a fixed bed reactor in the high temperature furnace in the temperature range up to 1500oC. The off-gas composition in the reduction process was monitored by a CO/CO2/CH4 infrared analyser. The extent of reduction was calculated using data on gas composition and LECO oxygen analysis. Phase composition and morphology of reduced samples were studied using XRD, SEM and optical microscopy. The major findings of this project are as follows: • The reduction of titania to titanium oxycarbide occurred in the following sequence: TiO2 → Ti5O9 → Ti4O7 → Ti3O5 → Ti2O3 → (TiO-TiC) solid solution. • Carbothermal reduction of ilmenite concentrates proceeded in two main stages. In the first stage pseudorutile and ilmenite were reduced to metallic iron and titania. Second stage involved the reduction of titania to titanium oxycarbide. • Rate and degree of reduction of titania and ilmenite concentrates increased with increasing temperature. • Reduction rate of titania and ilmenite concentrates was faster in hydrogen than in helium and argon. The difference in the reduction behavior in helium and argon was insignificant; reduction rate of ilmenite was slightly faster in helium than in argon. • High rate of reduction of titania and ilmenite in hydrogen was attributed to formation of methane which facilitated mass transfer of carbon from graphite to oxide. Hydrogen was also directly involved in reduction of titania and ilmenite concentrates; hydrogen reduced pseudorutile to iron and titania. Titania was further reduced to titanium oxycarbide by carbon through methane. • Increased gas flow rate slightly improved the reduction rate in hydrogen and suppressed the reduction in inert gases. • Addition of CO to hydrogen and inert gases above 3 vol% suppressed the reduction process.

The aim of the project was to establish the rate and mechanisms of solid stage reduction of titania and ilmenite ores. The project examined carbothermal reduction of titania and various types of ilmenite ores in argon, helium, hydrogen, and their mixtures. Effect of CO in the gas atmosphere on reduction behavior of titania and primary ilmenite ore was also studied. Isothermal and non-isothermal reduction experiments were conducted in a fixed bed reactor in the high temperature furnace in the temperature range up to 1500oC. The off-gas composition in the reduction process was monitored by a CO/CO2/CH4 infrared analyser. The extent of reduction was calculated using data on gas composition and LECO oxygen analysis. Phase composition and morphology of reduced samples were studied using XRD, SEM and optical microscopy. The major findings of this project are as follows: • The reduction of titania to titanium oxycarbide occurred in the following sequence: TiO2 → Ti5O9 → Ti4O7 → Ti3O5 → Ti2O3 → (TiO-TiC) solid solution. • Carbothermal reduction of ilmenite concentrates proceeded in two main stages. In the first stage pseudorutile and ilmenite were reduced to metallic iron and titania. Second stage involved the reduction of titania to titanium oxycarbide. • Rate and degree of reduction of titania and ilmenite concentrates increased with increasing temperature. • Reduction rate of titania and ilmenite concentrates was faster in hydrogen than in helium and argon. The difference in the reduction behavior in helium and argon was insignificant; reduction rate of ilmenite was slightly faster in helium than in argon. • High rate of reduction of titania and ilmenite in hydrogen was attributed to formation of methane which facilitated mass transfer of carbon from graphite to oxide. Hydrogen was also directly involved in reduction of titania and ilmenite concentrates; hydrogen reduced pseudorutile to iron and titania. Titania was further reduced to titanium oxycarbide by carbon through methane. • Increased gas flow rate slightly improved the reduction rate in hydrogen and suppressed the reduction in inert gases. • Addition of CO to hydrogen and inert gases above 3 vol% suppressed the reduction process.

This research deals with the synthesis and characterization of titanium diboride (TiB2) from novel carbon coated precursors. This work provides information on using different boron sources and their effect on the resulting powders of TiB2.The process has two steps in which the oxide powders were first coated with carbon by cracking of a hydrocarbon gas, propylene (C3H6) and then, mixed with boron carbide and boric acid powders in a stoichiometric ratio. These precursors were treated at temperatures in the range of 1200-1400° C for 2 h in flowing Argon atmosphere to synthesize TiB2.The process utilizes a carbothermic reduction reaction of novel carbon coated precursor that has potential of producing high-quality powders (sub-micrometer and high purity). Single phase TiB2 powders produced, were compared with commercially available titanium diboride using X-ray diffraction and Transmission electron microscopy obtained from boron carbide and boric acid containing carbon coated precursor.

Boron carbide is produced in a heat resistance furnace using boric oxide and petroleum coke as the raw materials. In this process, a large current is passed through the graphite rod located at the center of the cylindrical furnace, which is surrounded by the coke and boron oxide mixture. Heat generated due to resistance heating is responsible for the reaction of boron oxide with coke which results in the formation of boron carbide. The whole process is highly energy intensive and inefficient in terms of the production of boron carbide. Only 15% charge gets converted into boron carbide. The aim of the present work is to develop a mathematical model for this batch process and validate the model with experiments and to optimize the operating parameters to increase the productivity. To mathematically model the process and understand the influence of various operating parameters on the productivity, existing simple one-dimensional (1-D) mathematical model in radial direction is modified first. Two-dimensional (2-D) model can represent the process better; therefore in second stage of the project a 2-D mathematical model is also developed. For both, 1-D and 2-D models, coupled heat and mass balance equations are solved using finite volume technique. Both the models have been tested for time step and grid size independency. The kinetics of the reaction is represented using nucleation growth mechanism. Conduction, convection and radiation terms are considered in the formulation of heat transfer equation. Fraction of boron carbide formed and temperature profiles in the radial direction are obtained computationally. Experiments were conducted on a previously developed experimental setup consisting of heat resistance furnace, a power supply unit and electrode cooling device. The heating furnace is made of stainless steel body with high temperature ceramic wool insulation. In order to validate the mathematical model, experiments are performed in various conditions. Temperatures are measured at various locations in the furnace and samples are collected from the various locations (both in radial and angular directions) in the furnace for chemical analysis. Also, many experimental data are used from the previous work to validate the computed results. For temperatures measurement, pyrometer, C, B and K type thermocouple were used. It is observed that results obtained from both the models (1-D and 2-D) are in reasonable agreement with the experimental results. Once the models are validated with the experiments, sensitivity analysis of various parameters such as power supply, initial percentage of B4C in the charge, composition of the charge, and various modes of power supply, on the process is performed. It is found that linear power supply mode, presence of B4C in the initial mixture and increase in power supply give better productivity (fraction reacted). In order to have more confidence in the developed models, the parameters of one the computed results in the sensitivity analysis parameters are chosen (in present case, linear power supply is chosen) to perform the experiment. Results obtained from the experiment performed under the same simulated conditions as computed results are found in excellent match with each other.

The aim of the project was to establish rate and mechanisms of solid state reduction of manganese ores. The project studied carbothermal reduction of manganese oxide MnO, two Groote Eylandt (Australian) and Wessels (South African) manganese ores in hydrogen, helium and argon atmospheres at temperatures up to 1400C for MnO and 1200C for manganese ores. Experiments were conducted in the fixed bed reactor with on-line off-gas analysis. The major findings are as follows. ?? Rate and degree of reduction of MnO and ores increased with increasing temperature. ?? Reduction of MnO and manganese ores at temperatures up to 1200C was faster in helium than in argon, and much faster in hydrogen than in helium. The difference in MnO reduction in hydrogen and helium decreased with increasing temperature to 1400C. ?? Addition of up to 7 vol% of carbon monoxide to hydrogen had no effect on MnO reduction at 1200C. ?? In the process of carbothermal reduction of ores in hydrogen at 1200C, silica was reduced. ?? Reduction of both GE ores was slower than of Wessels ore. This was attributed to high content of iron oxide in the Wessels ore. ?? Carbon content in the graphite-ore mixture had a strong effect on phases formed in the process of reduction; thus, in the reduction of Wessels ore with 12-16 wt% C, a-Mn and Mn23C6 were formed; when carbon content was above 20 wt%, oxides were reduced to carbide (Mn,Fe)7C3. ?? Kinetic analysis showed that mass transfer of intermediate CO2 from oxide to graphite in carbothermal reduction in inert atmosphere was a contributing factor in the rate control. ?? High rate of reduction of manganese oxide in hydrogen was attributed to formation of methane which facilitated mass transfer of carbon from graphite to oxide. Hydrogen was also directly involved in reduction of manganese ore reducing iron oxides to metallic iron and higher manganese oxides to MnO. Reduction of Wessels and Groote Eyland Premium Fines ores in the solid state is feasible at temperatures up to 1200C; while temperature for solid state reduction of Groote Eyland Premium Sands is limited by 1100C.

This thesis outlines the work done on in-situ synthesis of Al2O3-ZrO2-SiCw ceramic composites and their property evaluation. The introductory chapter deals with the literature survey on ceramic matrix composites, properties desirable for structural applications and toughening mechanisms associated with these composites. The role of whisker toughening in ceramic matrix composites, the growth mechanisms involved in whisker growth and the conditions that favour or hamper the whisker growth are also discussed. The advantages and disadvantages of in-situ synthesis of composites as compared to physical mixing are also dealt with. The objective and scope of the work undertaken are outlined at the end. The second chapter describes the experimental techniques associated with carbothermal synthesis and characterisation of reaction products as well as properties of hot pressed bulk composites. The equipments used for this work are described here. The third chapter focuses on the results obtained by the carbothermal reduction of mixtures of kaolin, sillimanite and zircon taken in various proportions. The formation of the product phases with respect to variations in temperature, variations in composition and effect of catalyst is analysed with the help of XRD while their morphology is analysed using SEM. The conditions favouring the formation of tetragonal zirconia without the addition of stabilizers is also enumerated here. The fourth chapter deals with the compaction of these composite powders and the evaluation of some physical, thermal and mechanical properties. Density and porosity, coefficient of thermal expansion, modulus of rupture and fracture toughness of the composite specimens are evaluated and compared with binary and ternary composites made by other methods. Finally the thesis concludes by summarizing the work done and briefly projecting the areas for future work.

The aim of the project was to establish rate and mechanisms of solid state reduction of manganese ores. The project studied carbothermal reduction of manganese oxide MnO, two Groote Eylandt (Australian) and Wessels (South African) manganese ores in hydrogen, helium and argon atmospheres at temperatures up to 1400C for MnO and 1200C for manganese ores. Experiments were conducted in the fixed bed reactor with on-line off-gas analysis. The major findings are as follows. ?? Rate and degree of reduction of MnO and ores increased with increasing temperature. ?? Reduction of MnO and manganese ores at temperatures up to 1200C was faster in helium than in argon, and much faster in hydrogen than in helium. The difference in MnO reduction in hydrogen and helium decreased with increasing temperature to 1400C. ?? Addition of up to 7 vol% of carbon monoxide to hydrogen had no effect on MnO reduction at 1200C. ?? In the process of carbothermal reduction of ores in hydrogen at 1200C, silica was reduced. ?? Reduction of both GE ores was slower than of Wessels ore. This was attributed to high content of iron oxide in the Wessels ore. ?? Carbon content in the graphite-ore mixture had a strong effect on phases formed in the process of reduction; thus, in the reduction of Wessels ore with 12-16 wt% C, a-Mn and Mn23C6 were formed; when carbon content was above 20 wt%, oxides were reduced to carbide (Mn,Fe)7C3. ?? Kinetic analysis showed that mass transfer of intermediate CO2 from oxide to graphite in carbothermal reduction in inert atmosphere was a contributing factor in the rate control. ?? High rate of reduction of manganese oxide in hydrogen was attributed to formation of methane which facilitated mass transfer of carbon from graphite to oxide. Hydrogen was also directly involved in reduction of manganese ore reducing iron oxides to metallic iron and higher manganese oxides to MnO. Reduction of Wessels and Groote Eyland Premium Fines ores in the solid state is feasible at temperatures up to 1200C; while temperature for solid state reduction of Groote Eyland Premium Sands is limited by 1100C.

ZnO nanowires are a promising material with great semiconductor properties. ZnO nanowires were prepared by carbothermal reduction and vapor-liquid-solid growth mechanism. Altering a variety of parameters ranging from mole to mole ratio of ZnO to C all the way to gas flow rate was examined. The nanowires were then characterized and their morphology examined under a SEM to observe what effect the parameter had on the morphology of the nanowires. From the experiments and the parameters tested it was observed that in order to produce the highest quality straight nanowires one should use a mole to mole ratio of ZnO to C graphite of 1 to 3. With a dwell temperature and time of 900 °C for 3 hours. A gold seed catalyst of 4nm and a gas flow rate of 50 to 100sccm of Ar provides the straightest nanowires. Understanding the effect of each parameter on the morphology of ZnO nanowires is vital for the current research. This will only lead to further the research and provide a better understanding of the growth mechanism of these wires and how the production of specific wires with certain morphologic features and characteristics can be achieved.

Nanocrystalline beta-silicon carbide (ß-SiC) was synthesized at relatively low temperature (<1300C) by carbothermal reduction (CTR) reaction in fine scale carbon/silica mixtures. The fine scale mixing of the reactants (i.e., carbon and silica) was achieved by solution-based processing and subsequent heat treatment. The mechanism of the CTR reaction in the current system was investigated from different aspects. The condensates of the volatile species generated during the CTR reaction was collected and analyzed. The results supported previous investigations which suggested that the CTR reaction is a multi-step process that involves silicon monoxide (SiO) vapor as a reaction intermediate. The kinetics of the CTR reaction was investigated by isothermal weight loss study and by the study which determined the amount of SiC formed via quantitative X- ray diffraction (QXRD) analysis. The results of kinetic study were consistent with the "shrinking-core" model, in which the reaction between SiO vapor and carbon at the carbon surface to produce SiC is the rate-controlling step. In addition, several techniques, including XRD, gas adsorption analysis, laser diffraction particle size analysis, SEM, TEM, etc., had been used to study the structural evolutions of the reaction product of CTR. It was demonstrated that the evolutions of product structure characteristics such as crystallite size, specific surface area, specific pore volume, pore size distribution, particle size distribution, and powder morphology, etc. were consistent with each other and provided support to the reaction mechanism proposed.

It was the goal of this work to explore two different synthesis pathways using green chemistry. The first part of this thesis is focusing on the use of the urea-glass route towards single phase manganese nitride and manganese nitride/oxide nano-composites embedded in carbon, while the second part of the thesis is focusing on the use of the “saccharide route” (namely cellulose, sucrose, glucose and lignin) towards metal (Ni0), metal alloy (Pd0.9Ni0.1, Pd0.5Ni0.5, Fe0.5Ni0.5, Cu0.5Ni0.5 and W0.15Ni0.85) and ternary carbide (Mn0.75Fe2.25C) nanoparticles embedded in carbon. In the interest of battery application, MnN0.43 nanoparticles surrounded by a graphitic shell and embedded in carbon with a high surface area (79 m^2/g) were synthesized, following a previously set route.The comparison of the material characteristics before and after the discharge showed no remarkable difference in terms of composition and just slight differences in the morphological point of view, meaning the particles are stable but agglomerate. The graphitic shell is contributing to the resistance of the material and leads to a fine cyclic stability over 140 cycles of 230 mAh/g after the first charge/discharge and coulombic efficiencies close to 100%. Due to the low voltage towards Li/Li+ and the low polarization, it might be an attractive anode material for lithium ion batteries. However, the capacity is still noticeably lower than the theoretical value for MnN0.43. A mixture of MnN0.43 and MnO nanoparticles embedded in carbon (surface area 93 m^2/g) was able to improve the cyclic stability to over 160 cycles giving a capacity of 811 mAh/g, which is considerably higher than the capacity of the conventional material graphite (372 mAh/g). This nano-composite seems to agglomerate less during the process of discharge. Interestingly, although the capacity is much higher than of the single phase manganese nitride, the nano-composite seems to only contain MnN0.43 nanoparticles after the process of discharge with no oxide phase to be found. Concerning catalysis application, different metal, metal alloy, and metal carbide nanoparticles were synthesized using the saccharide route. At first, systems that were already investigated before, being Pd0.9Ni0.1, Pd0.5Ni0.5, Fe0.5Ni0.5 and Mn0.75Fe2.25C using cellulose as the carbon source were prepared and tested in an alkylation reaction of toluene with benzylchloride. Unexpectedly, the metal alloys did not show any catalytic activity, but the ternary carbide Mn0.75Fe2.25C showed fine catalytic activity of 98% conversion after 9 hour reaction time (110 °C). In a second step, the saccharide route was modified towards other carbon sources and carbon to metal ratios in order to improve the homogeneity of the samples and accessibility of the particle surfaces. The used carbon sources sucrose and glucose are similar in their basic structure of carbohydrates, but reducing the (polymeric) chain length. Indeed, the cellulose could be successfully replaced by sucrose and glucose. A lower carbon to metal ratio was found to influence the size, homogeneity and accessibility (as evidenced by TEM) of the samples. Since sucrose is an aliment, glucose is the better choice as a carbon source. Using glucose, the synthesis of Cu0.5Ni0.5 and W0.15Ni0.85 nano-composites was also possible, although the later was never obtained as pure phase. These alloy nano-composites were tested, along with nickel0 nanoparticles also prepared with glucose and on their catalytic activity towards the reduction of phenylacetylene. The results obtained let believe that any (poly) saccharide, including lignin, could be used as carbon source. The nickel0 nano-composites prepared with lignin as a carbon source were tested along with those prepared with cellulose and sucrose for their catalytic activity in the transfer hydrogenation of nitrobenzene (results compared with exposed nickel nanoparticles and nickel supported on carbon) leading to very promising results. Based on the urea-glass route and the saccharide route, simple equipment and transition metals, it was possible to have a one-pot synthesize with scale-up possibilities towards new material that can be applied in catalysis and battery systems. / Im Rahmen dieser Arbeit wird sowohl die Synthese von Mangannitrid- und -oxid-Nanopartikeln, als auch die Synthese verschiedener Metall- und Legierungsnanopartikel untersucht. Einen Schwerpunkt stellt dabei die Optimierung der Synthese unter den Gesichtspunkten der Nachhaltigkeit dar, was sich insbesondere in der Verwendung diverser nachwachsender Rohstoffe als Kohlenstoffquelle äußert. Für eine mögliche Anwendung in Akkumulatoren werden mit Graphit ummantelte MnN0.43-Nanopartikel mit einer großen Oberfläche (79 m^2/g) synthetisiert. Diese werden exemplarischen Ladezyklen unterzogen, wobei eine strukturelle und auch elektrochemische Stabilität festgestellt werden kann. Eine Mischung der Mangannitride mit Manganoxiden führt zu einer weiteren Verbesserung der Ladekapazität und einer weiteren Oberflächenvergrößerung (93 m^2/g). Die Langlebigkeit der Strukturen wird durch die Einbettung der Nanopartikel in Kohlenstoff unterstützt und kann zu einer Anwendung als Anodenmaterial in den heutzutage vielfach verwendeten Lithiumionen-Akkus führen. Im Sinne der Nachhaltigkeit ist auch die Entwicklung von Katalysatoren. Dabei soll insbesondere die Verwendung von Lignin, was als Bestandteil vieler Pflanzen zwar leicht verfügbar, aber unglücklicherweise bisher chemisch unverwertbar ist, fokussiert werden. Um sich diesem Ziel zu nähern und entsprechende Mechanismen zur Reduktion des Lignins zu entwickeln, werden in dieser Arbeit zunächst verschiedene Kohlenstoffquellen (wie Cellulose, Sucrose und Glucose) zur Synthese von reduktiven Katalysatoren untersucht. Der Kohlenstoff dient dabei sowohl als preiswertes Reduktionsmittel für Metallsalze zur Gewinnung von Metallnanopartikel als auch zur Stabilisierung ebendieser. Es werden vielfältige Legierungen mit Nickel (z.B. Pd0.9Ni0.1, Pd0.5.Ni0.5, Fe0.5.Ni0.5, und Cu0.5.Ni0.5) aber auch ternäre Carbide (z.B. Mn0.75Fe2.25C) erhalten, die schon in ersten Alkylierungs- und Hydrierungsreaktionen ein großes Potential als Katalysatoren zeigen. Um die erhaltenen Nanopartikel in zukünftigen Anwendungen nutzbar zu machen, ist eine ausführliche Charakterisierung unabdingbar. Auch die Ergebnisse der zahlreichen durchgeführten Analysen werden in dieser Arbeit zusammengestellt und bilden gemeinsam mit den optimierten Syntheserouten einen tiefgreifenden Überblick über dieses Forschungsfeld.