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Comparison of the Mechanical Properties of Ductile Cast Iron Intended for Gas Gate Valves with Nickel Cast Iron with an Austenitic Matrix

Archives of Foundry Engineering | 2024 | Accepted articles | DOI: 10.24425/afe.2024.151288

Keywords Nodular cast iron Austenitic matrix Nickel cast iron Impact strength

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Abstract

The study presents a comparison of the results of structural tests, impact strength and strength properties of cast iron EN-GJS-400-15, which is produced in industrial conditions and the ductile cast iron, with addition of nickel, in austenitic matrix. Due to the ongoing energy transformation and attempts to inject hydrogen into existing gas grids, gas fittings manufacturers are looking for materials that will be more resistant to the destructive effects of hydrogen than the currently used ductile cast iron. The aim of the work was to obtain cast iron with the addition of nickel (about 20%) with similar strength parameters, better impact strength, both at room temperature and at lower temperatures, as well as a stable austenitic matrix in ductile cast iron. All assumptions were achieved. In the future, research should be undertaken to develop an economically optimal chemical composition, without a significant loss of strength properties, and the resistance of gate valves made of austenitic cast iron to the destructive effects of hydrogen should be examined. The work is preliminary research.

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Bibliography

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Authors and Affiliations

A. Rączka

1

A. Szczęsny

2

e-mail:

ORCID:

D. Kopyciński

2

e-mail:

ORCID:

Fabryka Armatur JAFAR S.A. Kadyiego 12 Street 38-200 Jasło, Poland
AGH University of Science and Technology, Faculty of Foundry Engineering, Reymonta 23, 30-065 Kraków, Poland

Kinetic Model for the Decomposition Rate of the Binder in a Foundry Sand Application

Taishi Matsushita Dinesh Sundaram Ilja Belov Attila Dioszegi

Archives of Foundry Engineering | 2024 | Accepted articles | DOI: 10.24425/afe.2024.151289

Keywords Binder Casting Furan Kinetics Decomposition

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Abstract

Accurate kinetic parameters are vital for quantifying the effect of binder decomposition on the complex phenomena occurring during the casting process. Commercial casting simulation tools often use simplified kinetic parameters that do not comprise the complex multiple reactions and their effect on gas generation in the sand core. The present work uses experimental thermal analysis techniques such as Thermogravimetry (TG) and Differential thermal analysis (DTA) to determine the kinetic parameters via approximating the entire reaction during the decomposition by multiple first-order apparent reactions. The TG and DTA results reveal a multi-stage and exothermic decomposition process in the binder degradation. The pressure build-up in cores/molds when using the obtained multi-reaction kinetic model is compared with the earlier approach of using an average model. The results indicate that pressure in the mold/core with the multi-reaction approach is estimated to be significantly higher. These results underscore the importance of precise kinetic parameters for simulating binder decomposition in casting processes.

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Bibliography

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Authors and Affiliations

Taishi Matsushita

1

e-mail:

ORCID:

Dinesh Sundaram

1

e-mail:

ORCID:

Ilja Belov

1

e-mail:

ORCID:

Attila Dioszegi

1

e-mail:

ORCID:

Jönköping University, Sweden

Effect of Composition and Pouring Temperature of Cu-Sn on Fluidity and Mechanical Properties of Investment Casting

Sugeng Slamet Slamet Khoeron Ratri Rahmawati Suyitno Indraswari Kusumaningtyas

Archives of Foundry Engineering | 2024 | Accepted articles | DOI: 10.24425/afe.2024.151290

Keywords Tin bronze Investment casting Fluidity Pouring temperature Mechanical properties

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Abstract

The composition and pouring temperature are important parameters in metal casting. Many cast product failures are caused by ignorance of the influence of both. This research aims to determine the effect of adding tin composition and pouring temperature on fluidity, microstructure and mechanical properties including tensile strength and hardness of tin bronze (Cu-Sn). The Cu-Sn is widely used as employed in the research is Cu (20, 22 and 24) wt.%Sn alloy using the investment casting method. Variations in pouring temperature treatment TS1 = 1000°C and TS2 = 1100°C. The mold for the fluidity test is made with a wax pattern then coated in clay. The mold dimensions are 400 mm long with mold cavity variations of 1.5, 2, 3, 4, 5 mm. Several parameters: increasing the pouring temperature, adding tin composition, decreasing the temperature gradient between the molten metal and the mold walls result in a decrease in the solidification rate which can increase fluidity. The α + δ phase transition to β and γ intermetallic phases decreases fluidity at >22wt.%Sn. The columnar dendrite microstructure increases with the addition of tin composition and pouring temperature. The mechanical properties of tensile strength decrease, hardness increases and the alloy becomes more brittle with increasing tin composition.

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Authors and Affiliations

Sugeng Slamet

1

Slamet Khoeron

1

Ratri Rahmawati

1

Suyitno

2

Indraswari Kusumaningtyas

3

Mechanical Engineering, Universitas Muria Kudus, Jl. Gondang manis, Po. Box 53, Bae, Kudus, Indonesia
Mechanical Engineering, Universitas Tidar, Jl. Kapten Suparman 39, Magelang, Indonesia
Departement of Mechanical and Industrial Engineering, Universitas Gadjah Mada, Jl. Grafika No.2 Yogyakarta, Indonesia

Casting Production in Poland Versus European Trends in 21st Century

M.S. Soiński A. Jakubus

Archives of Foundry Engineering | 2024 | Accepted articles | DOI: 10.24425/afe.2024.151291

Keywords Casting production Gray cast iron Ductile cast iron Cast steel Aluminum alloys

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Abstract

This article presents changes of the total casting production volumes and of the production of castings made from basic casting alloys in Poland, in Europe and worldwide in years 2001–2021. Analogous casting production parameters were compared for Poland, Europe and countries being the leading European and global manufacturers in years 2001, 2011 and 2021. The leading casting manufacturers in Europe (with the manufacturing volume exceeding 1 million tons in the mentioned years) include Germany, Italy, the Ukraine, France and Spain. For years, the largest casting manufacturer worldwide has been China. In 2001–2021, global casting production increased from ca. 68 million tons to ca. 97 million tons (i.e. by ca. 42%), whereas the European one decreased from ca. 17 million tons to ca. 12 million tons (i.e. by close to 30%). In the analyzed period, the Polish production volume grew from ca. 0.75 million tons to ca. 0.88 million tons (i.e. by ca. 17%). The presented data reveal the decreasing importance of gray cast iron and cast steel and the increasing one of ductile cast iron and aluminum alloys. However, the Polish average annual growth rate for aluminum alloy casting production was 10.3%, whereas the global one was 3% and the European one 0.7%.

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Authors and Affiliations

M.S. Soiński

1

e-mail:

ORCID:

A. Jakubus

1

e-mail:

ORCID:

Jakub from Paradyz Academy in Gorzow Wielkopolski, 25 Teatralna St., 66-400 Gorzow Wielkopolski, Poland

Abrasive Wear Resistance of Nodular Cast Iron After Selected Surface Heat and Thermochemical Treatment Processes

C. Baron M. Stawarz A. Studnicki J. Jezierski T. Wróbel R. Dojka M. Lenert K. Piasecki

Archives of Foundry Engineering | 2024 | Accepted articles | DOI: 10.24425/afe.2024.151287

Keywords Surface hardening Nitriding Nitrocarburizing Nitrocarburizing with oxidation Abrasive wear

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Abstract

The article presents the test results on the technology of surface hardening of castings from unalloyed and low-alloy nodular cast iron using the method of surface heat treatment, i.e., induction surface hardening and methods of thermochemical treatment, i.e. gas nitriding, nitrocarburizing, and nitrocarburizing with oxidation. The scope of research included macro- and microhardness measurements using Rockwell and Vickers methods, respectively, as well as metallographic microscopic examinations using a light microscope. Furthermore, abrasive wear resistance tests were performed using the pin-on-disk method in the friction pair of nodular cast iron – SiC abrasive paper and the reciprocating method in the friction pair of nodular cast iron – unalloyed steel. Analysis of the test results shows that the size and depth of surface layer hardening strongly depend on the chemical composition of the nodular cast iron, determining its hardenability and its ability to create diffusion layers. Medium induction surface hardening made it possible to strengthen the surface layer of the tested nodular cast irons to the level of 700 HV0.5 with a hardening depth of up to approximately 4000μm, while various variants of thermochemical treatment provided surface hardness of up to 750 HV0.5 with a hardening depth of up to approximately 200μm. Furthermore, induction surface hardening increased the resistance to abrasive wear of nodular cast iron castings, depending on the test method, by an average of 70 and 45%, while thermochemical treatment on average by 15 and 60%.

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Bibliography

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Authors and Affiliations

C. Baron

1

e-mail:

ORCID:

M. Stawarz

1

e-mail:

ORCID:

A. Studnicki

1

J. Jezierski

1

e-mail:

ORCID:

T. Wróbel

1

e-mail:

ORCID:

R. Dojka

2

M. Lenert

1 2

K. Piasecki

1 2

e-mail:

ORCID:

Silesian University of Technology, Department of Foundry Engineering, Towarowa 7, 44-100 Gliwice, Poland
Odlewnia RAFAMET Sp. z o.o., ul. Staszica 1, 47-420 Kuźnia Raciborska, Poland

Utilizing Taguchi method and Regression Analysis for Optimizing Sand Mould Flowability

Dheya Abdulamer Ali A. Muhsan Sinan S. Hamdi

Archives of Foundry Engineering | 2024 | Accepted articles | DOI: 10.24425/afe.2024.151284

Keywords Green sand Moulding factors Flowability Taguchi method ANOVA

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Abstract

Parameters of the moulding process in foundry are usually determined by trial-and-error method, and this way contributes to time taken and adds further cost for production sand. The present work represents an attempt to optimize sand moulding parameters in terms of compactability, compaction time, and air pressure, and to study effect of these factors on the green sand flowability using L4 design of experiments. Regression model, Taguchi method, and experimental verification were used to investigate flow property of sodium bentonite- bonded BP-quartz sand for sand moulding.
Analysis of variance (ANOVA) was employed to measure significance and contributions of different moulding variables on flowability of green sand. The values obtained showed that the compaction time factor significantly affected flowability of green sand while compactability and air pressure have slight effects. The comparison results of Taguchi method, regression predictions and experiments exhibited good agreement.

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Bibliography

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[4] Karunakar D.B. & Datta, G.L, (2007). Controlling green sand mold properties using artificial neural networks and genetic algorithms- A comparison. Applied Clay Science. 37(1-2), 58-66. https://doi.org/10.1016/j.clay.2006.11.005.

[5] Abdulamer, D. & Kadauw, A. (2019). Development of mathematical relationships for calculating material-dependent flowability of green molding sand. Journal of Materials Engineering and Performance, 28, 3994-4001. https://doi.org/10.1007/s11665-019-04089-w.

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[8] Abdulamer, D. (2023). Utilizing of the statistical analysis for evaluation of the properties of green sand mould. Archives of Foundry Engineering. 23(3), 67-73. DOI: 10.24425/afe.2023.146664.

[9] Mahesh B. Parappagoudar, Dilip Kumar Pratihar, and Gouranga Lal Datta, (2011). Modeling and analysis of sodium silicate-bonded moulding sand system using design of experiments and response surface methodology. Journal for Manufacturing Science & Production. 11(1-3), 1-14, https://doi.org/10.1515/jmsp.2011.011.

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[12] Patel, M.G.C., Parappagoudar, M.B., Chate, G.R. & Deshpande, A.S. (2017). Modeling and optimization of phenol formaldehyde resin sand mould system. Archives of Foundry Engineering. 17(2), 162-170. DOI: 10.1515/afe-2017-0069.

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[15] Khare, M., Kumar, D. (2012). Optimization of sand casting parameters using factorial design. International Journal of Scientific Research. 3(1), 151-153.

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[17] Abdulamer, D. (2023). Impact of the different moulding parameters on properties of the green sand mould. Archives of Foundry Engineering. 23(2), 5-9. DOI: 10.24425/afe.2023.144288.

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[19] Lakshamanan Singaram, (2010). Improving quality of sand casting using taguchi and ANN analysis. International journal on design and manufacturing technologies. 4, 1-5.

[20] Kumari, A., Ohdar, R., Banka, H. (2016). Multiobjective parametric optimization of green sand moulding properties using genetic algorithm. In 3rd International Conference on Recent Advances in Information Technology RAIT, 03-05. March 2016 (pp. 279-283). Dhanbad, India: IEEE. DOI: 10.1109/RAIT.2016.7507916.

[21] Charnnarong Saikaew, & Sermsak Wiengwiset, (2012). Optimization of molding sand composition for quality improvement of iron castings. Applied Clay Science. 67-68, 26-31. DOI: 10.1016/j.clay.2012.07.005.

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Authors and Affiliations

Dheya Abdulamer

1

e-mail:

ORCID:

Ali A. Muhsan

1

e-mail:

ORCID:

Sinan S. Hamdi

1

e-mail:

ORCID:

University of Technology- Iraq

Effect of Addition of Ti on Selected Properties of AlSi5Cu2Mg Alloy

M. Sýkorová D. Bolibruchová M. Brůna M. Chalupová

Archives of Foundry Engineering | 2024 | Accepted articles | DOI: 10.24425/afe.2024.151285

Keywords AlSi5Cu2Mg Heat treatment Mechanical properties Titanium

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Abstract

The paper focuses on the investigation of the influence of Ti on selected properties of the hypoeutectic aluminium alloy AlSi5Cu2Mg. AlSi5Cu2Mg alloy finds application in the field of production of high-strength cylinder head castings intended for the automotive industry due to the optimal combination of mechanical, physical and foundry properties. In commercial production, the maximum Ti content is limited by the manufacturer (Ti max. = 0.03 wt.%), which significantly limits the possibilities of refinement the alloy with Ti-based grain refiners. Therefore, the possibility of increasing the Ti content beyond the manufacturer's recommendation is considered in this work. The main aim of the work is to evaluate the influence of graded Ti addition (0.1; 0.2; 0.3 wt.% Ti) on the resulting mechanical and physical properties of the AlSi5Cu2Mg alloy. Simultaneously, the influence of increased Ti content on the microstructure of AlSi5Cu2Mg alloy is evaluated. The alloying element was introduced into the melt in the form of AlTi5B1 master alloy. The effect of T6 heat treatment on the resulting mechanical and physical properties and microstructure of the hypoeutectic AlSi5Cu2Mg alloy with graded Ti addition was also investigated in the experimental work.

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Bibliography

[1] Bolibruchová, D., Sýkorová, M., Brůna, M., Matejka, M. & Širanec, L. (2023). Effect of Zr addition on selected properties and microstructure of aluminum alloy AlSi5Cu2Mg. International Journal of Metalcasting. 17(4), 2596-2611. DOI: 10.1007/s40962-023-01048-z.

[2] Javidani, M., Larouche, D. (2014). Application of cast Al-Si alloys in internal combustion engine components. International Materials Reviews. 59(3), 132-158. DOI: 10.1179/1743280413Y.0000000027.

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[4] Choi, S., Kim, Y., Kim, Y., Kang, Ch. (2019). Effects of alloying elements on mechanical and thermal characteristics of Al-6wt-%Si-0.4wt-%Mg-(Cu) foundry alloy. Materials Science and Technology. 35(11), 1365-1371. DOI: 10.1080/02670836.2019.1625170.

[5] Czerwinski, F. (2020). Thermal stability of aluminum alloys. Materials. 13(15), 1-49. DOI: 10.3390/ma13153441.

[6] Pourkia, N., Emamy, M., Farhangi, H., Ebrahimi, S. H. (2010). The effect of Ti and Zr elements and cooling rate on the microstructure and tensile properties of a new developed super high-strength aluminum alloy. Materials Science and Engineering: A. 527(20), 5318-5325. DOI: 10.1016/j.msea.2010.05.009.

[7] Kashyap, K.T., Chandrashekar, T. (2001). Effects and mechanism of grain refinement in aluminium alloys. Bulletin of Materials Science. 24(4), 345-353. DOI: 10.1007/BF02708630.

[8] Brůna, M., Remišová, A., Sládek, A. (2019). Effect of filter thickness on reoxidation and mechanical properties of aluminum alloy AlSi7Mg0.3. Archives of Metallurgy and Materials. 64(3), 1100-1106. DOI: 10.24425/amm. 2019.129500.

[9] Beroual, S., Boumerzoug, Z., Paillard, P. & Borjon-Piron, Y. (2019). Effects of heat treatment and addition of small amounts of Cu and Mg on the microstructure and mechanical properties of Al-Si-Cu and Al-Si-Mg cast alloys. Journal of Alloys and Compounds. 784, 1026-1035. DOI: 10.1016/j.jallcom.2018.12.365.

[10] Li, K., Zhang, J., Chen, X., Yin, Y., He, Y., Zhou, Z. & Guan, R. (2020). Microstructure evolution of eutectic Si in Al-7Si binary alloy by heat treatment and its effect on enhancing thermal conductivity. Journal of Materials Research and Technology. 9(4), 8780-8786. DOI: 10.1016/j.jmrt.2020.06.021.

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Authors and Affiliations

M. Sýkorová

1

e-mail:

ORCID:

D. Bolibruchová

1

e-mail:

ORCID:

M. Brůna

1

e-mail:

ORCID:

M. Chalupová

1

e-mail:

ORCID:

University of Zilina, Slovak Republic

Research of Hybrid Aluminium Castings with the Use of Porous Cores

M. Brůna M. Medňanský P. Oslanec

Archives of Foundry Engineering | 2024 | Accepted articles | DOI: 10.24425/afe.2024.151286

Keywords Hybrid castings Aluminium foams Porous materials Lightweighting

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Abstract

The paper focuses on the research of hybrid aluminium castings produced by overcasting technology. This is an advanced technology for ensuring the lightness of castings by using the principle of overcasting a core with a porous cellular structure produced by foaming. Process parameters in the foaming phase of the material have a great influence on the resulting porous structure. The article focuses on controlling the influence of pressure during the foaming process on the resulting porosity and evaluating by X-ray tomograph and measuring the relative density. Variants using an initial pressure of 0.3 MPa appear to be the most satisfactory. The challenge of this technology is to ensure adequate bonding of the metals at the interface between the porous core and the solidified metal without penetrating the coating layer. For this reason, the surface treatment of foamed cores with various etchants has been proposed to disrupt the oxide layer on their surface. Macrographs of the uncoated sample and samples etched with 0.5% HF and 10% H3PO4 demonstrated the need for core surface treatment to prevent liquid metal penetration. EDX analysis confirmed the presence of AlPO4 at the core/casting interface in the treated sample.

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Bibliography

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[2] Wang, B., Zhang, Z., Xu, G., Zeng, X., Hu, W., & Matsubae, K. (2023). Wrought and cast aluminum flows in China in the context of electric vehicle diffusion and automotive lightweighting. Resources, Conservation and Recycling. 191, 1-10, 106877. DOI: 10.1016/j.resconrec.2023.106877.

[3] Matejka, M., Bolibruchová, D., & Podprocká, R. (2021). The influence of returnable material on internal homogeneity of the high-pressure die-cast AlSi9Cu3(Fe) alloy. Metals. 11(7), 1-14, 1084. DOI: 10.3390/met11071084.

[4] Huang, Y., Tian, X., Li, W., He, S., Zhao, P., Hu, H., Jia, Q., & Luo, M. (2024). 3D printing of topologically optimized wing spar with continuous carbon fiber reinforced composites. Composites Part B: Engineering. 272, 1-9, 111166. DOI: 10.1016/j.compositesb.2023.111166

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[6] Ali, M. A., Jahanzaib, M., Wasim, A., Hussain, S., & Anjum, N. A. (2018). Evaluating the effects of as-casted and aged overcasting of Al-Al joints. The International Journal of Advanced Manufacturing Technology. 96(1-4), 1377-1392. DOI: 10.1007/s00170-018-1682-x.

[7] Papis, K., Hallstedt, B., Löffler, J., & Uggowitzer, P. (2008). Interface formation in aluminium–aluminium compound casting. Acta Materialia. 56(13), 3036-3043. DOI: 10.1016/j.actamat.2008.02.042.

[8] Lefebvre, L.-P., Banhart, J., & Dunand, D. C. (2008). Porous metals and metallic foams: Current status and recent developments. Advanced Engineering Materials. 10(9), 775-787. https://doi.org/10.1002/adem.200800241.

[9] Nosko, M. (2009). Reproducibility of Aluminium Foam Properties. Doctoral dissertation, Slovak Academy of Sciences, Bratislava, Slovak Republic.

[10] Zhang, H., Chen, Y., & Luo, A. A. (2014). A novel aluminum surface treatment for improved bonding in magnesium/aluminum bimetallic castings. Scripta Materialia, 86, 52-55. DOI: 10.1016/j.scriptamat.2014.05.007

[11] Rajak, D. K., & Gupta, M. (2020). An Insight Into Metal Based Foams. Singapore: Springer Nature. DOI: 10.1007/978-981-15-9069-6.

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Authors and Affiliations

M. Brůna

1

e-mail:

ORCID:

M. Medňanský

1

e-mail:

ORCID:

P. Oslanec

2

e-mail:

ORCID:

Faculty of Mechanical Engineering, Department of Technological Engineering, University of Zilina, Univerzitná 8215/1, 010 26 Žilina, Slovak Republic
Institute of Materials and Machine Mechanics, Slovak Academy of Sciences, Inoval - Innovation center, Priemyselná 525 Ladomerská Vieska, 965 01 Žiar nad Hronom, Slovak Republic

Bioreactor study of the metabolic repertoire and morphology of actinomycete Streptomyces rimosus ATCC 10970 under various initial concentrations of carbon and nitrogen sources

Marcin Bizukojć Anna Ścigaczewska Tomasz Boruta Agnieszka Ruda Aleksandra Kawka

Chemical and Process Engineering: New Frontiers | Accepted articles | e56 | DOI: 10.24425/cpe.2023.147414

Keywords actinomycetes batch bioreactor secondary metabolites Streptomyces rimosus microbial morphology

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Abstract

This work aims at investigating the influence of the initial concentrations of carbon (glucose) and organic nitrogen (yeast extract) sources on Streptomyces rimosus ATCC10970 secondary metabolism in the stirred tank bioreactors. Additionally, glucose utilisation, biomass formation, pH, redox potential and dissolved oxygen levels, and the morphological development of S. rimosus pseudomycelium were studied. Eighteen secondary metabolites were detected by mass spectrometry and identified with the use of the authentic standard, or putatively with the use of literature and database of secondary metabolites. Varied initial yeast extract concentration acted much stronger on the formation of secondary metabolites than glucose did. For example, oxytetracycline was not biosynthesised at high yeast extract concentration while the formation of three other metabolites was enhanced under these conditions. In the case of glucose its increasing initial concentration led to higher secondary metabolite levels with the exception of an unnamed angucycline. High initial yeast extract concentration also drastically changed S. rimosus pseudomycelial morphology from the pelleted to the dispersed one. Ultimately, the cultivation media with the varied initial levels of carbon and nitrogen sources were proved to have the marked effect on S. rimosus secondary metabolism and to be the simplest way to either induce or block the formation of the selected secondary metabolites.

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Authors and Affiliations

Marcin Bizukojć

1

e-mail:

ORCID:

Anna Ścigaczewska

1

e-mail:

ORCID:

Tomasz Boruta

1

e-mail:

ORCID:

Agnieszka Ruda

1

Aleksandra Kawka

1

Lodz University of Technology, Faculty of Process and Environmental Engineering,Department of Bioprocess Engineering, Wólczańska 213, 93-005 Łódź, Poland

Study of starch hydrolysis by α–amylasefrom porcine pancreas with deactivation of enzyme

Justyna Miłek Ireneusz Grubecki Wirginia Tomczak

Chemical and Process Engineering: New Frontiers | Accepted articles | e57 | DOI: 10.24425/cpe.2024.148551

Keywords α–amylase from porcine pancreas starch hydrolysis activation energy deactivation energy

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Abstract

The demand of energy and the search for alternative energy sources are the reason why scientists are interested in starch hydrolysis. The aim of the work was to experimental study of the hydrolysis of starch by α–amylase from porcine pancreas with α–amylase deactivation. Based on the experiments data, the parameters of starch hydrolysis by α– amylase with deactivation of enzyme was estimated. A mathematical model of temperature impact on the activity of α–amylase from porcine pancreas was used. It has been estimated that the activation energy E_a and the deactivation energy E_d were equal to 66 ± 4 kJ/mol and 161 ± 12 kJ/mol, respectively. Additionally, specific constant of starch hydrolysis k ₀ and specific constant of α–amylase deactivation k _d0 were calculated. The optimum temperature T_opt equal to 318 ± 0.5 K was obtained from mathematical model. The obtained values of E_a, E_d, k ₀ and k _d0 parameters were used to the model starch hydrolysis by α–amylase from porcine pancreas at 310 K and 333 K.

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Authors and Affiliations

Justyna Miłek

1

e-mail:

ORCID:

Ireneusz Grubecki

2

e-mail:

ORCID:

Wirginia Tomczak

1

e-mail:

ORCID:

Bydgoszcz University of Science and Technology, Department of Chemical and Biochemical Engineering, Faculty of Chemical Technology and Engineering, Semianryjna 3, 85-326 Bydgoszcz, Poland
Cracow University of Technology, Faculty of Chemical Engineering and Technology, Warszawska 24, 31-155 Cracow, Poland

Algal biochar in dairy wastewater treatment

Karolina Dziosa Monika Makowska

Chemical and Process Engineering: New Frontiers | Accepted articles | e58 | DOI: 10.24425/cpe.2024.148552

Keywords algae biomass biochar dairy wastewater Chlorella sp. sorption

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Abstract

The article presents a novel solution based on dairy wastewater sorption on a biochar substrate obtained through thermal decomposition of Chlorella sp. algae biomass. The algal biomass obtained in the culture medium containing wastewater from dairy production was separated from the culture medium through sedimentation and centrifugation and then freeze-dried. After freeze-drying, the dry biomass was pyrolysed at 600 °C in a CO ₂ atmosphere.The EDS analysis showed that the oxygen-tocarbon (O/C) and nitrogen-to-carbon (N/C) ratios in the obtained material averaged 0.24 and 0.54 respectively. The arrangement and structure of the obtained biochar was evaluated using Raman spectroscopy. The observed spectra revealed the presence of D bands located at 1346–1354 cm ^-1 and corresponding to disordered carbon structures, as well as G bands located at 1585–1594 cm ^-1 and corresponding to tensile vibrations. The D/G intensity ratio was determined at 0.28. The next phase of the research involved sorption of dairy wastewater from cleaning processes containing 1 g of the obtained biochar using solid phase extraction. The study results confirmed high sorption efficiency of the obtained algal biochar. Turbidity was reduced by 93%, suspension by 88%, sulphates by 61%, chlorides by 80%, and organic carbon by 17%. The research confirmed the possibility of using wastewater from dairy production as a natural culture medium for Chlorella sp. algae cultivation to manufacture valuable biochar, which could be used as a sorption bed in the treatment of dairy wastewater from cleaning processes.

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Authors and Affiliations

Karolina Dziosa

1

Monika Makowska

1

Łukasiewicz Research Network – Institute of Sustainable Technologies, Bioeconomy andEcoinnovation Centre, Pułaskiego 6/10, 26-660 Radom, Poland

From 3G biofuels to high value-added bioproducts

Stanisław Ledakowicz Anna Antecka Pawel Gluszcz Anna Klepacz-Smolka Damian Pietrzyk Rafal Szelag Radoslaw Slezak Maurycy Daroch

Chemical and Process Engineering: New Frontiers | Accepted articles | e59 | DOI: 10.24425/cpe.2024.148553

Keywords microalgae biorefinery biofuels value-added products phycocyanin

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Abstract

The paper focused on the co-production of high-value-added product thermostable C-phycocyanin (C-PC) and biomass, further utilized in pyrolysis. The photobiosynthesis of CPC was carried out by the thermophilic cyanobacteria Synechococcus PCC6715 cultivated in the helical and flat panel photobioreactors (PBR). Despite the application of different inorganic carbon sources, both PBRs were characterized by the same growth efficiency and similar C-PC concentration in biomass. To release the intracellular C-PC the biomass was concentrated and disintegrated by the freeze-thaw method. The crude C-PC was then further purified by foam fractionation (FF), aqueous two-phase extraction (ATPE), membrane techniques (UF) and fast protein liquid chromatography (FPLC). Each of the tested methods can be used separately; however, from a practical and economic point of view, a three-stage purification system (FF, FPLC and UF) was proposed. The purity ratio of the final C-PC was about 3.9, which allows it to be classified as a reactive grade. To improve the profitability of 3G biorefinery, the solid biomass residue was used as a substrate to pyrolysis process, which leads to production of additional chemicals in the form of oils, gas (containing e.g. H ₂) and biochar.

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Authors and Affiliations

Stanisław Ledakowicz

1

e-mail:

ORCID:

Anna Antecka

1

e-mail:

ORCID:

Pawel Gluszcz

1

e-mail:

ORCID:

Anna Klepacz-Smolka

1

e-mail:

ORCID:

Damian Pietrzyk

1

Rafal Szelag

1

Radoslaw Slezak

1

e-mail:

ORCID:

Maurycy Daroch

2

e-mail:

ORCID:

Lodz University of Technology, Faculty of Process and Environmental Engineering, Department of Bioprocess Engineering, Wolczanska 213, 93-005 Lodz, Poland
School of Environment and Energy, Peking University Shenzhen Graduate School, Shenzhen 518055, China

Isolation and characterization of new bacterial 1 strains degrading low-density polyethylene

Elżbieta Szczyrba Tetiana Pokynbroda Nataliia Koretska Agnieszka Gąszczak

Chemical and Process Engineering: New Frontiers | Accepted articles | e60 | DOI: 10.24425/cpe.2024.148554

Keywords LDPE biodegradation bacterial isolates FTIR SEM

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Abstract

Plastics have become indispensable in everyday life due to their properties. For this reason, the accumulation of polymer waste in the natural environment is becoming a serious global problem. The aim of the research was to isolate microorganisms capable of biodegrading plastics. The studies focused on the biodegradation of low-density polyethylene as the most common polymer. Seven and five bacterial strains were isolated from the landfill and compost, respectively. The morphological and biochemical characteristics of the isolates were determined. These isolates were able to survive in an environment where the only carbon source was LDPE, but no increase in biomass was obtained. However, analysis of the spectra obtained by the ATR-FTIR method showed the formation of chemical changes on the polymer surface. Bacterial biofilm formation was visualized by scanning electron microscopy. The toxicity of plastic biodegradation products in a liquid environment was tested and their safety for plants was confirmed. However, these biodegradation products have acute lethal toxicity for the Daphnia magna.
LDPE films were pre-treated with H ₂O ₂, HNO ₃, or heat. The biodegradation of HNO ₃-treated LDPE by isolated bacteria was the most significant. The weight loss was approximately 8%, and 6%, for landfill and compost-isolated bacterial strains, respectively.

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Authors and Affiliations

Elżbieta Szczyrba

1

e-mail:

ORCID:

Tetiana Pokynbroda

2

e-mail:

ORCID:

Nataliia Koretska

2

e-mail:

ORCID:

Agnieszka Gąszczak

1

e-mail:

ORCID:

Instytut Inżynierii Chemicznej Polskiej Akademii Nauk, ul. Bałtycka 5, 44-100 Gliwice, Poland
Department of Physical Chemistry of Fossil Fuels of the Institute of Physical-Organic Chemistry and Coal Chemistry named after L.M. Lytvynenko of the National Academy of Sciences of Ukraine, Naukova str, 79060, Lviv, Ukraine

The potential of Stenotrophomonas maltophilia KB2 for phenol degradation under exposure to heavy metal

Agnieszka Gąszczak Elżbieta Szczyrba Anna Szczotka

Chemical and Process Engineering: New Frontiers | Accepted articles | e64 | DOI: 10.24425/cpe.2024.149459

Keywords phenol heavy metal biodegradation kinetic equations synergism

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Abstract

The large diversity of chemical substances present in air, water, or soil makes it necessary tostudy their mutual impact on the effectiveness of microbiological decomposition ofcontaminants. This publication presents the results of the studies aimed at evaluating the effect of two biogenic heavy metals - zinc and copper - on the phenol biodegradation by the Stenotrophomonas maltophilia KB2 strain. The tests were carried out for concentrations ofmetals significantly exceeding the legally permitted wastewater values: for zinc up to13.3 g·m ^-3, and copper up to 3.33 g·m ^-3. In the tested metal concentration range, phenol biodegradation by the S. maltophilia KB2 strain was not significantly influenced by theintroduced dose of zinc. While the presence of copper inhibited both biomass growth andsubstrate degradation. Kinetic data of metal and phenol mixtures were analyzed and very goodcorrelations were obtained for the proposed equations. An equation consistents with the Hanand Levenspiel model was proposed for the system S. maltophilia KB2-phenol-copper, whilean equation consistents with the Kai model for the system St. maltophilia KB2-phenol-zinc. The simultaneous presence of Zn and Cu ions in the culture resulted in a stronger inhibition ofphenol biodegradation.

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Authors and Affiliations

Agnieszka Gąszczak

1

e-mail:

ORCID:

Elżbieta Szczyrba

1

e-mail:

ORCID:

Anna Szczotka

1

e-mail:

ORCID:

Polish Academy of Sciences, Institute of Chemical Engineering, Baltycka 5, 44-100 Gliwice, Poland

UAS and a virtual environment as possible response tools to the incidents involving uncontrolled release of dangerous gases – a case study

Anna Rabajczyk Jacek Zboina Maria Zielecka Radosław Fellner Piotr Kaczmarzyk Dariusz Pietrzela Grzegorz Zawistowski

Chemical and Process Engineering: New Frontiers | Accepted articles | e65 | DOI: 10.24425/cpe.2024.149460

Keywords unmanned aerial system (UAS) Ammonia emergency situations ALOHA

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Abstract

Various types of events and emergency situations have a significant impact on the safety of people and the environment. This especially refers to the incidents involving the emission of pollutants, such as ammonia, into the atmosphere. The article presents the concept of combining unmanned aerial vehicles with contamination plume modelling. Such a solution allows for mapping negative effects of ammonia release caused by the damage to a tank (with set parameters) during its transport as well as by the point leakage (such as unsealing in the installation). Simulation based on the ALOHA model makes it possible to indicate the direction of pollution spread and constitutes the basis for taking action. And, the use of a drone allows to control contamination in real time and verify the probability of a threat occurring in a given area.

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Authors and Affiliations

Anna Rabajczyk

1

Jacek Zboina

1

Maria Zielecka

1

Radosław Fellner

2

Piotr Kaczmarzyk

1

Dariusz Pietrzela

1

Grzegorz Zawistowski

1

Scientific and Research Centre for Fire Protection, National Research Institute, Nadwiślańska 213, 05-420 Józefów, Poland
Fire University of Warsaw, Słowackiego 52/54, 01-629 Warsaw, Poland

The influence of inoculum source and pretreatment on the biohydrogen production in the dark fermentation process

Marlena Domińska Katarzyna Paździor Radosław Ślęzak Stanisław Ledakowicz

Chemical and Process Engineering: New Frontiers | Accepted articles | e63 | DOI: 10.24425/cpe.2024.149458

Keywords dark fermentation hydrogen inoculum pretreatment food waste

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Abstract

The production of biohydrogen from food waste (FW) by dark fermentation (DF) is a promising technology for commercialisation, as it is both a clean fuel and a suitable means of sustainable waste management. The described experiments compared the biohydrogen production yields obtained after the use of inoculum from two different sources: digested sludge from the wastewater treatment plant (WWTP) in Lodz and sludge from the anaerobic treatment of dairy industry wastewater (DIW) (unconcentrated and double-concentrated). In addition, the effect of different temperatures (70, 90 and 121°C) of inoculum pretreatment on the biohydrogen production in DF was tested. The process was carried out batchwise at 37°C. The highest yield of hydrogen production was obtained after the inoculum pretreatment at 70°C. In addition, a higher amount of hydrogen could be obtained by using sludge from the WWTP as the inoculum (96 cm3 H2/gTVSFW) than unthickened sludge from the DIW (85 cm ³ H ₂/g _TVSFW). However, after thickening the sludge from the dairy industry, and at the same time balancing the dry matter of both sludges, the hydrogen production potential was comparable for bothsludges (for the WWTP sludge – 96 and for the DIW sludge – 93 cm ³ H ₂/g _TVSFW). The kinetics of hydrogen production was described by modified Gompertz equation, which showed a good fit (determination coefficient R2 between 0.909 and 0.999) to the experimental data.

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Authors and Affiliations

Marlena Domińska

1

e-mail:

ORCID:

Katarzyna Paździor

1

e-mail:

ORCID:

Radosław Ślęzak

1

e-mail:

ORCID:

Stanisław Ledakowicz

1

e-mail:

ORCID:

Department of Bioprocess Engineering, Faculty of Process and Environmental Engineering, Lodz University of Technology, 213 Wolczanska Street, 90-924 Lodz, Poland

Separation and purification of phycobiliproteins from Thermosynechococcus PCC 6715 by foam fractionation and aqueous twophase extraction

Anna Antecka Rafał Szeląg Stanisław Ledakowicz

Chemical and Process Engineering: New Frontiers | Accepted articles | e62 | DOI: 10.24425/cpe.2024.149457

Keywords phycobiliproteins purification aqueous two-phase extraction foam fractionation

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Abstract

The use of foam fractionation followed by aqueous two-phase extraction has emerged as a potential alternative to traditional liquid chromatography, hitherto irreplaceable in the purification of phycobiliproteins. The crude extracts of C-phycocyanin and allophycocyanin were obtained after Thermosynechococcus PCC 6715 biomass disintegration. The FF process with air flow of 2.4 L·h ^-1 resulted in purification factors up to 1.47 and partitioning coefficients of about 39, and did not require the addition of surfactants. A temperature of 35˚C allowed for the highest partitioning coefficient of 67.6 and yield of 76%; however, the purity of C-PC in condensate at this temperature was lower than at 25˚C. ATPE was tested in 20 different systems consisting of polyethylene glycol and phosphate or citrate salts, of which PEG1500-citrate gave the highest purification factor value of 2.31. Conversely, a partitioning coefficient of 2416 and 1094 were obtained for the PEG1500-phosphate and PEG3000-phosphate systems, respectively. Interestingly, the use of FF condensate in subsequent ATPE step resulted, for the first time, in the separation of the polymer phase into two fractions, one contained C-phycocyanin and the other allophycocyanin. It can be concluded that the use of a two-step system of FF and ATPE is a viable way to separate phycobiliproteins.

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Authors and Affiliations

Anna Antecka

1

e-mail:

ORCID:

Rafał Szeląg

1

Stanisław Ledakowicz

1

e-mail:

ORCID:

Lodz University of Technology, Faculty of Process and Environmental Engineering, Department of Bioprocess Engineering, Wolczanska 213, 93-005 Lodz, Poland

Influence of yeast size on the kinetics of cell disruption in an ultrasonic homogenizer

Anna Kacprowicz Marek Solecki

Chemical and Process Engineering: New Frontiers | Accepted articles | e61 | DOI: 10.24425/cpe.2024.149456

Keywords microorganisms disintegration process Ultrasounds process kinetics

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Abstract

The results of studies on the disintegration kinetics of the yeast Saccharomyces cerevisiae are presented. The process was carried out in a 500 W ultrasonic homogenizer equipped with a spherical working chamber with a volume of 100 cm ³. The concentration of the suspension of microorganisms was 0.05 g d.m./cm ³. The continuous phase was water solution containing 0.15 M NaCl and 4 mM K ₂HPO ₄. The kinetics of cell disruption were studied by the direct method. The theory of random transformation of dispersed matter was used to analyze the process. There was significant variation in the size of yeast cells. The range of changes in the values of parameters describing the size of microorganisms was divided into size classes. The kinetics of cell disruption in individual classes was described by a first-order linear differential equation. During the implosion of cavitation bubbles, the transformation volume of individual microorganisms is generated. It has been shown that as the volume of cells in subsequent size classes increases, their transformation volumes do not increase significantly. The safe volume for cells remains unchanged. As the size of the microorganisms increased, there was no increase in the constant rate of cell disruption.

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Authors and Affiliations

Anna Kacprowicz

1

e-mail:

ORCID:

Marek Solecki

1

e-mail: marek.solecki@p.lodz.pl

ORCID:

Lodz University of Technology, Faculty of Process and Environmental Engineering, Wolczanska 213, 93-005 Lodz, Poland

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