DLR-Logo -> http://www.dlr.de
DLR Portal Home | Imprint | Privacy Policy | Contact | Deutsch
Fontsize: [-] Text [+]

Challenges in the Up-scaling of Resorcinol-Formaldehyde Aerogel Micro-beads Production by Jet-Cutting Method

Kamal Mohamed, Seeni Meera and Anklam, Thomas and Niemeyer, Philipp David and Milow, Barbara (2023) Challenges in the Up-scaling of Resorcinol-Formaldehyde Aerogel Micro-beads Production by Jet-Cutting Method. 2nd Aerogel Industry-Academia Forum, 2023-05-31 - 2023-06-02, Empa, Überlandstrasse 129 CH-8600 Dübendorf, Switzerland.

[img] PDF


Carbon aerogels (CAs) are excellent materials with high surface area and unique micro-structures consisting nano-particles and nano-pores. CAs find potential applications in catalysis, chromatography, energy, adsorbents, desalination, etc. In recent times, research-ers focused on the development of CAs in the form of micro-spheres and/or micro-beads due to the reduction in process time and equipment costs for various applications. Car-bon micro-beads are produced from coal or petroleum pitch by carbonizing at 350-500 °C to achieve mesophase spheres in pitch. The carbonization is quenched before an exten-sive growth and aggregation of the spheres and separated as solids from soluble pitch by extraction with a solvent. Carbon aerogel micro-beads of 1 m to 3 mm are also fabricat-ed by using an inverse emulsion gelation of resorcinol-formaldehyde (RF) solution at ele-vated temperatures followed by freeze drying or super-critical drying and subsequent carbonization. The freeze drying or super-critical drying techniques consume large amount of solvents, energy and time for the large scale production. Herein, we report the development of RF aerogel micro-beads through dropping method. The shaping of RF sol solution into a micro-beads is quite challenging because of its low apparent viscosity ( 0.5 Pa.s) and faster sol-gel transition. Hence, we aimed to improve the viscosity of the RF sol solution using a sustainable polysaccharide based thickener to achieve suitable viscosity (1 - 10 Pa.s) in-order to shape them into a micro-beads. The pre-gelled RF sol solution with various concentrations of thickener is dropped into an acid bath to form micro-beads followed by curing, washing and ambient pressure drying and carbonization. The ambient pressure drying of the micro-beads is one of the greatest advantages of the process in-terms of low-cost. The overview of the RF and Carbon aerogel micro-beads production at the laboratory and large scale is depicted in Fig. 1. However, large scale production of RF aerogel micro-beads by Jet-Cutting method poses several challenges viz., handling of enormous amounts of RF sol and acid bath, process parameter optimization, waste disposal, etc. Hence, we adopted low to high viscous alginate solution (0.5 - 3wt.%) with a viscosity ranging from 0.08 to 10 Pa.s, as a model system to optimize the Jet-Cutting parameters. The diameter of the beads (dbead) can be described in eq. 1. d_bead= 3√(3/2 D^(2 ) (u_fluid/(n.Z)-d_wire ) ) -------(1) Where, D - diameter of the nozzle, ufluid - fluid velocity, n - number of cutting wires, Z - number of cutting tool rotation, dwire - diameter of the wire. The operation of Jet-Cutter for the production of micro-beads with low-viscous fluid is no means of complicated. However, the fluid velocity, diameter of the nozzle and number of cutting tool rotation need to be understood. In the next step, large scale production of the RF micro-beads using Jet-Cutting method will be optimized and demonstrated.

Item URL in elib:https://elib.dlr.de/195414/
Document Type:Conference or Workshop Item (Speech)
Title:Challenges in the Up-scaling of Resorcinol-Formaldehyde Aerogel Micro-beads Production by Jet-Cutting Method
AuthorsInstitution or Email of AuthorsAuthor's ORCID iDORCID Put Code
Kamal Mohamed, Seeni MeeraUNSPECIFIEDhttps://orcid.org/0000-0002-8812-1362UNSPECIFIED
Anklam, ThomasUNSPECIFIEDhttps://orcid.org/0000-0002-3192-907XUNSPECIFIED
Niemeyer, Philipp DavidUNSPECIFIEDhttps://orcid.org/0000-0002-4386-2589UNSPECIFIED
Milow, BarbaraUNSPECIFIEDhttps://orcid.org/0000-0002-6350-7728UNSPECIFIED
Refereed publication:Yes
Open Access:Yes
Gold Open Access:No
In ISI Web of Science:No
Keywords:Aerogel, Microbeads, Resorcinol-Formaldehyde, Upscaling, Xanthan Gum
Event Title:2nd Aerogel Industry-Academia Forum
Event Location:Empa, Überlandstrasse 129 CH-8600 Dübendorf, Switzerland
Event Type:international Conference
Event Start Date:31 May 2023
Event End Date:2 June 2023
Organizer:EMPA, Dübendorf, Switzerland
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Transport
HGF - Program Themes:Road Transport
DLR - Research area:Transport
DLR - Program:V ST Straßenverkehr
DLR - Research theme (Project):V - FFAE - Fahrzeugkonzepte, Fahrzeugstruktur, Antriebsstrang und Energiemanagement
Location: Köln-Porz
Institutes and Institutions:Institute of Materials Research > Aerogels and Aerogel Composites
Deposited By: Kamal Mohamed, Seeni Meera
Deposited On:12 Jun 2023 08:21
Last Modified:24 Apr 2024 20:55

Repository Staff Only: item control page

Help & Contact
electronic library is running on EPrints 3.3.12
Website and database design: Copyright © German Aerospace Center (DLR). All rights reserved.