The current research is based on the principles of three-dimensional discrete element method (3D – DEM) through simulations, by using heat transfer models in EDEM, to investigate the effects of fill level, rotation rate and particle size on the steady-state conduction heat transfer in rotary drums. The high heat and mass transfer rates obtained through rotary drums make them very useful for powder mixing and heating processes in metallurgical, cement, mining, pharmaceutical, detergent and other particulate processing applications. However, these complex processes are difficult to model and operate since the particles can have a wide range of properties, and there is currently no way to predict the optimal operating conditions for a given material.

Steady-state heat transfer by conduction forms the basis for understanding other steady-state and unsteady-state heat transfer in a rotary drum – conduction, convection and radiation. Statistical analysis is carried out to determine the effects of these process parameters and find optimal operating conditions, which will thereby improve the heat transfer efficiency in rotary drums. A stainless-steel drum with a diameter of 6 inches and a length of 3 inches was modeled in EDEM with silica beads of sizes 2 mm, 3 mm and 4 mm at fill levels of 10%, 17.5% and 25%, and at rotation rates of 2 rpm, 5 rpm and 10 rpm. It was found that the heating uniformity increased with decreasing particle size, decreasing fill level and increasing rotation rate. This research is the first step towards studying the other heat transfer modes and various other process parameters. Better understanding of the various heat transfer modes, when used in combination for heating the particles, will be beneficial in improving the operating efficiency, reducing material costs and leading to significant energy conservation on a global scale.

Granular material can be found in many industries and undergo process steps like drying, transportation, coating, chemical, and physical conversions. Understanding and optimizing such processes can save energy as well as material costs, leading to improved products. Silica beads are one such granular material encountered in many industries as a catalyst support material. The present research aims to obtain a fundamental understanding of the hydrodynamics and heat transfer mechanisms in silica beads. Studies are carried out using a hopper discharge bin and a rotary drum, which are some of the most common process equipment found in various industries. Two types of micro-glass beads with distinct size distributions are used to fill the hopper in two possible packing arrangements with varying mass ratios. For the well-mixed configuration, the fine particles clustered at the hopper bottom towards the end of the discharge. For the layered configuration, the coarse particles packed at the hopper bottom discharge first, opening a channel for the fine particles on the top. Also, parameters such as wall roughness (WR) and particle roughness (PR) are studied by etching the particles. The discharge rate is found to increase with WR, and found to be proportional to (Root mean square of PR)^(-0.58). Furthermore, the drum is used to study the conduction and convection heat transfer behavior of the particle bed with varying process conditions. A new non-invasive temperature measurement technique is developed using infrared thermography, which replaced the traditional thermocouples, to record the temperatures of the particles and the drum wall. This setup is used to understand the flow regimes of the particle bed inside the drum and the heat transfer mechanisms with varying process conditions. The conduction heat transfer rate is found to increase with decreasing particle size, decreasing fill level, and increasing rotation speed. The convection heat transfer rate increased with increasing fill level and decreasing particle size, and rotation speed had no significant effect. Due to the complexities in these systems, it is not always possible to conduct experiments, therefore, heat transfer models in Discrete Element Method codes (MFIX-DEM: open-source code, and EDEM: commercial code) are adopted, validated, and the effects of model parameters are studied using these codes.

Mixed-ionic electronic conducting (MIEC) oxides have drawn much attention from researchers because of their potential in high temperature separation processes. Among many materials available, perovskite type and fluorite type oxides are the most studied for their excellent oxygen ion transport property. These oxides not only can be oxygen adsorbent or O2-permeable membranes themselves, but also can be incorporated with molten carbonate to form dual-phase membranes for CO2 separation.

Oxygen sorption/desorption properties of perovskite oxides with and without oxygen vacancy were investigated first by thermogravimetric analysis (TGA) and fixed-bed experiments. The oxide with unique disorder-order phase transition during desorption exhibited an enhanced oxygen desorption rate during the TGA measurement but not in fixed-bed demonstrations. The difference in oxygen desorption rate is due to much higher oxygen partial pressure surrounding the sorbent during the fixed-bed oxygen desorption process, as revealed by X-ray diffraction (XRD) patterns of rapidly quenched samples.

Research on using perovskite oxides as CO2-permeable dual-phase membranes was subsequently conducted. Two CO2-resistant MIEC perovskite ceramics, Pr0.6Sr0.4Co0.2Fe0.8 O3-δ (PSCF) and SrFe0.9Ta0.1O3-δ (SFT) were chosen as support materials for membrane synthesis. PSCF-molten carbonate (MC) and SFT-MC membranes were prepared for CO2-O2 counter-permeation. The geometric factors for the carbonate phase and ceramic phase were used to calculate the effective carbonate and oxygen ionic conductivity in the carbonate and ceramic phase. When tested in CO2-O2 counter-permeation set-up, CO2 flux showed negligible change, but O2 flux decreased by 10-32% compared with single-component permeation. With CO2 counter-permeation, the total oxygen permeation flux is higher than that without counter-permeation.

A new concept of CO2-permselective membrane reactor for hydrogen production via steam reforming of methane (SRM) was demonstrated. The results of SRM in the membrane reactor confirm that in-situ CO2 removal effectively promotes water-gas shift conversion and thus enhances hydrogen yield. A modeling study was also conducted to assess the performance of the membrane reactor in high-pressure feed/vacuum sweep conditions, which were not carried out due to limitations in current membrane testing set-up. When 5 atm feed pressure and 10-3 atm sweep pressure were applied, the membrane reactor can produce over 99% hydrogen stream in simulation.

The applications utilizing nanoparticles have grown in both industrial and academic areas because of the very large surface area to volume ratios of these particles. One of the best ways to process and control these nanoparticles is fluidization. In this work, a new microjet and vibration assisted (MVA) fluidized bed system was developed in order to fluidize nanoparticles. The system was tested and the parameters optimized using two commercially available TiO2 nanoparticles: P25 and P90. The fluidization quality was assessed by determining the non-dimensional bed height as well as the non-dimensional pressure drop. The non-dimensional bed height for the nanosized TiO2 in the MVA system optimized at about 5 and 7 for P25 and P90 TiO2, respectively, at a resonance frequency of 50 Hz. The non-dimensional pressure drop was also determined and showed that the MVA system exhibited a lower minimum fluidization velocity for both of the TiO2 types as compared to fluidization that employed only vibration assistance. Additional experiments were performed with the MVA to characterize the synergistic effects of vibrational intensity and gas velocity on the TiO2 P25 and P90 fluidized bed heights. Mathematical relationships were developed to correlate vibrational intensity, gas velocity, and fluidized bed height in the MVA. The non-dimensional bed height in the MVA system is comparable to previously published P25 TiO2 fluidization work that employed an alcohol in order to minimize the electrostatic attractions within the bed. However, the MVA system achieved similar results without the addition of a chemical, thereby expanding the potential chemical reaction engineering and environmental remediation opportunities for fluidized nanoparticle systems.

In order to aid future scaling up of the MVA process, the agglomerate size distribution in the MVA system was predicted by utilizing a force balance model coupled with a two-fluid model (TFM) simulation. The particle agglomerate size that was predicted using the computer simulation was validated with experimental data and found to be in good agreement.

Lastly, in order to demonstrate the utility of the MVA system in an air revitalization application, the capture of CO2 was examined. CO2 breakthrough time and adsorption capacities were tested in the MVA system and compared to a vibrating fluidized bed (VFB) system. Experimental results showed that the improved fluidity in the MVA system enhanced CO2 adsorption capacity.

This thesis investigated the effects of differing diameters and varying moisture content on the flowability properties of granular glass beads through use of a Freeman FT4 Powder Rheometer. These parameters were tested in order to construct an empirical model to predict flowability properties of glass beads at differing size ranges and moisture contents. The final empirical model outputted an average error of 8.73% across all tested diameters and moisture ranges.

Mohr's circles were constructed from experimentally-obtained shear stress values to quantitatively describe flowability of tested materials in terms of a flow function parameter. A high flow function value (>10) was indicative of a good flow.

By testing 120-180 µm, 120-350 µm, 180-250 µm, 250-350 µm, 430-600 µm, and 600-850 µm glass bead diameter ranges, an increase in size was seen to result in higher flow function values. The limitations of testing using the FT4 became apparent as inconsistent flow function values were obtained at 0% moisture with size ranges above 120-180 µm, or at flow function values of >21. Bead sizes larger than 430 µm showed significant standard deviation over all tested trials--when excluding size ranges above that value, the empirical model showed an average error of only 6.45%.

Wet material testing occurred at all tested glass bead size ranges using a deionized water content of 0%, 1%, 5%, 15%, and 20% by weight. The results of such testing showed a decrease in the resulting flow function parameter as more water content was added. However, this trend changed as 20% moisture content was achieved; the wet material became supersaturated, and an increase in flow function values was observed. The empirical model constructed, therefore, neglected the 20% moisture content regime.

Vehicles traverse granular media through complex reactions with large numbers of small particles. Many approaches rely on empirical trends derived from wheeled vehicles in well-characterized media. However, the environments of numerous bodies such as Mars or the moon are primarily composed of fines called regolith which require different design considerations. This dissertation discusses research aimed at understanding the role and function of empirical, computational, and theoretical granular physics approaches as they apply to helical geometries, their envelope of applicability, and the development of new laws. First, a static Archimedes screw submerged in granular material (glass beads) is analyzed using two methods: Granular Resistive Force Theory (RFT), an empirically derived set of equations based on fluid dynamic superposition principles, and Discrete element method (DEM) simulations, a particle modeling software. Dynamic experiments further confirm the computational method with multi-body dynamics (MBD)-DEM co-simulations. Granular Scaling Laws (GSL), a set of physics relationships based on non-dimensional analysis, are utilized for the gravity-modified environments. A testing chamber to contain a lunar analogue, BP-1, is developed and built. An investigation of straight and helical grousered wheels in both silica sand and BP-1 is performed to examine general GSL applicability for lunar purposes. Mechanical power draw and velocity prediction by GSL show non-trivial but predictable deviation. BP-1 properties are characterized and applied to an MBD-DEM environment for the first time. MBD-DEM simulation results between Earth gravity and lunar gravity show good agreement with theoretical predictions for both power and velocity. The experimental deviation is further investigated and found to have a mass-dependant component driven by granular sinkage and engagement. Finally, a robust set of helical granular scaling laws (HGSL) are derived. The granular dynamics scaling of three-dimensional screw-driven mobility is reduced to a similar theory as wheeled scaling laws, provided the screw is radially continuous. The new laws are validated in BP-1 with results showing very close agreement to predictions. A gravity-variant version of these laws is validated with MBD-DEM simulations. The results of the dissertation suggest GSL, HGSL, and MBD-DEM give reasonable approximations for use in lunar environments to predict rover mobility given adequate granular engagement.

Membrane based technology is one of the principal methods currently in widespread use to address the global water shortage. Pervaporation desalination is a membrane technology for water purification currently under investigation as a method for processing reverse osmosis concentrates or for stand-alone applications. Concentration polarization is a potential problem in any membrane separation. In desalination concentration polarization can lead to reduced water flux, increased propensity for membrane scaling, and decreased quality of the product water. Quantifying concentration polarization is important because reducing concentration polarization requires increased capital and operating costs in the form of feed spacers and high feed flow velocities. The prevalent methods for quantifying concentration polarization are based on the steady state thin film boundary layer theory. Baker’s method, previously used for pervaporation volatile organic compound separations but not desalination, was successfully applied to data from five previously published pervaporation desalination studies. Further investigation suggests that Baker’s method may not have wide applicability in desalination. Instead, the limitations of the steady state assumption were exposed. Additionally, preliminary results of nanophotonic enhancement of pervaporation membranes were found to produce significant flux enhancement. A novel theory on the mitigation of concentration polarization by the photothermal effect was discussed.

Granulation is a process within particle technology where a liquid binding agent is added to a powder bed to create larger granules to modify bulk properties for easier processing. Three sets of experiments were conducted to screen for which factors had the greatest effect on granule formation, size distribution, and morphological properties when wet granulating microcrystalline cellulose and water. Previous experiments had identified the different growth regimes within wet granulation, as well as the granule formation mechanisms in single-drop granulation experiments, but little research has been conducted to determine how results extracted from single drop experiments could be used to better understand the first principles that drive high shear granulation. The experiment found that under a liquid solid ratio of 110%, the granule growth rate was linear as opposed to the induction growth regime experienced at higher liquid solid ratios. L/S ratios less than 100% led to a bimodal distribution comprised of large distributions of ungranulated powder and large irregular granules. Insufficient water hampered the growth of granules due to lack of enough water bridges to connect the granules and powder, while the large molecules continued to agglomerate with particles as they rotated around the mixer. The nozzle end was augmented so that drop size as well as drop height could be adjusted and compared to single-drop granulation experiments in proceeding investigations. As individual factors, neither augmentation had significant contributions to granule size, but preliminary screens identified that interaction between increasing L/S ratio and decreasing drop size could lead to narrower distributions of particles as well as greater circularity. Preliminary screening also identified that decreasing the drop height of the nozzle could increase the rate of particle growth during the 110% L/S trials without changing the growth mechanisms, indicating a way to alter the rate of steady-state particle growth. This paper screens for which factors are most pertinent to associating single-drop and wet granulation in order to develop granulation models that can ascertain information from single-drop granulations and predict the shape and size distribution of any wet granulation, without the need to run costly wet granulation experiments.

Rotary drums are commonly used for their high heat and mass transfer rates in the manufacture of cement, pharmaceuticals, food, and other particulate products. These processes are difficult to model because the particulate behavior is governed by the process conditions such as particle size, particle size distribution, shape, composition, and operating parameters, such as fill level and rotation rate. More research on heat transfer in rotary drums will increase operating efficiency, leading to significant energy savings on a global scale.

This research utilizes infrared imaging to investigate the effects of fill level and rotation rate on the particle bed hydrodynamics and the average wall-particle heat transfer coefficient. 3 mm silica beads and a stainless steel rotary drum with a diameter of 6 in and a length of 3 in were used at fill levels of 10 %, 17.5 %, and 25 %, and rotation rates of 2 rpm, 6 rpm, and 10 rpm. Two full factorial designs of experiments were completed to understand the effects of these factors in the presence of conduction only (Case 1) and conduction with forced convection (Case 2). Particle-particle friction caused the particle bed to stagnate at elevated temperatures in Case 1, while the inlet air velocity in Case 2 dominated the particle friction effects to maintain the flow profile. The maximum heat transfer coefficient was achieved at a high rotation rate and low fill level in Case 1, and at a high rotation rate and high fill level in Case 2. Heat losses from the system were dominated by natural convection between the hot air in the drum and the external surroundings.

The Basilisk lizard is known for its agile locomotion capabilities on granular and aquatic media making it an impressive model organism for studying multi-terrain locomotion mechanics. The work presented here is aimed at understanding locomotion characteristics of Basilisk lizards through a systematic series of robotic and animal experiments. In this work, a Basilisk lizard inspired legged robot with bipedal and quadrupedal locomotion capabilities is presented. A series of robot experiments are conducted on dry and wet (saturated) granular media to determine the effects of gait parameters and substrate saturation, on robot velocity and energetics. Gait parameters studied here are stride frequency and stride length. Results of robot experiments are compared with previously obtained animal data. It is observed that for a fixed robot stride frequency, velocity and stride length increase with increasing saturation, confirming the locomotion characteristics of the Basilisk lizard. It is further observed that with increasing saturation level, robot cost of transport decreases. An identical series of robot experiments are performed with quadrupedal gait to determine effects of gait parameters on robot performance. Generally, energetics of bipedal running is observed to be higher than quadrupedal operation. Experimental results also reveal how gait parameters can be varied to achieve different desired velocities depending on the substrate saturation level. In addition to robot experiments on granular media, a series of animal experiments are conducted to determine and characterize strategies

exhibited by Basilisk lizards when transitioning from granular to aquatic media.