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To further our understanding of iron particle combustion, especially in the liquid state, in situ optical measurements are performed for the size evolution and temperature of laser-ignited iron particles in a narrow size range around 45-55μm. The particle size evolution is monitored by a high-speed shadowgraphy system, and the particle temperature is probed using a two-color pyrometer synchronized with the shadowgraphy system. Before a particle reaches the peak temperature, its diameter grows linearly with elapsed time. Near the peak temperature, three types of particle size behavior are detected, namely, smooth transition, micro-explosion, and rapid inflation. For particles with smooth transition, the size and temperature reach the maximum values at the same time, and thereafter the size remains constant, while the temperature drops until rapid solidification of the iron oxide droplet. The micro-explosion and rapid inflation clearly indicate towards a quick gas release inside the particle. The ambient oxygen concentration has a strong effect on the growth rate of the particle size before the peak temperature but no influence on the final particle size. The measured relative particle diameter at the peak temperature suggests that iron has been fully oxidized and the degree of oxidation could be higher than FeO. At the onset of solidification, gas release occurs again, resulting in a second inflation or burst of already inflated particles. This suggests that the oxygen dissolved in the liquid iron oxide is at least more than needed to form solid Fe3O4, and the solidification process is accompanied with gaseous oxygen release via the phase transition: L2 → Fe3O4(s) + O2(g) at 1855 K, where L2 represents liquid iron oxide with dissolved excess oxygen.

Temporally, spatially, and thermally resolved measurements of in situ nanoparticle cloud formation during combustion of single micron-sized iron particles are carried out. The critical particle temperature for the cloud formation is identified using high-speed and high-magnification shadowgraphy, recording the evolution of a nanoparticle cloud, synchronized with two-color pyrometry probing the surface temperature of the burning micron particle. The finding could serve as an important criterion to minimize nanoparticle generation in the flame of iron-particle suspensions, making iron powders a cleaner and more recyclable fuel.

Large scale simulation models can aid in improving the design of spray dryers. In this work an Eulerian-Lagrangian model with coupled gas phase and droplet heat and mass transfer balances is used to study airflow dynamics, temperature and humidity profiles at different positions in the spray. The turbulent gas flow is solved using large eddy simulation (LES). A turbulent dispersion model accounts for the stochastic subgrid fluid velocity fluctuations along the droplet trajectory. The dispersed phase is treated with Lagrangian transport of droplets, and collisions between droplets which are detected with a stochastic Direct Simulation Monte Carlo (DSMC) method. The outcome of a binary collision is described by collision boundary models for water and milk concentrates. The drying of droplets is modeled by the reaction engineering approach (REA). The effect of the inlet air conditions and of droplet viscosity on the temperature and humidity distributions are analyzed. Most of the heat and mass transfer occurs in the first 10-20 cm from the nozzle where the slip velocities and temperature and humidity driving forces are higher. The droplets size increases, both in the axial and radial direction, because of the dominance of coalescence over separation in the droplet spray studied here. Because the spray domain considered in this work is relatively small, the droplet residence time is small, and consequently the amount of evaporation is still low. The droplet size distributions of milk concentrates are affected by the predominance of coalescence over separation events. The coalescence dominated regime increases when the droplet viscosity is higher.

The combustion behavior of single laser-ignited iron particles is investigated. Transient particle radiant intensities at 850 nm and 950 nm are measured by post-processing recorded high-speed camera images using an in-house developed particle tracking program. Then, the time-resolved particle temperature is obtained based on two-color pyrometry. A plateau-like stage shortly after the ignition is repeatedly observed, and identified as iron particle melting by the measured temperature and the estimated melting time. Besides, an abrupt brightness jump near the end of combustion is observed for most burning particles, while a small portion of the particles (< 10%) show a second plateau-like stage instead. The particle temperature right after the brightness jump (1880±70 K) is almost identical to that during the second plateau-like stage. This temperature corresponds to two phase-change temperatures in the Fe-O phase diagram: i) L2 Fe 3O 4 (s) at 1869 K (congruent melting) and ii) L2 Fe 3O 4 (s) + O 2 (g) at 1855 K (eutectic reaction), where L2 represents a liquid iron oxide. Based on this, the presence of the brightness jump (spear point) is explained by a sudden solidification of supercooled iron oxide droplets with an atomic O/Fe ratio larger than or close to 4/3. Particles’ near-peak temperatures are also measured based on time-integrated spectra. The results indicate that the near-peak temperature increases first fast and then slowly with an increase of oxygen concentration. At higher oxygen concentrations, smaller particles have a slightly lower temperature. The effect of particle size on the near-peak temperature is negligible at lower oxygen concentrations due to weaker radiation. The morphology of combusted particles is examined by micrography. Some burned particles appear as hollow thin-shell spheres at all adopted oxygen concentrations. Additionally, nano oxides are found at 13–51% oxygen concentrations. Less traces of nano oxides were observed at reduced oxygen concentrations. The nano-oxide formation mechanisms are analyzed based on thermochemical equilibrium calculations.

In this work we investigate droplet-droplet collision interactions in a spray system using an Eulerian-Lagrangian model with subgrid turbulence dispersion. The effect of different droplet viscosities on the type and frequency of droplet collision is investigated, knowledge of which is essential for industrial processes such as spray drying for production of milk powder. The dispersed phase is treated with Lagrangian transport of droplets and the turbulent self-induced gas flow using large eddy simulation (LES). A stochastic Direct Simulation Monte Carlo (DSMC) method is used to detect collisions between droplets. The outcome of a binary collision is described by a collision boundary models for water and milk concentrates. A turbulence dispersion model, based on the Langevin equation, accounts for the stochastic subgrid fluid velocity fluctuations along the droplet trajectory. We compare the spray dynamics with and without droplet interactions and turbulence dispersion. For a spray with typical droplet size of 50 µm, we find that the turbulence dispersion model enhances the total collision frequencies by approximately 25%. The performance of the turbulent dispersion model is tested by investigating the rate of collisions for different milk concentrates. The evolution of size distributions inside the spray is strongly influenced by the complementary effects of collision boundary models and turbulence dispersion.

An improved particle generator based on electrodynamic powder fluidization is proposed and constructed for investigating single metal particle’s combustion. The designed setup is able to generate a single metal particle moving upward with a well controlled velocity and trajectory and ignite it at near-uniform conditions by an infrared laser beam with flattened elliptical beam profile. Mechanically sieved narrow fractions of spherical iron particles with mean sizes in the range of around 26–54 μ m were used in experiments. Particles burned in O 2 /N 2 mixtures with oxygen content varying from 21% to 36%. Particle’s trajectories, velocities, and arbitrary radiant intensities were measured by taking images with a high-speed camera and processing them with an in-house developed data processing program. Two characteristic times associated with particle combustion were measured: 1) total duration of high-temperature phase ( t t o t ) and 2) time to the maximum brightness ( t m a x ). The results show that t t o t and t m a x can be described by a d n -law with 1.57 ≲ n ≲ 1.72 and 1.46 ≲ n ≲ 1.60 , respectively. The effect of oxygen concentration on t t o t , t m a x , and t d e c = t t o t − t m a x was analyzed for selected particle sizes of 30, 40, and 50 μ m. It was found that t m a x ∝ ( 1 / X O 2 ) n with 1.04 ≲ n ≲ 1.18 is almost linearly proportional to 1 / X O 2 , while t d e c shows a very weak dependency on the oxygen concentration at 26%–36%. This can be explained by the idea that the overall combustion process of iron is controlled by first external and then internal diffusion of oxygen owing to the saturation of oxygen on the particle surface.

We investigate the collision behaviour of a shear thinning non-Newtonian fluid xanthan, by binary droplet collision experiments. Droplet collisions of non-Newtonian fluids are more complex than their Newtonian counterpart as the viscosity no longer remains constant during the collision process. Despite the complex collision dynamics, we are able to present a complete regime map based on non-dimensional Weber (We) number and impact parameter (B). We compare the collision outcomes of xanthan, glycerol and a milk concentrate at similar impact conditions. These experiments reveal very rich and complex collision morphologies for shear thinning xanthan solution, strikingly different from Newtonian droplet collisions. Unlike glycerol and milk, xanthan collisions show no reflexive separation even at very high We number. Instead of breakup, we observe disc-like shapes with an oscillating behaviour of the colliding droplets. A detailed analysis reveals that this outcome is related to increased viscous energy dissipation and extensional effects.

Spray drying is an important industrial process to produce powdered milk, in which concentrated milk is atomized into small droplets and dried with hot gas. The characteristics of the produced milk powder are largely affected by agglomeration, combination of dry and partially dry particles, which in turn depends on the outcome of a collision between droplets. The high total solids (TS) content and the presence of milk proteins cause a relatively high viscosity of the fed milk concentrates, which is expected to largely influence the collision outcomes of drops inside the spray. It is therefore of paramount importance to predict and control the outcomes of binary droplet collisions. Only a few studies report on droplet collisions of high viscous liquids and no work is available on droplet collisions of milk concentrates. The current study therefore aims to obtain insight into the effect of viscosity on the outcome of binary collisions between droplets of milk concentrates. To cover a wide range of viscosity values, three milk concentrates (20, 30 and $$46\%$$ TS content) are investigated. An experimental set-up is used to generate two colliding droplet streams with consistent droplet size and spacing. A high-speed camera is used to record the trajectories of the droplets. The recordings are processed by Droplet Image Analysis in MATLAB to determine the relative velocities and the impact geometries for each individual collision. The collision outcomes are presented in a regime map dependent on the dimensionless impact parameter and Weber (We) number. The Ohnesorge (Oh) number is introduced to describe the effect of viscosity from one liquid to another and is maintained constant for each regime map by using a constant droplet diameter (d $$\sim 700\ \upmu \hbox {m}$$ ). In this work, a phenomenological model is proposed to describe the boundaries demarcating the coalescence-separation regimes. The collision dynamics and outcome of milk concentrates are compared with aqueous glycerol solutions experiments. While milk concentrates have complex chemical composition and rheology, glycerol solutions are Newtonian fluids and therefore easy to characterize. The collision morphologies of glycerol solutions and milk concentrates are similar, and the regime maps can be described by the same phenomenological model developed in this work. The regime of bouncing, however, was not observed for any of the milk concentrates.

A complete knowledge of the effect of droplet viscosity on droplet-droplet collision outcomes is essential for industrial processes such as spray drying. When droplets with dispersed solids are dried, the apparent viscosity of the dispersed phase increases by many orders of magnitude, which drastically changes the outcome of a droplet-droplet collision. However, the effect of viscosity on the droplet collision regime boundaries demarcating coalescence and reflexive and stretching separation is still not entirely understood and a general model for collision outcome boundaries is not available. In this work, the effect of viscosity on the droplet-droplet collision outcome is studied using direct numerical simulations employing the volume of fluid method. The role of viscous energy dissipation is analysed in collisions of droplets with different sizes and different physical properties. From the simulations results, a general phenomenological model depending on the capillary number (Ca, accounting for viscosity), the impact parameter (B), the Weber number (We), and the size ratio (Δ) is proposed.

Iron is a prospective candidate for energy carriers in the energy transition era with high energy density. In this concept, energy is released by the combustion of iron powder whilst the solid product - iron oxide - can be collected and reduced back to metallic iron, forming a recyclable iron fuel cycle. The electrochemical technique is considered to be a suitable reduction method as it has attractive aspects including low electric energy consumption, low temperature, direct usage of renewable energy, and a short process chain. In this study, the performance of iron electrodeposition is investigated using an electrolysis cell containing a suspension of micron-sized combusted iron powder in aqueous NaOH (50%wt, 18 M) at a temperature of 110°C. The parallel plate electrolyzer used in these experiments consists of a stainless-steel plate (cathode) and a nickel gauze (anode). The effects imposed by varying current density, iron oxide composition, and iron oxide particle diameter on Faradaic efficiency and reduced iron yield are evaluated. Additional experiments using a rotating disc electrode (RDE) are also conducted to determine the system's diffusion coefficient under different operating conditions. Generally, cathodic deposition of metallic iron is successfully achieved and the morphology of the deposited iron depends on the operation conditions including the current density and heterogeneity of the flow system. The obtained results open new perspectives for efficient and cost-effective iron production/regeneration. Figure 1

Electrowinning is the electrodeposition of metals from their oxides which are either solvent or suspended in an electrolyte solution. It receives increasing attention in the last decade as the promotion of CO2-free metal production. The design of the electrochemical cell is essential for the process performance, e.g., Faradaic efficiency. In this experimental study, we focus on the effect of different cathode materials on the electrodeposition performance of iron. Experiments are conducted in a lab-scale parallel-plates cell with the electrolyte composed of the aqueous sodium hydroxide (NaOH) 50%wt, 18 M (pH = 14.5) and micron-sized iron oxide powder with a mass fraction of around 20%. Different electrode materials are tested as the cathode for iron electrodeposition, including copper, stainless steel, graphite, and nickel mesh plates, whilst a nickel gauze is used as the anode. Characterizations of the deposition are conducted to obtain microstructural analysis and element identification. As a result, different deposit types and morphology are observed from the experiments. Stainless steel shows the highest current efficiency. The electrolyzed iron in all electrodes shows high purity (above 98%). The results from this study provide some guidance in designing key industrial processes of iron electrowinning