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Simulating the electromagnetic‐thermal treatment of thin aluminium layers for adhesion improvement
(2015)
A composite layer material used in packaging industry is made from joining layers of different materials using an adhesive. An important processing step in the production of aluminium-containing composites is the surface treatment and consequent coating of adhesive material on the aluminium surface. To increase adhesion strength between aluminium layer and the adhesive material, the foil is heat treated. For efficient heating, induction heating was considered as state-of-the-art treatment process. Due to the complexity of the heating process and the unpredictable nature of the heating source, the control of the process is not yet optimised. In this work, a finite element analysis of the process was established and various process parameters were studied. The process was simplified and modelled in 3D. The numerical model contains an air domain, an aluminium layer and a copper coil fitted with a magnetic field concentrating material. The effect of changing the speed of the aluminium foil (or rolling speed) was studied with the change of the coil current. Statistical analysis was used for generating a general control equation of coil current with changing rolling speed.
The performance and biomass yield of the perennial energy plant Sida hermaphrodita (hereafter referred to as Sida) as a feedstock for biogas and solid fuel was evaluated throughout one entire growing period at agricultural field conditions. A Sida plant development code was established to allow comparison of the plant growth stages and biomass composition. Four scenarios were evaluated to determine the use of Sida biomass with regard to plant development and harvest time: (i) one harvest for solid fuel only; (ii) one harvest for biogas production only; (iii) one harvest for biogas production, followed by a harvest of the regrown biomass for solid fuel; and (iv) two consecutive harvests for biogas production. To determine Sida's value as a feedstock for combustion, we assessed the caloric value, the ash quality, and melting point with regard to DIN EN ISO norms. The results showed highest total dry biomass yields of max. 25 t ha⁻¹, whereas the highest dry matter of 70% to 80% was obtained at the end of the growing period. Scenario (i) clearly indicated the highest energy recovery, accounting for 439 288 MJ ha⁻¹; the energy recovery of the four scenarios from highest to lowest followed this order: (i) ≫ (iii) ≫ (iv) > (ii). Analysis of the Sida ashes showed a high melting point of >1500 °C, associated with a net calorific value of 16.5–17.2 MJ kg⁻¹. All prerequisites for DIN EN ISO norms were achieved, indicating Sida's advantage as a solid energy carrier without any post-treatment after harvesting. Cell wall analysis of the stems showed a constant lignin content after sampling week 16 (July), whereas cellulose had already reached a plateau in sampling week 4 (April). The results highlight Sida as a promising woody, perennial plant, providing biomass for flexible and multipurpose energy applications.