Steel slag waste combined with melamine pyrophosphate as a flame retardant for rigid polyurethane foams

To explore the potential application of industrial waste, steel slag powder in combination with melamine pyrophosphate (MPP) was adopted to improve the flame retardancy of rigid polyurethane foam (RPUF). The incorporation of steel slag slightly reduced the thermal conductivity of the resulting flame-retardant RPUF samples. The addition of MPP and/or steel slag did not significantly alter the thermal stability in terms of T_-10% and T_max but did obviously increase the T_-50% value, suggesting the improved thermal resistance of the residues. The coaddition of MPP and steel slag into RPUF resulted in higher LOI values and lower peak heat release rates than the samples incorporating either MPP or steel slag alone. The superior flame retardancy could be attributed to MPP promoting char formation, which then acted as a barrier at the beginning of RPUF thermal decomposition; simultaneously, the thermally stable inorganics in the steel slag powder strengthened the thermal resistance of this char layer.     

Influence of the solvent evaporation rate on the β-Phase content of electrosprayed PVDF particles and films studied by a fast Multi-Overtone QCM

A combination of an electrospray setup and a quartz crystal microbalance with dissipation monitoring (QCM-D) was employed to study the drying of droplets of poly(vinylidene fluoride) (PVDF) dissolved in dimethylformamide (DMF). A novel variant of the QCM was used, which interrogates the resonance frequency and the resonance bandwidth on four overtones at the same time, achieving a time resolution of 2 ms. This instrument allowed to elucidate the mechanism of β-phase formation in electrospray deposition of PVDF. When the distance between the nozzle and the substrate was small, the droplets landed in a partially wet state, as evidenced from an increase in the resonance bandwidth. No such increase in bandwidth was observed when the distance was large. From the flight time (milliseconds) and the drying time on the substrate (seconds), one concludes that drying in the plume is faster than drying on the substrate. IR spectra show that the β–phase content is close to 100 % for particles, which dried in the plume. It is less than 50 % for particles having dried on the substrate. Fast drying promotes the formation of the β-phase. Follow-up experiments with thicker films on steel substrates also show increased β-phase content for larger distances.     

Size-dependent aerosol penetration through facemasks and respirators (FMRs) during simulated exhalation and cough

Despite a good understanding of the filtration properties of various face and nose coverings during aerosol inhalation, their effectiveness in reducing aerosol emitted by infected individuals during exhalation or coughing is not fully characterized. This paper presents experiments conducted using a silicone model of a standardized face for controlled flow patterns (steady flow, typical exhalation or flow pulses associated with coughing/sneezing) used to push test aerosols (0.5–20 μm) through valved or non-valved respirators, surgical masks and cloth masks. The aerosol characteristics determined during experiments allowed quantitative comparison of size-dependent aerosol penetration for different flow conditions. The results showed that only aerosols smaller than 8.5–10 μm more easily penetrated beyond the face coverings tested but their concentrations outside were significantly reduced. Calculations based on experimental data showed that the amount of emitted airborne particles that can be inhaled into the lower respiratory tract of bystanders was reduced 1.3–5.7 times compared to the case when the spreader does not use a mask. These results bring additional quantitative information on the role of selected masks and respirators in reducing aerosol emission that potentially contribute to the transmission of viral diseases, including COVID.     

Predicting the flowability of alumina powder during batch grinding through the establishment of a grinding kinetic model

Grinding is one of the main unit operation in industrial processes handling powders. The particle size reduction that takes place during grinding tests, usually results in a significant change in the flow behavior of the ground powder. Up to now, a model predicting the evolution of powder flowability with grinding time, according to the operating conditions is still missing. In this paper, a methodology combining a grinding kinetic model and a flowability model involving the population-dependent granular Bond number is developed. The methodology has been applied to an alumina powder, ground in a batch ball mill. The flow function coefficient of the ground samples is measured after various grinding times in a powder shear tester. The comparison between model predictions and experimental data shows that this method allows an accurate prediction of the powder flow behavior over the first sixteen minutes of grinding.     

3D printing vertically: Direct ink writing free-standing pillar arrays

Over the last three decades, a variety of additive manufacturing techniques have gradually gained maturity and will potentially play an important role in future manufacturing industries. Among them, direct ink writing has attracted significant attention from both material and tissue engineering areas, where the colloidal ink is extruded and dispensed according to a pre-designed path, usually in the X-Y plane with suitable increments in the Z direction. Undoubtedly, this way of disassembling geometries, simple or complex, can facilitate most of the printing process. However, for one extreme case, i.e. pillar arrays, the size resolution can deviate from both nozzle and design if the common way of slicing and additive manufacturing is used. Therefore, a different printing path is required – directly depositing pillars in a converse gravitational direction. This paper gives multiple examples of printing viscoelastic colloidal ceramic and metal inks uniaxially and periodically into free-standing and height-adjustable pillar arrays. It is expected to inspire the additive manufacturing community that more versatile degrees of freedom and complex printing paths, not confined within only complex shapes, can be achieved by ink-based 3D printing.     

Granulation of ibuprofen/isonicotinamide co-crystals by continuous spray granulator (CTS-SGR)

The importance of granulation is paramount for tablet manufacturing, and is based on the fact that granulated powders are characterized by improved flowability, compressibility, segregation, and dust reduction. The aim of this study was to prepare and characterize continuous granules of high drug content by using a continuous-spray granulator (CTS-SGR). Ibuprofen (IBU), a drug of low-flowability, was selected as the model drug. As IBU has a low melting point and cannot easily granulate on its own, we employed isonicotinamide (INA) as a coformer that would allow us to prepare co-crystal granules containing 60 % IBU. The results of the undertaken differential scanning calorimetry and powder X-ray diffraction revealed that the IBU and the INA in the granules formed co-crystals. The granulation conditions affected the particle size and the yield of the granules; in fact, a low air supply temperature, a low atomizing air rate, and a high solution flow rate ensured a high granulation efficiency. Moreover, continuous granulation increased the yields of the formulations compared to those obtained through a short-run granulation, and high yields were obtained after applying a low atomizing air rate. The circularity of the granules exceeded 90 %, and their flowability improved when compared to that of the IBU bulk. The undertaking of dissolution studies revealed no change in the elution amount of IBU as a result of the co-crystallization. Our study shows that it is possible to produce high-content IBU granules in a direct and continuous manner through the co-crystallization of IBU and the use of a CTS-SGR.     

Full-loop study of a dual fluidized bed cold flow system: Hydrodynamic simulation and validation

The unsteady behaviors of the air-silica sand flow in a lab-scale dual fluidized bed gasification cold flow system have been studied. A two-dimensional computational fluid dynamics full-loop model with poly-size distribution in solid phases was developed as an innovation of this study to investigate the effects of crucial parameters on system hydrodynamics. The results showed a decrease in the mixture static pressure from the bottom to the upper regions of the system, which maintained the system operations stable. The riser air inlet velocity and the gasifier static bed height were found to play considerable roles in enhancing the total sand flow rates. The same tendencies in the prediction and experiment of both the mixture pressure and the sand flow rate showed the feasibility of the proposed model. Besides, the residual evaluation enhanced data reliability and supported model validation. Especially, undesirable phenomena possibly occurring in the system operation under improper conditions could also be predicted. Accordingly, the inventory of bed material and the fluidizing gas flow rates should be suitably regulated to maintain pressure balances, trouble-free continuous flow, optimal sand circulation rate, and low solids loss. Furthermore, the obtained results in this study can be used as a reference for optimizing the designs and operational conditions of large-scale plants.     

Screening of sugars and cyclodextrins as carriers in montelukast dry powder inhalers processed by spray freeze drying

The purpose of this study was to develop a site targeting montelukast sodium (MTK) microparticles as a respiratory drug delivery system using the spray freeze drying (SFD) process. A range of sugars and cyclodextrins (CDs) were screened as carrier in order to find compatible excipients for the preparation of dry powder inhalers (DPIs). The physical characteristics of collected powders were studied by scanning electron microscopy (SEM), laser light scattering, differential scanning calorimetry (DSC), and X-ray diffraction (XRD). The aerodynamic behavior of the particles was also assessed using twin stage impinge (TSI). In the presence of simple sugars as carriers, highly porous particles in irregular shapes were produced. The use of CDs resulted in the formation of spherical particles with high porosity. Among all carriers that were used during the preparation of powders, raffinose had the best aerodynamic behavior with a fine particle fraction (FPF) of 60 % in sugar groups, while the lowest FPF was related to trehalose as carrier. Powders containing CDs mostly showed proper aerodynamic behavior, especially in formulations containing alfa-cyclodextrin (A-CD), beta-cyclodextrin (β-CD), and highly branched cyclic dextrin (HBCD). Overall, data indicated that the CDs were excellent excipients for use with MTK for respiratory drug delivery.     

Machine learning aided nanoindentation: A review of the current state and future perspectives

The solution of instrumented indentation inverse problems by physically-based models still represents a complex challenge yet to be solved in metallurgy and materials science. In recent years, Machine Learning (ML) tools have emerged as a feasible and more efficient alternative to extract complex microstructure-property correlations from instrumented indentation data in advanced materials. On this basis, the main objective of this review article is to summarize the extent to which different ML tools have been recently employed in the analysis of both numerical and experimental data obtained by instrumented indentation testing, either using spherical or sharp indenters, particularly by nanoindentation. Also, the impact of using ML could have in better understanding the microstructure-mechanical properties-performance relationships of a wide range of materials tested at this length scale has been addressed.The analysis of the recent literature indicates that a combination of advanced nanomechanical/microstructural characterization with finite element simulation and different ML algorithms constitutes a powerful tool to bring ground-breaking innovation in materials science. These research means can be employed not only for extracting mechanical properties of both homogeneous and heterogeneous materials at multiple length scales, but also could assist in understanding how these properties change with the compositional and microstructural in-service modifications. Furthermore, they can be used for design and synthesis of novel multi-phase materials.     

Powder flow and mixing in different tablet press feed frames

Tablets can be manufactured using a rotary tablet press, which consists of a feed frame followed by the compression and compaction of the powder and subsequent ejection of the tablets. From Quality by Design (QbD) perspectives the feed frame plays a critical role and effects products critical quality attributes (CQAs). Thus optimizing this stage is of huge interest. It is preferable to achieve narrow residence time distributions of the powder in the feed frames as well as homogeneous tablets with respect to their height, weight and tensile strength. In the present study three design approaches of feed frames are simulated using the Discrete Element Method (DEM). We investigate the influence of operational input parameters (i.e., rotational rates) on the behaviour of a free flowing and a cohesive material. The detailed simulation data allows us to compare the mentioned setups in terms of residence times, tablet masses and occurring deviations. Therefore, we are able to determine the optimal feed frame and process settings for both free-flowing and cohesive powders.     

pH-responsive dual-functional hydrogel integrating localized delivery and anti-cancer activities for highly effective therapy in PDX of OSCC

As one of the most promising localized drug delivery systems for enhancing therapeutic efficacy and reducing systemic toxicity, supramolecular hydrogels self-assembled from natural products have recently attracted tremendous attention. However, the intricate drug loading process, limited drug entrapment efficacy, and lack of stimulus responsiveness considerably impede their potential for biological applications and raise the need for advanced hydrogel-based delivery systems. Therefore, the development of updated materials that integrate localized delivery and drug activity into a single system is extremely desired and has great potential to overcome the aforementioned shortcomings. In this study, a pH-responsive dual-functional isoG-based supramolecular hydrogel with both localized delivery and anti-cancer activity in one molecule is successfully developed in one pot by following a simple and green procedure. The isoguanosine-phenylboronic-guanosine (isoGPBG) hydrogel exhibits exceptional stability (more than one year), outstanding pH-responsiveness and excellent sustained release capability. Both in vitro and in vivo experiments demonstrate that the isoGPBG hydrogel not only shows acceptable biocompatibility and biodegradability but also significantly inhibit tumor growth (approximately 60% inhibition of tumor growth) and improve overall survival, especially in preclinical patient-derived xenograft (PDX) model of oral squamous cell carcinoma (OSCC). Therefore, the isoGPBG hydrogel, to the best of our knowledge, is the first example of pH-responsive dual-functional isoG-based supramolecular hydrogel integrating localized delivery and anti-cancer activity in one molecule. It is implied that the isoGPBG hydrogel could act as a smart dual-functional localized delivery system in the future for clinical cancer therapy.     

Breaking behaviour and interactions in maize and soybean meal while grinding of a hammer mill

The objective of the present study was to investigate whether mixing ratio of maize and soybean meal (SBM) affects the breaking behaviour during hammer-milling in terms of the nutrient properties and in vitro digestibility of fractionated particles. Mixtures of maize and SBM with different proportions (% Maize:SBM; 0:100, 25:75, 50:50, 75:25, 100:0) were hammer milled using a 2-mm screen. The obtained powder was sieved into seven fractions with size ranges from 0.149 to 1.190 mm. Results show that energy consumption of grinding mixtures increased from 3.8 to 48.4 kJ/kg with the maize proportion increasing from zero to 100%. Mixing proportion of maize and SBM showed significant effects on nutrient content of fractionated material. For hammer milled material <595 µm, the in vitro digestibility of crude protein (CP) and organic matter (OM) of fractionated material decreased with increasing particle size. Additionally grinding fractionated particles ≥595 µm over a 1-mm sized screen before in vitro digestion analysis increased the digestibility of OM and CP. Equivalent particle size (EPS) and geometric standard deviation (GSD) of hammer milled maize and SBM and their mixtures correlated better than geometric mean diameter (GMD) to OM and CP in vitro digestibility in a linear regression model. In summary, the mixing ratio of maize and SBM had a significant effect on the breaking behaviour of ingredients and in vitro digestibility of CP and OM of the isolated fractions. Mixing ingredients before grinding is suggested in terms of saving energy consumption. The GSD/EPS of ground material should be considered while studying the effects of particle size distribution on the in vitro digestibility of nutrients.     

Immersed-boundary/soft-sphere method for particle–particle-fluid interaction in a viscous flow: An OpenFOAM solver

We developed a stable OpenFOAM solver for Immersed Boundary Method based on direct forcing and regularized delta function. The soft-sphere model and a lubrication model were implemented to consider particle–particle collision in a viscous flow. We proposed a fluid–structure interaction (FSI) coupling method to accurately calculate the fluid forcing term and particle velocity. Our solver was validated for fixed and moving bodies, including rotation. The accuracy of various FSI schemes was evaluated in predicting the solid and fluid flow behavior in a viscous flow. It was demonstrated that neglecting or simplifying the fluid momentum change affects the accuracy of the solid velocity and fluid flow dynamic; for higher solid-to-fluid density ratios, a larger deviation was predicted. Furthermore, the FSI schemes highly influenced the behavior of the formed vortices.The solver was validated to predict the effective restitution coefficient of particles in a viscous flow as a function of the Stokes number. We also thoroughly analyzed the dynamic flow behavior of colliding particles through the pressure and velocity field and fluid force. This analysis helped us accurately determine the rebound velocity of particles in case of high Stokes numbers when the effect of viscous force is significant.     

CFD modelling and simulation of an industrial scale continuous fluidized bed roaster

In the present work, computational fluid dynamics (CFD) based modelling of an industrial scale continuous fluidised bed roaster (FBR) has been carried out to study its performance at different operating conditions, so that the sulphide-sulphur content in the product is within 0.4% at the designed feed rate of 39.75 DMT/h. Eulerian-Eulerian multiphase model, considering four granular phases and one gas phase has been implemented to investigate the velocity and mass fraction profile of the particles in the FBR. The heat and species mass balance calculations have been performed external to CFD, by dividing the roaster into several sections. The conversion of ZnS to ZnO at various sections of the roaster has been estimated using reaction kinetics under isothermal condition (1203 K). The heat liberated and possible temperature rise at each section was predicted based on the heat of reaction and sensible heat of the solid and gaseous products. The CFD model was validated with the plant data for a feed rate of 36.5 DMT/h, air flow rate of 65,000 Nm³/h and O₂ content of 21%. The proposed model predicted the sulphide-sulphur content in the product to be 0.4% for the designed feed rate of 39.75 DMT/h, when the O₂ content in the inlet air was increased to 25%.     

3D HCN nanotexture with synergistic effect of nickel and hole scavengers for enhancing photocatalytic H2 production: Role of morphology and influential parameters

Well-designed three-dimensional (3D) nanotextures of graphitic carbon nitride (g-C₃N₄), synthesized using template free single step method and mediated with nickel as a noble free metal, for solar hydrogen production, has been investigated. The photoactivity was investigated in a slurry type continuous flow photoreactor system by using different influential parameters such as hole scavengers, diffusion effects, time, and mass transfer. Compared to bulk g-C₃N₄, H₂ yield was increased with 3D hierarchical carbon nitride (HCN) nanotexture. The H₂ evolution rate was reached to 1310 µmol g^?1 h^?1 with optimized 2 % Ni loading to 3D HCN. This H₂ evolution rate was 19.8 and 24.9 times higher than it was generated using 3D HCN and g-C₃N₄, respectively. The special interlayer opening, more light penetration and suppressed charge carrier recombination were the main contributors for this photoactivity enhancement. Among the different influential parameters, lower viscosity, higher number of protons and less diffusion effects were promising to give significantly higher H₂ production. The stability of nanotextures was entirely dependent on the attached reactants over the nickel reactive sites, which was more promising for Triethanolamine (TEOA) than using methanol. This newly developed low-cost 3D HCN can be promising in solar energy conversion and other energy applications.     

Investigation of the molecular state of 4-aminosalicylic acid in matrix formulations for dry powder inhalers using solid-state fluorescence spectroscopy of 4-dimethylaminobenzonitrile

Carrier-free method is an alternative approach for dry powder inhaler (DPI) formulations, which overcome poor drug mobility and distribution. Here we investigated the properties of an active pharmaceutical ingredient (API) within composite particles. We used highly-branched cyclic dextrin (HBCD) as the excipient matrix that was prepared using a spray-drying technique. 4-Aminosalicylic acid (4-ASA) and 4-dimethylaminobenzonitrile (DMABN) were selected as a hydrophilic second-line antitubercular agent and a surrogate for 4-ASA as a model compound, respectively. The spray-dried particles (SDPs) containing 4-ASA or DMABN with HBCD had geometric median diameters (D₅₀) of 2.34 ± 0.07 μm and 2.26 ± 0.10 μm, respectively. Further, the in vitro aerodynamic properties were similar for SDPs containing 4-ASA and DMABN with HBCD. To determine the properties of APIs within composite particles, we performed solid-state fluorescence spectroscopy of DMABN. As a candidate excipient, hydroxypropyl methylcellulose (HPMC) was compared to HBCD. We determined the intensity ratio of twisted intramolecular charge transfer (TICT) emission to locally excited emission within the excipient matrix environment. The HBCD matrix environment was better than HPMC to trigger a more robust TICT reaction of DMABN. A potent state-changing interaction of APIs occurred in the HBCD matrix environment versus another excipient environment.     

Stabilizing effect of the cyclodextrins additive to spray-dried particles of curcumin/polyvinylpyrrolidone on the supersaturated state of curcumin

Although curcumin is considered to have various therapeutic effects, its use as a functional food or supplement is restricted owing to its low water solubility and bioavailability. To increase the solubility of curcumin in water, the use of polyvinylpyrrolidone (PVP) and vinylpyrrolidone-vinyl acetate copolymers with a pyrrolidone skeleton was noted to be promising. In particular, the bi-component formulations of curcumin/PVP prepared through spray drying exhibited an amorphous state in powder X-ray diffraction observations and temporally increased the apparent solubility of curcumin to over 5000 times that of untreated curcumin; nevertheless, after 24 h, the solubility decreased owing to the unstable supersaturated state of curcumin. The addition of α-cyclodextrin (α-CyD) in the bi-component curcumin/PVP formulation helped maintain the supersaturated state of curcumin, whereas the addition of β- and γ-CyD led to the collapse of the supersaturated state. The addition of α-CyD can likely help inhibit the nucleation and crystal growth of curcumin, through the interaction among the solubilized units of curcumin/PVP and α-CyD.     

Improving hydrothermal performance of hybrid nanofluid in double tube heat exchanger using tapered wire coil turbulator

Tapered wire coil insert is proposed as a novel enhancer in the double tube heat exchanger and experimental studies on Al₂O₃ + MgO hybrid nanofluid flowing under the turbulent condition are performed to investigate the hydrothermal characteristics. Effects of using tapered wire coil turbulator and hybrid nanofluid on the hydrothermal behaviors are examined for different coil configurations (Converging (C) type, Diverging (D) type and Conversing-Diverging (C-D) type) and hybrid nanofluid inlet temperatures and volume flow rates. Results show that D-type wire coil insert promotes better hydrothermal performance as compared to C-type and C-D type. Nusselt number and friction factor of hybrid nanofluid using D-type, C-D type and C-type wire coil inserts enhance up to 84%, 71% and 47%, and 68%, 57% and 46%, respectively than that of water in tube without insert. The entropy generation of hybrid nanofluid is lower than that of base fluid in all cases. The thermal performance factor for hybrid nanofluid is found more than one with all inserts. The thermal performance factor is observed a maximum of 1.69 for D-type coil. The study reveals that the hybrid nanofluid and tapered wire coil combination is promising option for improving the hydrothermal characteristics of double pipe heat exchanger.     

Thermal properties of hierarchical YSZ and LZO ceramic microspheres with multi-scaled voids investigated by using theoretical,experimental and simulation methods

Heat transfer within ceramic feedstock powders is still unclear, which impedes optimization of the thermal and mechanical properties of the thermal sprayed coatings. The microspheres (yttria-stabilized zirconia YSZ and lanthanum zirconate LZO) were prepared via the electro-spraying assisted phase inversion method (ESP). The thermal properties of the two ESP microspheres and a commercial hollow spherical powder (HOSP) were investigated by using theoretical, experimental, and simulation methods. Thermal conductivity of the single microsphere was estimated via a novel nest model that was derived from the Maxwell-Eucken 1 and the EMT model. Thermal conductivity of a single YSZ/LZO-ESP microsphere prepared at 1100–1200 °C was within 0.36–0.75 W/m K, which was ～ 20 % lower than that of a single YSZ-HOSP microsphere with a similar porosity. Heat flux simulation showed that high tortuosity around the multi-scaled voids of the ESP microsphere led to a more efficient decrease in thermal conductivity compared with total porosity.     

Changes in the oxygen content,morphology, and microstructure of Mo-10Nb composite powders during mechanical alloying

The prefabrication of Mo-Nb composite powders is an effective way of improving the homogeneity of Mo-10Nb targets, which have broad application prospects in the photoelectric sensor industry. However, this aspect has been rarely addressed so far. Therefore, we prepared Mo-10Nb composite powders by mechanical alloying (MA), and investigated the effects of the experimental parameters such as the milling speed and duration on the particle morphology, size distribution, compositional homogeneity, crystallite size, inner strain, and oxygen content. High-quality Mo-10Nb composite powders with 3-μm spherical particles of narrow size distribution, homogeneous elemental distribution, and nanometric crystalline structure were obtained by implementing optimum MA parameters, viz., a milling speed of 250 rpm and duration of 36 h using an MITR QM-QX-4L omnidirectional ball mill. The mechanically alloyed Mo-10Nb composite powders were prone to oxidation when exposed to air, which led to a sharp increase in the oxygen content to ~5400 ppm. X-ray photoelectron spectroscopic analysis revealed the presence of Nb₂O₅, MoO₂, and MoO₃ on the surface of the Mo-10Nb particle. We believe that this study demonstrates an interesting strategy for the fabrication of high-quality Mo-10Nb targets.