Analytical and Numerical Modeling of Gravity Multi Effects Thermal System (G-METS) Distillation for Enhanced Metal Recycling and Production

Telgerafchi, Amy

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Analytical and Numerical Modeling of Gravity Multi Effects Thermal System (G-METS) Distillation for Enhanced Metal Recycling and Production

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This thesis presents a comprehensive analysis of metal recycling via a novel distillation technology named Gravity-Driven Multiple Effect Thermal System (G-METS). Initially, the research encompasses a thorough literature review of the current state of the art in metal separation processes, including distillation techniques, with a focus on enhancing the efficiency and sustainability of these methods. The study extends to an investigation into the thermodynamics of magnesium and lead alloys, emphasizing the interaction of key elements such as tin (Sn), Arsenic (As), Zinc (Zn), and Aluminum (Al), which are critical for optimizing separation processes. A significant portion of the research is dedicated to asymptotic studies of alloy evaporation kinetics, providing analytical insights into the fundamental mechanisms driving the distillation process for magnesium alloys and lead bullion. Complementing this, a basic techno-economic analysis evaluates the viability of applying G-METS distillation for metal recycling, revealing its potential economic and environmental benefits. Further, this work develops preliminary finite element analysis (FEA) models using COMSOL software to simulate alloy evaporation and vapor phase transport in both batch and continuous distillers for magnesium alloys and lead bullion. These models serve as a foundation for designing an experimental setup to investigate multicomponent evaporation kinetics and inter-effect heat transfer dynamics, crucial for optimizing the distillation process. Experimental investigations include conducting several single-effect batch and partial single-effect batch distillation experiments to assess various kinetic and dynamic parameters of the distillation process. Lastly, the research advances to build and validate two-dimensional axisymmetric FEA models of the distillation process, further refining the simulation of evaporation and vapor phase transformations. These models are rigorously tested against experimental results, providing a robust framework for scaling up the technology. Enhanced models of counter-flow evaporators and condensers are also developed, aiming to improve the separation efficiency of volatile components significantly. Through analytical calculations, numerical modeling, and experimental validations, this thesis demonstrates the feasibility and advantages of the G-METS distillation system for the sustainable and efficient recycling of metals, potentially revolutionizing the metal production industry.

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