Numerical and experimental investigation of gamma alumina macro particle synthesis via the oil-drop method

Abstract

Gamma alumina possesses exceptional catalytic properties, making it a highly sought-after material in various industrial applications. The ability to control the size, shape, and morphology of these particles is crucial for optimizing their performance. The oil-drop method offers a promising technique for the synthesis of uniform and spherical particles. This research aims to enhance the understanding of the oil-drop method through a combined approach of numerical simulations and experimental validations. The results obtained from this study will contribute to the development of advanced techniques for the preparation of tailored gamma alumina macro particles with improved catalytic performance. Using Computational Fluid Dynamics (CFD) minimizes experimental time and costs by accounting for the process's physical dynamics and the characteristics of the liquid systems. This allows for precise control over the mixing and droplet formation processes. The results show that using this method, particles with a relatively narrow size distribution can be produced, allowing for the regulation of mean particle size and sphericity. After designing the experiment and conducting the modeling process, the objective is to achieve a droplet diameter of 1.8 mm and a maximum sphericity of 1.01. In order to meet these specific targets, it is necessary to adjust the effective parameters accordingly. The oil density should be set to 689.9 kg/m3, the oil viscosity to 0.02816 Pa.s, the sol density to 1194 kg/m3, the sol viscosity to 0.2412 Pa.s, the interfacial tension coefficient to 0.026 N/m, the contact angle to 2.4137 rad, and the injection speed to 0.0046 m/s.