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KTN for Resource Efficiency

KTN for Resource Efficiency

12 Projects, page 1 of 3
  • Funder: UK Research and Innovation Project Code: EP/E040551/1
    Funder Contribution: 515,959 GBP

    Summary: A novel laboratory scale continuous hydrothermal flow synthesis (CHFS) system has been developed for the controlled synthesis of inorganic nano-materials (particles <100nm) with potential commercial applications from sunscreens and battery materials to fuel cell components and photocatalysts. The CHFS system has many advantages; it is a green technology (using supercritical water as the reagent), which utilises inexpensive precursors (metal nitrate salts) and can controllably produce high quality, technologically important functional nano-materials in an efficient single step (or fewer steps than conventionally). This project seeks to move the existing laboratory scale CHFS system (developed over the past few years at QMUL) towards a x10 pilot scale-up (nano-powder production of up to 500g per 12h depending on variables). The proposed research will initially compare the ability to control particle characteristics of the CHFS system at the laboratory scale over a large range of process variables (flow rates, temperatures, pressures, etc), building full operational envelopes that will describe reactor variables versus particle properties for each material. In particular, we will utilise process analytical technology (PAT)and the data will help develop univariate and multivariate understanding of the temporal operational spaces and interactions between process variables and product quality. PATand chemometrics incorporated with combined computational fluid dynamics modelling of hydrodynamics/mixing and population balance modelling of particle size evolution via nano-precipitation will be used to study alternative nozzles designs and other potential bottleneck factors. This will lead to a generic strategy for scaling up and controlled manufacture of nanomaterials with consistent, reproducible and predictable quality. The scale up quantities of nano-powders from the pilot plant will allow industrial partners to perform prototyping or comprehensive commercial evaluation of nano-powders in a range of applications which they have hitherto not been able to conduct due to lack of sufficient high quality material. Importantly, the know-how acquired on the project and the proposed feasibility studies will reduce the risk and commercial barriers for industry that might consider building a larger industrial scale CHFS plant in the future.

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  • Funder: UK Research and Innovation Project Code: EP/G060096/2
    Funder Contribution: 116,344 GBP

    This project aims to compare the energy used in traditional foundry processes and a novel single shot foundry technology, CRIMSON, and to develop a model of the processes that encapsulates the energy content at each stage. This model can then be used to persuade casting designers to use more energy-efficient processes which consider casting quality as well as design flexibility. The UK retains a globally recognised casting expertise, in copper, aluminium and new light-metal alloys that underpins many competitive, technology-based industries vital to keep the UK's aerospace and automotive base ahead of the competition. These industries draw on advanced R&D work carried out by Birmingham's high-profile Casting Research Group.The University of Birmingham has been at the leading edge of casting R&D for many years. Today, it is internationally acknowledged as a front runner, and the CRIMSON technique - Constrained Rapid Induction Melting Single Shot method - is one such technology which is helping the casting industry make a step-change in product quality, manufacturing responsiveness and energy use.A typical light-metal foundry will tend to work in the following way: from 100 kg to several tonnes of metal is melted in a first furnace, held at about 700 oC in a second, transferred into a ladle and finally poured into the casting mould. It can take a shift (8 hours) to use all the melt in a typical batch and any leftover unused melt is poured off to be used again, or becomes scrap. Quality issues also arise, which must be mitigated: during the time for which the melt is held at temperature, atmospheric water is reduced to hydrogen and oxygen. The hydrogen is highly soluble in the metal at this temperature, but as the casting cools and solidifies, the gas is ejected into bubbles. The bubbles become porosity in the solid casting and have a detrimental effect on performance, therefore, as much gas must be removed as possible from the melt. The oxygen forms a thin layer of oxide on the melt surface, which is then inevitably entrained in the liquid metal when it is transferred between the different furnaces and when the metal is finally poured. The oxide layer (or bi-film) is now an inclusion which, again, has a detrimental effect on the material properties. The longer the metal is held liquid, the more hydrogen is absorbed and the thicker the oxide becomes on the surface.At each stage of the process there are energy losses due to oxidation and furnace inefficiencies, casting yields and eventually scrap. So from an initial theoretical 1.1 GJ/tonne required tomelt aluminium it is possible to estimate that each tonne of aluminium castings shipped will actually use about 182 GJ/tonne.Instead of going through this batch process, the CRIMSON method uses a high-powered furnace to melt just enough metal to fill a single mould, in one go, in a closed crucible. It transfers the crucible into an up-casting station for highly computer-controlled filling of the mould, against gravity, for an optimum filling and solidification regime. The CRIMSON method therefore only holds the liquid aluminium for a minimum of time thus drastically reducing the energy losses attributed to hold the metal at temperature. With the rapid melting times achieved, of the order of minutes, there isn't a long time at temperature for hydrogen to be absorbed or for thick layers of oxide to form. The metal is never allowed to fall under gravity and therefore any oxide formed is not entrained within the liquid. Thus higher quality castings are produced, leading to a reduction in scrap rate and therefore reduced overall energy losses.The first challenge in the project is to measure accurately the energy used at each stage in each of the processes investigated and to calculate the energy losses from oxidation and scrap. The second challenge is to incorporate this information into a model that can be used by casting designers and foundry engineers.

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  • Funder: UK Research and Innovation Project Code: EP/F06585X/1
    Funder Contribution: 389,225 GBP

    The project aims to create a prototype multi-sensor device, and undertake fundamental enabling research, for the location of underground utilities by combining novel ground penetrating radar, acoustics and low frequency active and passive electromagnetic field (termed quasi-static field) approaches. The multi-sensor device is to employ simultaneously surface-down and in-pipe capabilities in an attempt to achieve the heretofore impossible aim of detecting every utility without local proving excavations. For example, in the case of ground penetrating radar (GPR), which has a severely limited penetration depth in saturated clay soils when deployed traditionally from the surface, locating the GPR transmitter within a deeply-buried pipe (e.g. a sewer) while the receiver is deployed on the surface has the advantage that the signal only needs to travel through the soil one way, thereby overcoming the severe signal attenuation and depth estimation problems of the traditional surface-down technique (which relies on two-way travel through complex surface structures as well as the soil). The quasi-static field solutions employ both the 50Hz leakage current from high voltage cables as well as the earth's electromagnetic field to illuminate the underground infrastructure. The MTU feasibility study showed that these technologies have considerable potential, especially in detecting difficult-to-find pot-ended cables, optical fibre cables, service connections and other shallow, small diameter services. The third essential technology in the multi-sensor device is acoustics, which works best in saturated clays where GPR is traditionally problematic. Acoustic technology can be deployed to locate services that have traditionally been difficult to discern (such as plastic pipes) by feeding a weak acoustic signal into the pipe wall or its contents from a remote location. The combination of these technologies, together with intelligent data fusion that optimises the combined output, in a multi-sensor device is entirely novel and aims to achieve a 100% location success rate without disturbing the ground (heretofore an impossible task and the 'holy grail' internationally).The above technologies are augmented by detailed research into models of signal transmission and attenuation in soils to enable the technologies to be intelligently attuned to different ground conditions, thereby producing a step-change improvement in the results. These findings will be combined with existing shallow surface soil and made ground 3D maps via collaboration with the British Geological Society (BGS) to prove the concept of creating UK-wide geophysical property maps for the different technologies. This would allow the users of the device to make educated choices of the most suitable operating parameters for the specific ground conditions in any location, as well as providing essential parameters for interpretation of the resulting data and removing uncertainties inherent in the locating accuracy of such technologies. Finally, we will also explore knowledge-guided interpretation, using information obtained from integrated utility databases being generated in the DTI(BERR)-funded project VISTA.

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  • Funder: UK Research and Innovation Project Code: EP/F065906/1
    Funder Contribution: 16,960 GBP

    The project aims to create a prototype multi-sensor device, and undertake fundamental enabling research, for the location of underground utilities by combining novel ground penetrating radar, acoustics and low frequency active and passive electromagnetic field (termed quasi-static field) approaches. The multi-sensor device is to employ simultaneously surface-down and in-pipe capabilities in an attempt to achieve the heretofore impossible aim of detecting every utility without local proving excavations. For example, in the case of ground penetrating radar (GPR), which has a severely limited penetration depth in saturated clay soils when deployed traditionally from the surface, locating the GPR transmitter within a deeply-buried pipe (e.g. a sewer) while the receiver is deployed on the surface has the advantage that the signal only needs to travel through the soil one way, thereby overcoming the severe signal attenuation and depth estimation problems of the traditional surface-down technique (which relies on two-way travel through complex surface structures as well as the soil). The quasi-static field solutions employ both the 50Hz leakage current from high voltage cables as well as the earth's electromagnetic field to illuminate the underground infrastructure. The MTU feasibility study showed that these technologies have considerable potential, especially in detecting difficult-to-find pot-ended cables, optical fibre cables, service connections and other shallow, small diameter services. The third essential technology in the multi-sensor device is acoustics, which works best in saturated clays where GPR is traditionally problematic. Acoustic technology can be deployed to locate services that have traditionally been difficult to discern (such as plastic pipes) by feeding a weak acoustic signal into the pipe wall or its contents from a remote location. The combination of these technologies, together with intelligent data fusion that optimises the combined output, in a multi-sensor device is entirely novel and aims to achieve a 100% location success rate without disturbing the ground (heretofore an impossible task and the 'holy grail' internationally).The above technologies are augmented by detailed research into models of signal transmission and attenuation in soils to enable the technologies to be intelligently attuned to different ground conditions, thereby producing a step-change improvement in the results. These findings will be combined with existing shallow surface soil and made ground 3D maps via collaboration with the British Geological Society (BGS) to prove the concept of creating UK-wide geophysical property maps for the different technologies. This would allow the users of the device to make educated choices of the most suitable operating parameters for the specific ground conditions in any location, as well as providing essential parameters for interpretation of the resulting data and removing uncertainties inherent in the locating accuracy of such technologies. Finally, we will also explore knowledge-guided interpretation, using information obtained from integrated utility databases being generated in the DTI(BERR)-funded project VISTA.

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  • Funder: UK Research and Innovation Project Code: EP/F06599X/1
    Funder Contribution: 645,161 GBP

    The project aims to create a prototype multi-sensor device, and undertake fundamental enabling research, for the location of underground utilities by combining novel ground penetrating radar, acoustics and low frequency active and passive electromagnetic field (termed quasi-static field) approaches. The multi-sensor device is to employ simultaneously surface-down and in-pipe capabilities in an attempt to achieve the heretofore impossible aim of detecting every utility without local proving excavations. For example, in the case of ground penetrating radar (GPR), which has a severely limited penetration depth in saturated clay soils when deployed traditionally from the surface, locating the GPR transmitter within a deeply-buried pipe (e.g. a sewer) while the receiver is deployed on the surface has the advantage that the signal only needs to travel through the soil one way, thereby overcoming the severe signal attenuation and depth estimation problems of the traditional surface-down technique (which relies on two-way travel through complex surface structures as well as the soil). The quasi-static field solutions employ both the 50Hz leakage current from high voltage cables as well as the earth's electromagnetic field to illuminate the underground infrastructure. The MTU feasibility study showed that these technologies have considerable potential, especially in detecting difficult-to-find pot-ended cables, optical fibre cables, service connections and other shallow, small diameter services. The third essential technology in the multi-sensor device is acoustics, which works best in saturated clays where GPR is traditionally problematic. Acoustic technology can be deployed to locate services that have traditionally been difficult to discern (such as plastic pipes) by feeding a weak acoustic signal into the pipe wall or its contents from a remote location. The combination of these technologies, together with intelligent data fusion that optimises the combined output, in a multi-sensor device is entirely novel and aims to achieve a 100% location success rate without disturbing the ground (heretofore an impossible task and the 'holy grail' internationally).The above technologies are augmented by detailed research into models of signal transmission and attenuation in soils to enable the technologies to be intelligently attuned to different ground conditions, thereby producing a step-change improvement in the results. These findings will be combined with existing shallow surface soil and made ground 3D maps via collaboration with the British Geological Society (BGS) to prove the concept of creating UK-wide geophysical property maps for the different technologies. This would allow the users of the device to make educated choices of the most suitable operating parameters for the specific ground conditions in any location, as well as providing essential parameters for interpretation of the resulting data and removing uncertainties inherent in the locating accuracy of such technologies. Finally, we will also explore knowledge-guided interpretation, using information obtained from integrated utility databases being generated in the DTI(BERR)-funded project VISTA.

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