In this webinar, Drs. Jun Qu from Oak Ridge National Laboratory and George Fenske from Argonne National Laboratory will discuss the FCIC Materials of Construction team’s characterization, modeling, and mitigation of wear issues in feedstock size reduction systems.

Specifically, two conventional size reduction systems, hammer mill and knife mill, and the recently developed Crumbler rotary shear were studied. Distinct tool wear mechanisms were identified for these three systems based on tribo-system analysis and worn component characterization. The content and composition of the biomass extrinsic and intrinsic inorganics were determined for various feedstocks and correlated to the tool wear performance. The effectiveness of several feedstock modification methods including air classification, size separation, and water washing on reducing tool wear was investigated. Detailed analysis of wear trends obtained from lab-scale simulation led to the development of semi-mechanistic analytical quality by design models of erosive and abrasive wear of materials to predict performance and durability of milling components and develop material property requirements for predictable and efficient unit operation. Candidate tool alloys, coatings, and surface treatments were selected and screened using bench-scale abrasion and/or erosion tests. Finite element analysis was used to optimize the tool geometric design. Prototype tools are being fabricated using the top candidate materials and/or designs and will be tested in actual comminution systems to demonstrate improved throughput and tool life. The knowledge and tools developed in this study enable rapid mitigation selection for sustainable performance and product quality during biomass preprocessing. 

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