Preliminary Design and Experimental Investigation of a Novel Pneumatic Conveying Method to Disperse Natural Fibers in Thermoset Polymers

Natural fibers can be attractive reinforcing materials in thermosetting polymers due to their low density and high specific mechanical properties. Although the research effort in this area has grown substantially over the last 20 years, manufacturing technologies to make use of short natural fibers in high volume fraction composites; are still limited. Natural fibers, after retting and preprocessing, are discontinuous and easily form entangled bundles. Dispersion and mixing these short fibers with resin to manufacture high quality, high volume fraction composites presents a significant challenge. In this paper, a novel pneumatic design for dispersion of natural fibers in their original discontinuous form is described. In this design, compressed air is used to create vacuum to feed and convey fibres while breaking down fibre clumps and dispersing them in an aerosolized resin stream. Model composite materials, made using proof-of-concept prototype equipment, were imaged with both optical and X-ray tomography to evaluate fibre and resin dispersion. The images indicated that the system was capable of providing an intimate mixture of resin and detangled fibres for two different resin viscosities. The new pneumatic process could serve as the basis of a system to produce well-dispersed high-volume fraction composites containing discontinuous natural fibres drawn directly from a loosely packed source

Understanding the Stress Relaxation Behavior of Polymers Reinforced with Short Elastic Fibers

Although it has been experimentally shown that the addition of short-fibers slows the stress relaxation process in composites, the underlying phenomenon is complex and not well understood. Previous studies have proposed that fibers slow the relaxation process by either hindering the movement of nearby polymeric chains or by creating additional covalent bonds at the fiber-matrix interface that must be broken before bulk relaxation can occur. In this study, we propose a simplified analytical model that explicitly accounts for the influence of polymer viscoelasticity on shear stress transfer to the fibers. This model adequately explains the effect of fiber addition on the relaxation behavior without the need to postulate structural changes at the fiber-matrix interface. The model predictions were compared to those from Monte Carlo finite-element simulations, and good agreement between the two was observed

Preliminary Design and Experimental Investigation of a Novel Pneumatic Conveying Method to Disperse Natural Fibers in Thermoset Polymers

Natural fibers can be attractive reinforcing materials in thermosetting polymers due to their low density and high specific mechanical properties. Although the research effort in this area has grown substantially over the last 20 years, manufacturing technologies to make use of short natural fibers in high volume fraction composites; are still limited. Natural fibers, after retting and preprocessing, are discontinuous and easily form entangled bundles. Dispersion and mixing these short fibers with resin to manufacture high quality, high volume fraction composites presents a significant challenge. In this paper, a novel pneumatic design for dispersion of natural fibers in their original discontinuous form is described. In this design, compressed air is used to create vacuum to feed and convey fibres while breaking down fibre clumps and dispersing them in an aerosolized resin stream. Model composite materials, made using proof-of-concept prototype equipment, were imaged with both optical and X-ray tomography to evaluate fibre and resin dispersion. The images indicated that the system was capable of providing an intimate mixture of resin and detangled fibres for two different resin viscosities. The new pneumatic process could serve as the basis of a system to produce well-dispersed high-volume fraction composites containing discontinuous natural fibres drawn directly from a loosely packed source

Understanding the Stress Relaxation Behavior of Polymers Reinforced with Short Elastic Fibers

Although it has been experimentally shown that the addition of short-fibers slows the stress relaxation process in composites, the underlying phenomenon is complex and not well understood. Previous studies have proposed that fibers slow the relaxation process by either hindering the movement of nearby polymeric chains or by creating additional covalent bonds at the fiber-matrix interface that must be broken before bulk relaxation can occur. In this study, we propose a simplified analytical model that explicitly accounts for the influence of polymer viscoelasticity on shear stress transfer to the fibers. This model adequately explains the effect of fiber addition on the relaxation behavior without the need to postulate structural changes at the fiber-matrix interface. The model predictions were compared to those from Monte Carlo finite-element simulations, and good agreement between the two was observed

Factors affecting the electrical resistivity of kraft recovery boiler precipitator ash

The electrical resistivity of ash particles is an important parameter that determines the efficiency of electrostatic precipitators. This systematic study examines the resistivity of recovery boiler precipitator ash as a function of electrical field strength, time of exposure, particle composition, and gas composition and temperature. Synthetic ash and actual ash samples from several pulp mills are used. The results show that most ash samples tested had a resistivity between 109 and 1010 Ω·cm, but one of the samples had an unusually high resistivity, 1012 Ω·cm. The resistivity increases with temperature up to about 140°C, then decreases. At a given temperature, the resistivity decreases with increasing moisture and sulfur dioxide concentration in the gas. Resistivity also increases with an increase in chloride content in the ash, but is not affected by the carbonate, sulfate, and potassium contents. The results imply that recovery boilers burning liquors with high solids and high chloride contents produce ash with higher resistivity, making it more difficult for electrostatic precipitators to capture.This work was conducted as part of the Increasing Energy and Chemical Recovery Efficiency in the Kraft Process-II re-search program, jointly supported by the Natural Sciences and Engineering Research Council of Canada (NSERC) and a consortium of the following companies: Andritz, Babcock & Wilcox, Boise Paper, Carter Holt Harvey, Celulose Nipo-Brasileira, Clyde-Bergemann, DMI Peace River Pulp, Fibria, International Paper, Irving Pulp & Paper, Metso Power, Mead-Westvaco, StoraEnso Research, and Tembec

Modeling and Predicting the Stress Relaxation of Composites with Short and Randomly Oriented Fibers

The addition of short fibers has been experimentally observed to slow the stress relaxation of viscoelastic polymers, producing a change in the relaxation time constant. Our recent study attributed this effect of fibers on stress relaxation behavior to the interfacial shear stress transfer at the fiber-matrix interface. This model explained the effect of fiber addition on stress relaxation without the need to postulate structural changes at the interface. In our previous study, we developed an analytical model for the effect of fully aligned short fibers, and the model predictions were successfully compared to finite element simulations. However, in most industrial applications of short-fiber composites, fibers are not aligned, and hence it is necessary to examine the time dependence of viscoelastic polymers containing randomly oriented short fibers. In this study, we propose an analytical model to predict the stress relaxation behavior of short-fiber composites where the fibers are randomly oriented. The model predictions were compared to results obtained from Monte Carlo finite element simulations, and good agreement between the two was observed. The analytical model provides an excellent tool to accurately predict the stress relaxation behavior of randomly oriented short-fiber composites

High Temperature Fracture Resistance of Model Kraft Recovery Boiler Deposits

In kraft paper mills, supersonic steam jets are used to remove deposits that build up on the heat exchanger tubes in the recovery boiler. In this study, the fracture toughness KC and work of fracture, WF, of simulated boiler deposits were measured at temperatures up to 500 °C to determine the optimal conditions for deposit removal. The model deposits experienced an important brittle to ductile transition at ~450 °C. Above this temperature, ductile deposits required lower peak force, but four times more energy to fracture when compared to those tested at lower temperatures. The transition was clear in scanning electron micrographs of the fracture surfaces. The findings have significant implications for mills wishing to optimize sootblower performance