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| 1022 | FCIC Task 1 - Materials of Construction | The overall objectives of this Task are to use a systematic quality-by-design approach with integrated efforts of characterization, modeling, and testing to gain fundamental understanding of the failure modes and wear mechanisms of biomass and MSW preprocessing equipment, develop analytical tools/models to predict wear and establish material property specifications, select and evaluate candidate mitigations based on modeling and lab-scale testing and identify top-performing mitigation for PDU validation, and share the fundamentals and mitigations with the biomass industry. The major task outcomes will include fundamental understanding of the failure modes and wear mechanisms of biomass and MSW preprocessing equipment including knife mill in FY22 and shredder in FY23; analytical tools/models to predict wear and establish material property specifications; and mitigation strategies to address wear in preprocessing equipment employed for biomass conversion and Material Recovery Facilities (MRFs).
The following collections of data have been generated by FCIC Task 1 (Materials of Construction):
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Finite Element Modeling Data containing Abaqus model database files (.cae) for Finite Element Analysis (FEA) for simulation of knife mill blade and hammer mill hammer wear, along with the input (.inp) files used to run the models. FEA was used to study the contact pressures on the stationary and rotary blades, suggesting that the stationary blades experience a higher maximum contact pressure due to higher structural stiffness. An open-source abrasion wear model from Argonne National Laboratory (ANL), ABRADE, was utilized to predict the edge recession of the knife due to abrasive wear.
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Eberbach Knife Mill Blade Material Testing - The Eberbach Knife Mill Model 3803 was used in a series of tests to study the wear and tear of different blade materials. The mill, which operates at 800 RPM, was used to grind biomass and other materials. The blades tested included tungsten carbide-tipped blades, D2 steel blades treated with iron boriding, and M2 steel blades coated with diamond-like carbon (DLC). The wear resistance of the blades was measured by comparing the blade gap measurements against the mass of biomass processed. The tungsten carbide blade showed the most wear resistance, followed by the borided blade. The DLC coating on the blade tips was noticeably gone after about 2 hours of operation, indicating that it offered less protection. The stationary blades experienced higher wear loss than the rotary blades in the knife mill testing. The research also revealed that the initial assumption about the blades installed on the Eberbach knife mill was incorrect. It was initially thought that the knives were the less expensive standard tool steel blades, but they turned out to be the more expensive tungsten carbide blades, which are very wear resistant.
- Power Consumption was recorded throughout each experiment. The knives tested included tungsten carbide-tipped blades, D2 steel blades treated with iron boriding, and M2 steel blades coated with diamond-like carbon (DLC). The power consumption for the mill was reported as 1946.7 +/- 5.7 KWH for the tungsten carbide-tipped blades, 1920.5 +/- 8.6 KWH for the D2 steel blades, and 1824.2 +/- 173 KWH for the M2 steel blades.
| ORNL: Jun Qu, Tomas Grejtak, Lianshan Lin, Jim Keiser, Peter Blau INL: Jeff Lacey, Miranda Kuns, Blesson Isaac, Vicki Thompson ANL: Oyelayo Ajayi, and George Fenske | True |
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