Thomas Butcher

The thermo-mechanical response of PP nanocomposites at high graphene loading

Abstract Authors have successfully fabricated polypropylene/graphene nanoplatelets (PP/GNPs), nanocomposites that are thermally conductive, processable, and flame resistant. Thermal conductivity measurements indicated that the thermal coefficient scaled linearly with GNP loading, where a value of 2.0 W m− 1 K− 1 was achieved at 40 wt-% loading. Tensile measurements indicated that the modulus increased linearly with GNP loading, while the Izod impact, after an initial decrease, remained constant for loadings up to 50 wt-%. Small angle X-ray scattering (SAXS) showed a large decrease in the amount of lamellar structure relative to the neat PP, while wide angle X-ray scattering (WAXS) showed a high degree of crystallinity. These results are consistent with formation of a new type of layered nanocomposite, composed of crystalline PP chains oriented onto layered GNPs.

SOOT REDUCTION IN DIESEL ENGINES BY CATALYTIC EFFECTS

The diesel engine’s proven fuel economy and lower emissions of unburned hydrocarbons and carbon monoxide makes it a viable alternative to a gasoline automotive plant, but the inherent production of particulate matter (soot) threatens the expanded use of the diesel engine.

Evaluation of a Pulse Width Modulated Bypass Nozzle for the Development of a Variable Load Residential Oil Burner

Due to the need for energy conservation in buildings and the simultaneous benefit of cost savings, the development of a low firing rate load modulating residential oil burner is very desirable. One of the two main requirements of such a burner is the development of a burner nozzle that is able to maintain the particle size distribution of the fuel spray in the desirable (small) size range for efficient and stable combustion. The other being the ability to vary the air flow rate and air distribution around the fuel nozzle in the burner for optimal combustion at the current fuel firing rate. In this paper, which deals with the first requirement, we show that by using pulse width modulation in the bypass channel of a commercial off-the-shelf bypass nozzle, this objective can be met. Here we present results of spray patterns and particle size distribution for a range of fuel firing rates. The results show that a desirable fuel spray pattern can be maintained over a fuel firing rate turndown ratio (Maximum Fuel Flow Rate/Minimum Fuel Flow Rate) of 3.7. Thus here we successfully demonstrate the ability to electronically vary the fuel firing rate by more than a factor of 3 while simultaneously maintaining good atomization.

Evaluation of alternative filter media for particulate matter emission testing of residential wood heating devices

ABSTRACT The performance of Teflon-coated glass fiber filter media (Pallflex Emfab TX40) is evaluated for particulate matter (PM) sampling of residential wood heating devices in a dilution tunnel. Thirty samples of varying duration and PM loading and concentration were collected from an U.S. Environmental Protection Agency (EPA) Method 28 dilution tunnel using dual Method 5G sample trains with untreated glass fiber and Emfab filters. Filters were weighed soon after the end of sampling and again the next day after equilibration at 35% relative humidity (RH). PM concentrations from both types of filters agreed very well with 1-day equilibration, demonstrating that Emfab filters are appropriate for use in measuring PM from residential wood burning appliances in a dilution tunnel and have performance equal to or better than the glass fiber filter media. Agreement between filter media without equilibration was erratic, with PM from glass fiber filter samples varying from slightly less than the Emfab samples to as much as 2.8 times higher. Some of the glass fiber filters lost substantial mass with equilibration, with the highest percent loss at lower filter mass loadings. Mass loss for Emfab samples was a small percentage of the mass and very consistent across the range of mass loadings. Taken together, these results may indicate water uptake on the glass fiber media that is readily removed with 1-day equilibration at moderate RH conditions. Implications: EPA regulations now allow the use of either glass fiber or Teflon filter media for wood appliance PM emission testing. Teflon filter media minimizes the potential for acid-gas PM artifacts on glass fiber filters; this is important as EPA moves toward the use of locally sourced cordwood for testing that may have higher sulfur content. This work demonstrates that the use of Teflon-coated glass fiber filters can give similar PM measurement results to glass fiber filters after 1 day of equilibration. With no equilibration, measured PM from glass fiber filters was usually higher than from Teflon-coated glass fiber filters.

Low Cost Polymer heat Exchangers for Condensing Boilers

Work in this project sought to develop a suitable design for a low cost, corrosion resistant heat exchanger as part of a high efficiency condensing boiler. Based upon the design parameters and cost analysis several geometries and material options were explored. The project also quantified and demonstrated the durability of the selected polymer/filler composite under expected operating conditions. The core material idea included a polymer matrix with fillers for thermal conductivity improvement. While the work focused on conventional heating oil, this concept could also be applicable to natural gas, low sulfur heating oil, and biodiesel- although these are considered to be less challenging environments. An extruded polymer composite heat exchanger was designed, built, and tested during this project, demonstrating technical feasibility of this corrosion-resistant material approach. In such flue gas-to-air heat exchangers, the controlling resistance to heat transfer is in the gas-side convective layer and not in the tube material. For this reason, the lower thermal conductivity polymer composite heat exchanger can achieve overall heat transfer performance comparable to a metal heat exchanger. However, with the polymer composite, the surface temperature on the gas side will be higher, leading to a lower water vapor condensation rate.