Pilot plant studies of novel membranes and devices for direct contact membrane distillation-based desalination

A small pilot plant for direct contact membrane distillation (DCMD) based desalination was built and operated successfully on a daily basis for 3 months. The operation employed hot brine at 64–93 °C and distillate at 20–54 °C. The hot brine was either city water, city water containing salt at the level of 3.5, 6 or 10%, or sea water trucked in from Long Island Sound, CT. One to ten horizontal crossflow hollow fiber membrane modules each having either 2448 or 2652 hollow fibers and 0.61 or 0.66 m² surface area were combined in various configurations to study the plant performance. The highest water vapor flux of 55 kg/(m² h) was achieved with two modules in series; the flux varied between 15 and 33 kg/(m² h) for configurations employing 6–10 modules. The highest distillate production rate achieved was 0.62 gallons per minute (gpm). The membrane modules never showed any sign of distillate contamination by salt. The plant operated successfully with a very limited flux reduction at salt concentrations up to 19.5% from sea water. A mathematical model was successfully developed to describe the performance of the pilot plant with multiple crossflow modules in different test configurations.     

First use of millicurie levels of172Hf−172Lu in the industrial sector

The first use of the¹⁷²Hf–¹⁷²Lu generator system in industry is reported. Millicurie quantities of¹⁷²Lu have been utilized for radiotracer studies of oil pipeline flow rates, refinery column residence times, and the performance of a coal liquefaction pilot plant.     

A quick method to determine uranium concentration by gamma spectroscopy: Its application for extraction of uranium from wet phosphoric acid

A rapid and accurate method to measure uranium was established using gamma spectroscopy with a high purity germanium detector. This can be done by measuring the gamma radiation intensity at 186 keV which corresponds to the concentration of ²³⁵U only since all the ²²⁶Ra which also shows a peak at this energy level, remains in the solid phosphogypsum. The method was proved to be accurate when compared with other methods. It has also the advantage of measuring uranium concentrations over a wide range suitable to the operation of the pilot plant for extraction of uranium from wet process phosphoric acid without the need to dilution or concentration. It can also measure the uranium in the different media such as acid, organic or alkaline media found in the pilot plant at different stages.     

Modeling the (^{15}N) isotope separation column

The chemical processes developed in the $^{15}$ N-isotope separation plant are very complex and many details are not yet known in totality. Accurate models for such isotope separation plants offer an invaluable insight towards optimizing the production and establishing an adequate control action. A model of such an isotope plant is presented in the paper. The results are validated by simulation, based on a lot of experiments. The model is then used to evaluate and establish the necessary conditions for a maximum production for an existing pilot plant. For protection purposes, the experimental data used in this paper have been scaled.     

Rotary kiln pyrolysis of straw and fermentation residues in a 3 MW pilot plant – Influence of pyrolysis temperature on pyrolysis product performance

The idea of co-firing biomass in an already existing coal-fired power plant could play a major contribution in the reduction of carbon dioxide emissions. Huge amounts of unused biomass in terms of agricultural residues such as straw, which is a cheap and local feedstock, are often available. But due to the high amount of corrosive ash elements (K, Cl, etc.), the residues are usually not suitable for co-firing in a thermal power plant. Therefore, the feedstock is converted by low temperature pyrolysis into gaseous pyrolysis products and charcoal. A 3 MW pyrolysis pilot plant located next to a coal-fired power plant near Vienna was set up in 2008. For the process, an externally heated rotary kiln reactor with a design fuel power of 3 MW is used which can handle about 0.6–0.8 t/h straw. The aim is to investigate the fundamentals for scale-up to the desired size for co-firing in a coal-fired power plant. In addition to the desired fuel for the process, which is wheat straw, a testing series for DDGS was also performed. The high amount of pyrolysis oil in the gas had positive effects on the heating value of the pyrolysis gas. Chemical efficiencies of this pyrolysis pilot plant of up to 67% for pyrolysis temperatures between 450 °C and 600 °C can be reached. The focus of this work is set on the pyrolysis products and their behavior at different pyrolysis temperatures as well as the performance of the pyrolysis process.     

Performance of a bench-scale membrane pilot plant for the upgrading of biogas in a wastewater treatment plant

A bench-scale membrane pilot plant for upgrading biogas generated at a municipal wastewater treatment plant was constructed and operated for extended periods of time. The raw biogas was available at 45–60 psia (3.1–4.1 bar) and contained 62.6 mol% CH₄, the balance being mainly CO₂ and a large number of organic impurities. The operation of the pilot plant was tested with two identical hollow-fiber modules for periods of over 1000 h (41 days) with each module. One of the hollow-fiber modules was tested at an average pressure of about 525 psia (36 bar) and at stage-cuts of 0.34–0.41, and the other module at about 423 psia (29 bar) and at stage-cuts of 0.36–0.39. The flow rates of the biogas feed were 30–36 ft³/h (2.4×10⁻⁴–2.8×10⁻⁴ m³/s) and 21–24 ft³/h (1.7×10⁻⁴–1.9×10⁻⁴ m³/s), respectively. The CH₄ concentration in the retentate stream (the upgraded biogas) was raised in these tests to 92–95 mol% CH₄. The performance of the pilot plant was stable over the entire test periods. An even higher CH₄ concentration of 97 mol% was reached in short-term tests at a stage-cut of 0.46. The raw biogas had to be pretreated to prevent the condensation of organic impurities which tended to dissolve the hollow fibers. Upgraded biogas containing over 90 mol% CH₄ produced in a large-scale membrane separation plant could be used for the generation of electricity. At the same time, the permeate (waste) stream would contain over 15 mol% CH₄ and could be used for heating applications.     

Biogas Plasticization Coupled Anaerobic Digestion: Continuous Flow Anaerobic Pump Test Results

In this investigation, the Anaerobic Pump (®TAP) and a conventional continuous flow stirred tank reactor (CFSTR) were tested side by side to compare performance. TAP integrates anaerobic digestion (AD) with biogas plasticization–disruption cycle to improve mass conversion to methane. Both prototypes were fed a “real world” 50:50 mixture of waste-activated sludge (WAS) and primary sludge and operated at room temperature (20°C). The quantitative results from three steady states show TAP peaked at 97% conversion of the particulate COD in a system hydraulic residence time (HRT) of only 6 days. It achieved a methane production of 0.32 STP cubic meter CH₄ per kilogram COD fed and specific methane yield of 0.78 m³ CH₄ per cubic meter per day. This was more than three times the CFSTR specific methane yield (0.22 m³ CH₄ per cubic meter per day) and more than double the CFSTR methane production (0.15 m³ CH₄ per kilogram COD fed). A comparative kinetics analysis showed the TAP peak substrate COD removal rate (R _o) was 2.24 kg COD per cubic meter per day, more than three times the CFSTR substrate removal rate of 0.67 kg COD per cubic meter per day. The three important factors contributing to the superior TAP performance were (1) effective solids capture (96%) with (2) mass recycle and (3) stage II plasticization–disruption during active AD. The Anaerobic Pump (®TAP) is a high rate, high efficiency–low temperature microbial energy engine that could be used to improve renewable energy yields from classic AD waste substrates like refuse-derived fuels, treatment plant sludges, food wastes, livestock residues, green wastes and crop residuals.     

A neutron monitor for in-situ real-time determination of transuranics in a processed waste effluent stream

A pilot plant operation at the Savannah River Site will remove ⁹⁰Sr, ¹³⁷Cs, and transuranics from a high-level liquid waste stream prior to encapsulation in a Saltstone Facility. Monitors are required to determine the concentrations of all radionuclides, including transuranics, in real-time on this processed waste stream. A neutron counter used to measure the concentration of each actinide isotope present in the stream is described. The neutron counter assembly consists of nested annular layers of shielding, reflectors, detectors, and moderators. On-line, live-time system control and calibration is provided by a time-tagged neutron source embedded in the moderator assembly.     

Multivariate monitoring of fermentation processes with non-linear modelling methods

Multiway principal components analysis (MPCA) and parallel factor analysis (PARAFAC) are widely used in exploratory data analysis and multivariate statistical process control (MSPC). These models are linear in nature, thus, limited when non-linear relations are present in the data. Principal component analysis (PCA) can be extended to non-linear principal components analysis using autoassociative neural networks. In this paper, the network’s bottleneck layer outputs (non-linear components) were made orthogonal. A method to estimate confidence limits based on a kernel probability density function was proposed since these limits do not assume that the non-linear scores are normally distributed. A measure for the non-linear scores (D_NL) was presented here to monitor on-line the process replacing the well known Hotelling’s T² statistic. One hundred and two industrial fermentation runs were used to evaluate the performance of a non-linear technique for multivariate process statistical monitoring. Three process runs with faults were used to compare the error detection performance using a statistic for the non-linear scores and the residuals statistic (SPE).     

Parametric study of catalytic reforming process?

Summary A parametric study of catalytic reforming process in a pilot plant was carried out by varying the pressure, H₂/HC ratio, and space velocity. The results show that lower aromatics and higher hydrogen yields can be accomplished by increasing the space velocity in existing reformers, which will also result in better C₅⁺yield.     

Scale-up of the vortex wave microfilter using the power ratio

The vortex wave technique enhances microfiltration performance by combining the mixing characteristics of oscillatory flow and flow deflectors. The ability to reproduce these highly convective mixing patterns on a scale applicable to pilot plant studies has been investigated in this paper. The scale-up of a single channel membrane unit (18200 mm²) to a double channel element (106080 mm²) has been investigated in terms of geometric, kinematic and dynamic similarity. A non-dimensional approach has been adopted, wherever possible, to characterise the performance of both microfilters. The kinetics of each system are dominated by the Reynolds number, and the dynamics have been classified in terms of a new non-dimensional number — the power ratio. The power ratio has been employed to predict accurately the performance of the scaled-up filter, and also to provide an indication of transitional flow patterns. The inhibition of a gel-layer within the vortex wave modules has been demonstrated by the non-linear relationship between flux and transmembrane pressure. Experimental results and a theory which includes the effects of osmotic-pressure show that the flux is directly proportional to the cube root of the transmembrane pressure. Non-dimensional analysis of the experimental results indicates a similar trend, whereby the flux is directly proportional to the cube root of power dissipation under two-dimensional, laminar flow conditions.     

Simultaneous Production of Amyloglucosidase and Exo-Polygalacturonase by <Emphasis Type="Italic">Aspergillus niger</Emphasis> in a Rotating Drum Reactor

Simultaneous production of amyloglucosidase (AMG) and exo-polygalacturonase (exo-PG) was carried out by Aspergillus niger in substrate of defatted rice bran in a rotating drum bioreactor (RDB) and studied by a 3¹ × 2² factorial experimental design. Variables under study were A. niger strains (A. niger NRRL 3122 and A. niger t0005/007-2), types of inoculum (spore suspension and fermented bran), and types of inducer (starch, pectin, and a mix of both). Solid-state fermentation process (SSF) was conducted at 30 °C under 60-vvm aeration for 96 h in a pilot scale. Production of AMG and exo-PG was significantly affected by the fungal strain and the type of inoculum, but inducers did not trigger any significant effect, an evidence of the fact that these enzymes are constitutive. The maximum activity of exo-PG was 84 U g_dm ^?1 whereas the maximum yield of AMG was 886.25 U g_dm ^?1.     

Calibration of an automated high resolution gamma-ray spectroscopy system for in-situ real-time monitoring of a processed waste effluent stream

A pilot plant is being designed at the U. S. Department of Energy's Savannah River Site (SRS) to demonstrate the removal of ⁹⁰Sr, ¹³⁷Cs, and transuranics from a high-level liquid waste stream prior to encapsulation in a Saltstone Facility. In-line monitors are required to determine the concentration of all radionuclides on this processed waste stream. Calibration standards containing ⁶⁰Co, ¹³⁷Cs, and ⁹⁰Sr were prepared and counted. Efficiency curves were generated. Strontium-90 is readily observable above the system background in the calibration standard count, and is observable at less than 3 nCi/ml in a mixed solution having the maximum allowable concentration of all other activities present in the proposed SRS effluent stream.     

以脉冲萃取柱利用三异辛胺从高浓度铀溶液中回收铀

利用三异辛胺（TOA）纯化Gattar小型试验工厂的高浓度铀溶液（洗脱液的铀浓度7 g·L^-1）,研究了脉冲萃取柱的性能。利用实验室级脉冲萃取柱进行了实验室规模的溶剂萃取实验和后续实验。结果表明,在室温、pH=1和有机相与水相的比例（V_O/V_A）约为1.8∶1时,加入二（2-乙基己基）磷酸（D2EHPA）使其与TOA的比例（V_D2EHPA/V_TOA）为2∶3,可使萃取克服Cl^-的抑制效应,提高效率。将结论用于考察试验工厂级萃取柱的流体力学和传质性能,结果表明用脉冲萃取柱萃取铀可以达到97%的萃取效率,具有可行性。     

Fast and Minimal‐Solvent Production of Superinsulating Silica Aerogel Granulate

With their low thermal conductivity (λ ), silica aerogels can reduce carbon emissions from heating and cooling demands, but their widespread adoption is limited by the high production cost. A one‐pot synthesis for silica aerogel granulate is presented that drastically reduces solvent use, production time, and global warming potential. The inclusion of the hydrophobization agent prior to gelation with a post‐gelation activation step, enables a complete production cycle of less than four hours at the lab scale for a solvent use close to the theoretical minimum, and limits the global warming potential. Importantly, the one‐pot aerogel granulate retains the exceptional properties associated with silica aerogel, mostly λ =14.4±1.0 mW m⁻¹⋅K⁻¹ for the pilot scale materials, about half that of standing air (26 mW m⁻¹⋅K⁻¹). The resource‐, time‐, and cost‐effective production will allow silica aerogels to break out of its niche into the mainstream building and industrial insulation markets.     

Scale-up of Thermally Dried Kefir Production as Starter Culture for Hard-Type Cheese Making: An Economic Evaluation

This paper concerns the effect of thermal-drying methodology on the investment cost for dried kefir cells production in order to be used as starter culture in cheese manufacturing. Kefir cells were produced at pilot plant scale using a 250-L bioreactor and whey as the main substrate. Kefir cells were subsequently dried in a thermal dryer at 38?°C and used as a starter culture in industrial-scale production of hard-type cheeses. The use of thermally dried kefir as starter culture accelerated ripening of cheeses by increasing both lipolysis and fermentation rate as indicated by the ethanol, lactic acid, and glycerol formation. Additionally, it reduced coliforms and enterobacteria as ripening proceeded. This constituted the basis of developing an economic study in which industrial-scale production of thermally dried kefir starter culture is discussed. The industrial design involved a three-step process using three bioreactors of 100, 3,000, and 30,000 L for a plant capacity of 300 kg of thermally dried kefir culture per day. The cost of investment was estimated at 238,000 €, which is the 46% of the corresponding cost using freeze-drying methodology. Production cost was estimated at 4.9 €/kg of kefir biomass for a 300-kg/day plant capacity, which is the same as with the corresponding cost of freeze-dried cells. However, the estimated added value is up to 10.8?×?10⁹ € within the European Union.     

Comparative study of different types of granular activated carbon in removing medium level radon from water

Granular activated carbon (GAC) has proven its effectiveness in removing radon from water supplies. Laboratory and pilot plant studies were carried out using three different types of activated carbons (F-300, F-400, and HD-4000) to remove radon from water supply. From the experimental kinetic study, the data indicated that at least 6 h are needed to attain equilibrium between radon activity adsorbed onto carbon and its concentration in the aqueous phase. Also, it showed that HD-4000 has higher capacity for removing radon than the other two investigated carbons F-300 and F-400. The adsorption isotherms were satisfactorily explained by Freundlich equation. In the pilot plant study, the performance of the three activated carbons in removing radon at medium concentration (~111 Bq dm⁻³) was evaluated over 60 days of continuous water flow. Four empty-bed contact times (EBCTs) corresponding to four bed depths were continuously monitored and the corresponding steady state adsorption-decay constant values were calculated and the efficiency of each carbon was used to provide a facet for comparison. The γ-radiation exposure rate distribution throughout each GAC bed was measured and compared. This study, despite paucity of literature in this field, is useful for designing a GAC adsorption system for the removal of medium level radon concentration from water supplies.     

以脉冲萃取柱利用三异辛胺从高浓度铀溶液中回收铀

利用三异辛胺(TOA)纯化Gattar小型试验工厂的高浓度铀溶液(洗脱液的铀浓度7 g·L^-1),研究了脉冲萃取柱的性能。利用实验室级脉冲萃取柱进行了实验室规模的溶剂萃取实验和后续实验。结果表明,在室温、pH=1和有机相与水相的比例(V_O/V_A)约为1.8：1时,加入二(2-乙基己基)磷酸(D2EHPA)使其与TOA的比例(V_D2EHPA/V_TOA)为2：3,可使萃取克服Cl-的抑制效应,提高效率。将结论用于考察试验工厂级萃取柱的流体力学和传质性能,结果表明用脉冲萃取柱萃取铀可以达到97%的萃取效率,具有可行性。     

Quality assessment of hydrosphere in the vicinity of Czech nuclear power plants by radioanalytical methods

Summary The paper deals with the impact of nuclear plants and radioactive waste disposal on surface and ground water quality in their vicinity using various radiometric and radioanalytical methods. The impact of nuclear power plant Temelin on activation concentrations and fission products in hydrosphere, including tritium, was detected. The annual average tritium concentrations in Vltava River correspond to the previously calculated estimates for average and minimal quaranteed flow rates. The concentrations histories of ⁹⁰Sr and ¹³⁷Cs in surface water show a decreasing trend. This trend was not influenced by the nuclear power plant pilot operation. In the case of tritium, a concentration increase trend has been already observed since the startup of pilot operation. An attempt has made interpreting the sorption and diffusion data for radionuclides of cesium, strontium and tritium and technetium as representatives of multivalent elements. Sorption and diffusion data of ¹³⁷Cs and ⁹⁰Sr in contact with natural sorbent bentonite lead to the conclusion that both diffusion and batch sorption experiments can be simulated by an exchange model. Sorption of technetium on various bentonites plus additives materials is described. Retention of technetium on these solid phases is driven by sorption of reduced form of technetium Tc(IV).     

Tests of Pilot and Industrial Pilot Installations for Catching of Nitrogen Oxides with Water Condensation Aerosols

A pilot installation for catching of nitrogen oxides with water-condensation aerosols, with a throughput of 10 m³ h^?1, was tested. A shell-and-tube industrial pilot installation for catching of nitrogen oxides with water-condensation aerosols, with a throughput of 1800 m³ h^?1, was fabricated and tested.