Advances in Manufacturing Engineering: Selected

articles from ICMMPE 2019 Seyed Sattar Emamian

pdf download
https://textbookfull.com/product/advances-in-manufacturing-engineering-selected-articles-from-
icmmpe-2019-seyed-sattar-emamian/

★★★★★ 4.7/5.0 (21 reviews) ✓ 104 downloads ■ TOP RATED

"Perfect download, no issues at all. Highly recommend!" - Mike D.

DOWNLOAD EBOOK
 Advances in Manufacturing Engineering: Selected articles
from ICMMPE 2019 Seyed Sattar Emamian pdf download

TEXTBOOK EBOOK TEXTBOOK FULL

Available Formats

■ PDF eBook Study Guide TextBook

EXCLUSIVE 2025 EDUCATIONAL COLLECTION - LIMITED TIME

INSTANT DOWNLOAD VIEW LIBRARY

Collection Highlights

Advances in Materials and Manufacturing Engineering:

Select Proceedings of ICMME 2019 T. Rajmohan

Embracing Industry 4 0 Selected Articles from MUCET 2019

Mohd Azraai Mohd Razman

Advances in Computational Methods in Manufacturing Select

Papers from ICCMM 2019 R. Ganesh Narayanan

Advances in Materials Engineering and Manufacturing

Processes: Select Proceedings of ICFTMM 2019 Inderdeep
Singh
Advances in Mechanical Engineering, Materials and
Mechanics: Selected contributions from the 7th
International Conference on Advances in Mechanical
Engineering and Mechanics, ICAMEM 2019, December 16-18,
2019, Hammamet, Tunisia Mohamed Kharrat

ICPES 2019 Selected articles from the 9th International

Conference on Power and Energy Systems Perth Australia
Farhad Shahnia

Advances in Manufacturing II Volume 4 Mechanical

Engineering Bartosz Gapi■ski

Not from Here Selected UFO Articles 1st Edition Preston

Dennett

Practical Aspects of Chemical Engineering: Selected

Contributions from PAIC 2019 Marek Ochowiak
Lecture Notes in Mechanical Engineering

Seyed Sattar Emamian

Mokhtar Awang
Farazila Yusof Editors

Advances in
Manufacturing
Engineering
Selected Articles from ICMMPE 2019
Lecture Notes in Mechanical Engineering

Series Editors
Francisco Cavas-Martínez, Departamento de Estructuras, Universidad Politécnica
de Cartagena, Cartagena, Murcia, Spain
Fakher Chaari, National School of Engineers, University of Sfax, Sfax, Tunisia
Francesco Gherardini, Dipartimento di Ingegneria, Università di Modena e Reggio
Emilia, Modena, Italy
Mohamed Haddar, National School of Engineers of Sfax (ENIS), Sfax, Tunisia
Vitalii Ivanov, Department of Manufacturing Engineering Machine and Tools,
Sumy State University, Sumy, Ukraine
Young W. Kwon, Department of Manufacturing Engineering and Aerospace
Engineering, Graduate School of Engineering and Applied Science, Monterey,
CA, USA
Justyna Trojanowska, Poznan University of Technology, Poznan, Poland
Lecture Notes in Mechanical Engineering (LNME) publishes the latest develop-
ments in Mechanical Engineering—quickly, informally and with high quality.
Original research reported in proceedings and post-proceedings represents the core of
LNME. Volumes published in LNME embrace all aspects, subfields and new
challenges of mechanical engineering. Topics in the series include:
• Engineering Design
• Machinery and Machine Elements
• Mechanical Structures and Stress Analysis
• Automotive Engineering
• Engine Technology
• Aerospace Technology and Astronautics
• Nanotechnology and Microengineering
• Control, Robotics, Mechatronics
• MEMS
• Theoretical and Applied Mechanics
• Dynamical Systems, Control
• Fluid Mechanics
• Engineering Thermodynamics, Heat and Mass Transfer
• Manufacturing
• Precision Engineering, Instrumentation, Measurement
• Materials Engineering
• Tribology and Surface Technology
To submit a proposal or request further information, please contact the Springer
Editor of your location:
China: Dr. Mengchu Huang at [email protected]
India: Priya Vyas at [email protected]
Rest of Asia, Australia, New Zealand: Swati Meherishi at
[email protected]
All other countries: Dr. Leontina Di Cecco at [email protected]
To submit a proposal for a monograph, please check our Springer Tracts in
Mechanical Engineering at http://www.springer.com/series/11693 or contact
[email protected]
Indexed by SCOPUS. The books of the series are submitted for indexing to
Web of Science.

More information about this series at http://www.springer.com/series/11236

Seyed Sattar Emamian Mokhtar Awang
• •

Farazila Yusof
Editors

Advances in Manufacturing
Engineering
Selected Articles from ICMMPE 2019

123
Editors
Seyed Sattar Emamian Mokhtar Awang
Department of Mechanical Engineering Department of Mechanical Engineering
University of Malaya Universiti Teknologi Petronas
Kuala Lumpur, Selangor, Malaysia Seri Iskander, Perak, Malaysia

Farazila Yusof
Department of Mechanical Engineering
University of Malaya
Kuala Lumpur, Selangor, Malaysia

ISSN 2195-4356 ISSN 2195-4364 (electronic)

Lecture Notes in Mechanical Engineering
ISBN 978-981-15-5752-1 ISBN 978-981-15-5753-8 (eBook)
https://doi.org/10.1007/978-981-15-5753-8
© Springer Nature Singapore Pte Ltd. 2020
This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part
of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations,
recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission
or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar
methodology now known or hereafter developed.
The use of general descriptive names, registered names, trademarks, service marks, etc. in this
publication does not imply, even in the absence of a specific statement, that such names are exempt from
the relevant protective laws and regulations and therefore free for general use.
The publisher, the authors and the editors are safe to assume that the advice and information in this
book are believed to be true and accurate at the date of publication. Neither the publisher nor the
authors or the editors give a warranty, expressed or implied, with respect to the material contained
herein or for any errors or omissions that may have been made. The publisher remains neutral with regard
to jurisdictional claims in published maps and institutional affiliations.

This Springer imprint is published by the registered company Springer Nature Singapore Pte Ltd.
The registered company address is: 152 Beach Road, #21-01/04 Gateway East, Singapore 189721,
Singapore
Contents

The Effect of Composition on CO2 Freeze-Out and Critical Locus

of Binary CO2–CH4 Mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Muhammad Babar, Mohamad Azmi Bustam, Abul Hassan Ali,
Abdulhalim Shah Maulud, and Aymn Abdulrahman
Influence of the Agglomeration Phenomenon on the Recast Surface
in PMEDM Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
M. A. Abbas and M. A. Lajis
Comparison of the Removal Rate in EDM Based on the Mixed
Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
D. R. Abbas, M. A. Lajis, and M. A. Abbas
Influence of Projectile Penetration on the Multiple-Layered Target
Based on Statistical and Numerical Analysis . . . . . . . . . . . . . . . . . . . . . 35
O. M. Merzah, M. N. Ibrahim, M. A. Abbas, and M. A. Lajis
Fractal Wear Behaviour of Gear Tooth: A Review . . . . . . . . . . . . . . . . 47
Enesi Y. Salawu, A. O. Inegbenebor, O. O. Ajayi, Stephen A. Akinlabi,
and Esther T. Akinlabi
Finite Element Modeling of Nano Porous Sintered Silver Material . . . . 55
Bahman Meyghani, S. Emamian, Mokhtar Awang, and Chuan Song Wu
Creep Behaviour and Adhesion Properties of TiC Thin Film Coating
Grown by RF Magnetron Sputtering . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Abegunde Olayinka, Esther T. Akinlabi, and O. P. Oladijo
Taguchi Analysis of Surface Roughness of TiC Thin Films Deposited
by RF Magnetron Sputtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Olayinka Oluwatosin Abegunde, Esther T. Akinlabi, and O. P. Oladijo
Laser Metal Deposition of Titanium Alloy: A Review . . . . . . . . . . . . . . 87
Bonolo S. Boshoman, Esther T. Akinlabi, Mutiu F. Erinosho,
and Oluwagbenga T. Johnson

v
vi Contents

Effect of Novel Swirl Distributor Plate on Gasification Efficiency

of Bubbling Fluidized Bed Gasifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Iman Eslami Afrooz and Dennis Ling Chuan Ching
A Review of Recent Developments in Mechanical Properties
of Polymer–Clay Nanocomposites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Mohd Shahneel Saharudin, Syafawati Hasbi,
Muhammad Naguib Ahmad Nazri, and Fawad Inam
Effect of Some Additives on Tribological Properties of SAE20W40
Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Harpreet Singh Grewal, Surinder Singh, Harpreet Singh,
and Narinder Singh
Performance Evaluation on the Smartness of Malaysian Timber . . . . . . 139
Amirah Abdull Razak, Nasrul Izan Shahrin, Jaronie Mohd Jani,
and Norul Hisham Hamid
A Brief Overview of Bending Operation in Sheet Metal
Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Omolayo M. Ikumapayi, Esther T. Akinlabi, Nkosinathi Madushele,
and Samuel O. Fatoba
Emerging Trend in Forging Operation . . . . . . . . . . . . . . . . . . . . . . . . . 161
Omolayo M. Ikumapayi, Esther T. Akinlabi, and Peter Onu
Effect of AFM Scan Size on the Scaling Law of Sputtered Aluminium
Thin Films . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
F. M. Mwema, Esther T. Akinlabi, O. P. Oladijo, Stephen A. Akinlabi,
and S. Hassan
Energy Content Modelling for Municipal Solid Waste Using Adaptive
Neuro-Fuzzy Inference System (ANFIS) . . . . . . . . . . . . . . . . . . . . . . . . . 177
Oluwatobi Adeleke, Stephen A. Akinlabi, Paul A. Adedeji,
and Tien-Chien Jen
Predicting the Effect of Seasonal Variation on the Physical
Composition of Municipal Solid Waste: A Case Study of the City
of Johannesburg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Oluwatobi Adeleke, Stephen A. Akinlabi, S. Hassan, and Tien-Chien Jen
Optimization of Process Parameters Using Taguchi for Friction Stir
Welding of Dissimilar Aluminum Alloys . . . . . . . . . . . . . . . . . . . . . . . . 199
Olatunji P. Abolusoro and Esther T. Akinlabi
Effect of Equal Channel Angular Pressing Die Angle on Corrosion
Behavior of Bulk Nanostructured Metal . . . . . . . . . . . . . . . . . . . . . . . . . 213
N. A. N. Mokhtar, D. N. Awang Shri, and M. M. Mahat
Contents vii

Investigation of Maximum Erosion Zone in the Horizontal

90° Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Rehan Khan, H. H. Ya, William Pao, T. V. V. L. N. Rao, Azad Alam,
and M. Azeem
An Overview: Mechanical and Wear Properties of HDPE Polymer
Nanocomposites Reinforced with Treated/Non-treated Inorganic
Nanofillers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Tauseef Ahmed, H. H. Ya, Shuhaimi Mahadzir, Rehan Khan,
and Muhammad Azad Alam
Liquid Desiccant Membrane Regeneration of DES for Air
Conditioning Systems Using Electrodialysis Technique . . . . . . . . . . . . . 243
Temidayo Lekan Oladosu, Aklilu Tesfamichael Baheta, and P. B. Hussain
Effects of Process Conditions on Calorific Value and Yield of Charcoal
Produced from Pyrolysis of Coconut Shells . . . . . . . . . . . . . . . . . . . . . . 253
Rabi K. Ahmad, S. A. Sulaiman, M. Inayat, and Hadiza A. Umar
Palm Kernel Shell as Potential Fuel for Syngas Production . . . . . . . . . . 263
Hadiza A. Umar, S. A. Sulaiman, Mior Azman B. Meor Said,
and Rabi K. Ahmad
Potential Roles of Artificial Intelligence in the LCI of Renewable
Energy Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Paul A. Adedeji, Stephen A. Akinlabi, Nkosinathi Madushele,
and Obafemi O. Olatunji
Fault Detection System for Long-Distance Gas Mixture Pipelines
Using Statistical Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Syed Muhammad Mujtaba, Tamiru Alemu Lemma,
and Mebrahitom Asmelash Gebremariam
Feasibility Study on Metal Inert Gas (MIG) Welding on Zincalume
G550 Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
WaliSiJiang Tayier, Shamini Janasekaran, and Arvinth Rajandran
The Influence of Welding Parameters on the Microhardness
of Zincalume Steel Welded Joint Using Taguchi Technique in Metal
Inert Gas (MIG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Walisijiang Tayier, Shamini Janasekaran,
and Abdullah Hussein Ali Alzubydi
Construction of a Hybrid Geometric Model for an Injection Mould
Using CAD/CAM System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Jian Xin Tan and Mohd Salman Abu Mansor
Development of a Face Sculpture Prototype Using a Reverse
Engineering Technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Mohd Zhafran Anwar Mohd Tahar and Mohd Salman Abu Mansor
viii Contents

Experimental Investigations on the Surface Hardness of Synthesized

Polystyrene/ZnO Nanocomposites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
Mohammad Azad Alam, H. H. Ya, P. B. Hussain, M. Azeem,
S. M. Sapuan, Rehan khan, and Tauseef Ahamad
A Review: Hybrid Welding of High Strength Materials . . . . . . . . . . . . . 353
Okwudili S. Ogbonna, Stephen A. Akinlabi, Nkosinathi Madushele,
Abiodun A. Abioye, and S. Hassan
Image Segmentation and Particle Size Analysis of Vibratory Disc
Milled Titanium Alloy Powder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
Okwudili S. Ogbonna, Stephen A. Akinlabi, Nkosnathi Madushele,
Paul A. Adedeji, and Stephen Ekolu
Hydrodynamic Analysis of Floating Offshore Solar Farms Subjected
to Regular Waves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
A. M. Al-Yacouby, Emiruddin Redza Bin Abdul Halim, and M. S. Liew
Open-Hole and Filled-Hole Failure Envelopes of BFRP and GFRP:
A Comparative Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
Z. Sajid, S. Karuppanan, and S. Z. H. Shah
Investigation on Effect of Fly Ash Volume Percentage on
Microstructure and Microhardness of AA7075—Fly Ash Surface
Composites via FSP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
Namdev Ashok Patil, Ng Zhongyan, Srinivasa Rao Pedapati,
and Othman Bin Mamat
Design-Point Performance Adaptation of Small Gas Turbine
Using Particle Swarm Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Affiani Machmudah and Tamiru Alemu Lemma
Finite Element Analysis of the Heat Generated During FSP
of 1100 Al Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Adedotun Adetunla and Esther Akinlabi
A Concise Review of the Effects of Hybrid Particulate Reinforced
Aluminium Metal Matrix Composites on the Microstructure,
Density and Mechanical Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
Ndudim Ononiwu, Esther T. Akinlabi, Chigbogu G. Ozoegwu,
and Victor Aigbodion
Application of Molecular Dynamics Simulation: A Case Study
to Estimate Wettability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
Vahid Khosravi, Syed Mohammad Mahmood, and Davood Zivar
A Comparison of Single-Vacuum-Bag and Double-Vacuum-Bag
Methods for Manufacturing High-Quality Laminated
Composites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
Yasir Mujahid, Nabihah Sallih, and Mohamad Zaki Abdullah
Contents ix

Experimental Studies of FPSO Responses with Validation

by Numerical and Artificial Neural Network
Prediction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
N. L. Azizan, Ruly Irawan, M. S. Liew, A. M. Al-Yacouby,
and Kamaluddeen Usman Danyaro
Surface Coating Processes: From Conventional to the Advanced
Methods; a Short Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
A. D. Baruwa, Esther T. Akinlabi, and O. P. Oladijo
Surface Coating Processes: From Conventional to Silane Organic
Compound Applications: Recent and Prospects . . . . . . . . . . . . . . . . . . . 495
A. D. Baruwa, Esther T. Akinlabi, O. P. Oladijo, and F. M. Mwema
Study of Additive Manufactured Ti–Al–Si–Cu/Ti–6Al–4V Composite
Coating by Direct Laser Metal Deposition (DLMD) Technique . . . . . . . 503
L. C. Naidoo, O. S. Fatoba, Stephen A. Akinlabi, R. M. Mahamood,
M. Y. Shatalov, E. V. Murashkin, S. Hassan, and Esther T. Akinlabi
Experimental Investigation of Laser Metal Deposited Al–Cu–Ti
Coatings on Ti–6Al–4V Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
A. M. Lasisi, O. S. Fatoba, Stephen A. Akinlabi, R. M. Mahamood,
M. Y. Shatalov, E. V. Murashkin, S. Hassan, and Esther T. Akinlabi
Effect of Process Parameters on the Hardness Property of Laser Metal
Deposited Al–Cu–Ti Coatings on Ti–6Al–4V Alloy . . . . . . . . . . . . . . . . 523
A. M. Lasisi, O. S. Fatoba, Stephen A. Akinlabi, R. M. Mahamood,
M. Y. Shatalov, E. V. Murashkin, S. Hassan, and Esther T. Akinlabi
Feasibility Study of Through Hole Fabrication on Aluminium Nitride
Ceramic Using Die-Sinking Electro-Discharge
Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 531
Asif Rashid, M. P. Jahan, D. Talamona, and A. Perveen
CFD Study on the Thermal Performance of n-Octadecane (PCM)
Doped with Graphene Nanoparticles as a Potential Thermal Energy
Storage Medium for Trombe Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 539
Chukwumaobi K. Oluah, Esther T. Akinlabi, and Howard O. Njoku
Laser Metal Deposition of Titanium Composites: A Review . . . . . . . . . . 555
Esther T. Akinlabi, Ganiyat A. Soliu, R. M. Mahamood,
Stephen A. Akinlabi, S. Hassan, M. Y. Shatalov, Evgenii Murashkin,
and O. S. Fatoba
Efficacy of Quasi Agro Binding Fibre on the Hybrid Composite Used
in Advance Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 565
J. O. Dirisu, O. S. I. Fayomi, and S. O. Oyedepo
x Contents

Review on Ergonomics Application on Car Modification for Limbs

Disabled Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
Salami Bahariah Suliano, Siti Azfanizam Ahmad, Azizan As’arry,
and Faieza Abdul Aziz
Hybrid Microgrid Systems: Operational Schedule Optimization
Considering Time of Use Demand Response and Battery
Wear Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591
Tope Roseline Olorunfemi and Nnamdi Nwulu
A Review of Mathematical Optimization Applications in Renewable
Energy-Powered Microgrids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603
Tope Roseline Olorunfemi and Nnamdi Nwulu
Optimal Grid-Connected Microgrid Scheduling Incorporating
an Incentive-Based Demand Response Program . . . . . . . . . . . . . . . . . . . 615
Tope Roseline Olorunfemi and Nnamdi Nwulu
Free-End Damage Detection in Cantilever Steel Plate Using Wavelet
Transform Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623
Muyideen Abdulkareem and Norhisham Bakhary
Determining the Potentials of Renewable Energy Sources
for Distributed Generation in Ghana . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
Ernestina Amewornu and Nnamdi Nwulu
Optimal Location of Distributed Generators in a Radial Distribution
Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641
Ernestina Amewornu and Nnamdi Nwulu
Integrated Appliance Scheduling and Optimal Sizing
of an Autonomous Hybrid Renewable Energy System
for Agricultural Food Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
Omolola A. Ogbolumani and Nnamdi Nwulu
Cost Analysis of Hybrid Energy Storage System Benefits
to Distribution Network Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661
Azizat Olusola Gbadegesin, Yanxia Sun, and Nnamdi Nwulu
The Awareness and Obstacle Factor of Machine Maintenance Toward
Total Productive Maintenance in Manufacturing Company . . . . . . . . . . 673
Yunos Ngadiman, Md Fauzi Ahmad, Nor Aziati Abd Hamid,
Raja Zuraidah Raja Mohd Rasi, Kamilah Ahmad,
and Nor Hadilah Abdul Hamid
A Multifractal Study of Al Thin Films Prepared by RF Magnetron
Sputtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 687
F. M. Mwema, Esther T. Akinlabi, O. P. Oladijo, Stephen A. Akinlabi,
and S. Hassan
Contents xi

Influence of Elbow Orientation on Solid Particle Erosion

for Multiphase Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 695
Rehan Khan, H. H. Ya, William Pao, Armaghan Khan, R. Zahoor,
and Tauseef Ahmed
High-Speed Machining for CNC Milling Simulation Using CAM
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 703
Kwok Cheat Gan and Mohd Salman Abu Mansor
Structural Fabrication and Dynamic Simulation of Stress
of a Vibrosieve for Efficient Industrial Applications . . . . . . . . . . . . . . . . 715
Enesi Y. Salawu, O. O. Ajayi, Fajobi Muyiwa, Felix Ishola,
and Azeta Joseph
Recycling of Polylactic Acid (PLA) Wastes from 3D Printing
Laboratory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725
Thai Kiat Ong, Hui Leng Choo, Wei Jean Choo, Seong Chun Koay,
and Ming Meng Pang
A Framework for the Optimal Sizing of Hybrid Solar PV-Battery-
Hydro System for a Rural House in Malaysia . . . . . . . . . . . . . . . . . . . . 733
Bilawal A. Bhayo, Hussain H. Al-Kayiem, and Syed I. U. Gilani
Anaerobic Treatment of Chicken Manure Co-digested with
Sawdust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 741
H. Y. Kok, M. R. Shamsuddin, and A. Aqsha
Temperature Distribution Investigation During Friction Stir Welding
(FSW) Using Smoothed-Particle Hydrodynamics (SPH) . . . . . . . . . . . . . 749
Bahman Meyghani, Mokhtar Awang, Chuan Song Wu, and S. Emamian
The Effect of Composition on CO2
Freeze-Out and Critical Locus of Binary
CO2 –CH4 Mixture

Muhammad Babar, Mohamad Azmi Bustam, Abul Hassan Ali,

Abdulhalim Shah Maulud, and Aymn Abdulrahman

Abstract Cryogenic CO2 capture technology is one of the emerging technologies

used for natural gas purification. Thermodynamic phase study of the natural gas
has a significant effect on the cryogenic CO2 removal from natural gas. The present
work describes the impact of composition on CO2 freeze-out and critical locus of
the binary CO2 –CH4 mixtures with different CO2 content. Critical locus and CO2
freeze-out were modelled for nine binary CO2 –CH4 mixtures and were correlated
with the composition of the binary mixtures. Aspen HYSYS version 8.0 with the
Peng Robinson equation of state and Eureka modelling tool were used in the present
research work. It was found that the predicted models can precisely calculate the CO2
freeze-out point and the critical locus of the mixtures. By comparing the calculated
data with the reported experimental data, an excellent agreement was found. R-
squared value for the models was 0.99, which shows the reliability of the models.
The effect of composition on three-phase loci of the binary and multicomponent
mixtures of CO2 with light H.C is recommended for future research.

Keywords Thermodynamic study · Cryogenic CO2 capture · CO2 freeze-out ·

Critical locus · Binary CO2 -CH4 mixture

1 Introduction

Natural gas, which is a mixture of different hydrocarbons, is mainly used as energy

source. The energy contribution of natural gas to the domestic and industrial sector
is 38% and 60% of the total energy requirements, respectively [1]. Compared to

M. Babar (B) · M. A. Bustam · A. S. Maulud

CO2 Research Centre (CO2RES), Universiti Teknologi PETRONAS, 32610 Bandar Seri
Iskandar, Perak, Malaysia
e-mail: [email protected]
M. A. Bustam
e-mail: [email protected]
A. H. Ali · A. Abdulrahman
Department of Chemical Engineering, University of Jeddah, Jeddah, Saudi Arabia

© Springer Nature Singapore Pte Ltd. 2020 1

S. S. Emamian et al. (eds.), Advances in Manufacturing Engineering, Lecture Notes
in Mechanical Engineering, https://doi.org/10.1007/978-981-15-5753-8_1
2 M. Babar et al.

other fossil fuels, natural gas is generally recommended as a neat and clean fuel [2].
However, besides methane and other light hydrocarbons, natural gas may also contain
some impurities like CO2 , N2 , He and H2 S. One of the significant greenhouse gases
in natural gas is CO2 . Natural gas from different sources has different CO2 content
depending upon the gas well conditions [3, 4]. The maximum CO2 content in some
of the discovered natural gas fields, e.g. Changling, Gudian, Honggang, Shengping,
Fangshen and other gas reservoirs in Jilin oilfield of Songliao basin, may reach up to
90% [5]. According to reported literature, some of the natural gas fields of Malaysia
may contain 87% CO2 [6]. Malaysia has more than 13 Tetra standard cubic feet
(Tscf) of high CO2 content undeveloped natural gas reservoirs [7, 8]. A natural gas
having high CO2 content has a lower calorific value than the sale gas specification
[9].
In the twentieth century, many countries of the world came across a severe energy
crisis, which increased petroleum prices [10]. Also, as CO2 and CH4 both are consid-
ered as the major greenhouse gases, their escape to the atmosphere needs to be
controlled [11]. These problems encouraged oil and gas companies to utilize the
contaminated natural gas fields with high CO2 content. Many technologies that have
been used for purification of high CO2 content natural gas include absorption, adsorp-
tion, membrane separation and cryogenic CO2 capture technology [12–14]. Cryo-
genic CO2 processes are applicable for high CO2 content natural gas, its low footprint
value increases its offshore applicability, and there is no chemical involvement [15].
These advantages and applicability at both atmospheric and high pressures make
cryogenic technology one of the emerging technologies for CO2 capture.
The cryogenic process is the process of capturing CO2 at low temperatures
(−153 °C or below) [16, 17]. This process consists of three steps: the cooling cycle,
CO2 capture step and CO2 recovery step [18]. The cryogenic CO2 capture from
natural gas requires accurate knowledge of the CO2 freeze points and thermody-
namic phase equilibria for the individual pure components as well as for the gaseous
mixture [19, 20]. Generally, the phase diagram is an easy and excellent way of under-
standing the properties of a system. A phase diagram shows temperature and pressure
conditions at which different phases occur and coexist at equilibrium [21]. Bubble
point curve, dew point curve, three-phase locus and CO2 freeze-out line are the main
components of a P-T phase diagram.
In the P-T phase envelope, the curve surrounding the S-V region, on which all the
three phases of CO2 exist, is the three-phase locus [22, 23]. Cryogenic CO2 separation
from natural gas is mostly done in the S-V region. A part of the three-phase locus is the
boundary of the L-V and S-V region, which is helpful in defining the temperature
range for the L-V region. Therefore, it is of crucial importance to have accurate
knowledge of P-T conditions of S-L-V locus. So far, limited data are available for
the three-phase locus of CO2 -NG mixture. Also, the effect of composition on the
critical locus of the CO2 –CH4 binary mixture has been rarely studied.
Donnelley et al. experimentally studied the phase behaviour of the CO2 -CH4
binary system [24]. A pressure cell in an alcohol bath was used to confine the system.
The Effect of Composition on CO2 Freeze-Out and Critical Locus … 3

By changing the pressure, the author avoided solidification of mercury at the low
temperatures. The author used dry ice or liquid nitrogen for cooling the bath. The cell
was gently shaken to mix the existing phases to achieve equilibrium. Temperatures
and pressure were measured by calibrated thermocouples in the wall of the cell,
and Bourdon tube gauges, respectively. He studied three-phase locus, temperature-
composition phase envelopes and pressure–temperature phase envelope. The author
in his work examined the three-phase locus for a temperature and pressure range
of −57.78 °C to −78.61 °C and 9.1 bar to 47.9 bar, respectively. Furthermore, he
extrapolated the three-phase locus up to −106.67 °C.
Pikaar determined the V-L, V-S and L-S equilibria of CO2 by measuring their
boiling, dew and freezing points [25]. The liquid and vapour composition in equi-
librium with the solid CO2 at a pressure up to 101.325 bar and a temperature range
of −63 to −160 °C were determined. By comparison with Donnelly and Katz data
at low temperature, a disagreement was observed at −67 and −73 °C. Furthermore,
at the lower temperatures, the divergence with Donnelly and Katz data was about
4.053 bar. Pikaar mentioned that the three-phase locus determined by Donnelly and
Katz is incorrect below −67 °C.
Sterner extended Donnelly and Katz’s [24] experimental data and measured the
VLE and the solid phase boundaries near the critical temperature of methane [26].
For the SLV, Sterner’s data [26] showed good agreement with the Pikaar’s data [25].
Davis et al. conducted his experimental study and presented a P-T phase envelope
for the CH4 –CO2 binary system at three-phase locus [27]. Figure 1 shows the P-T
phase envelope of the experimental three-phase locus data obtained by Davis et al.
[28]. P-T phase envelope was generated along the V-L-S locus in a range from the
triple point of CO2 to −176.1 °C. By comparing his data with Donnelley’s data, Davis
et al. found a disagreement between the two sets of data below −67.78 °C. Davis
found a good comparison with the Sterner’s data, excluding the highest temperature
of Sterner’s data [26] as shown in Fig. 1.
Ozturk et al. [29] used Perturbed Chain-SAFT (PC-SAFT) EoS to model the phase
behaviour of the CO2 -H.C system. V-L equilibria, V-S equilibria and S-L equilibria of
the gaseous mixtures having carbon dioxide along with methane, ethane and butane.
Furthermore, the author also examined the influence of adding C2 H6 and C4 H10 on
S-L equilibria of the binary CH4 –CO2 mixture.
Very few experimental studies are reported for the effect of composition on the
critical locus of the binary CO2 –CH4 system. The aim of this work is also to provide
a modelling approach for three-phase locus based on Aspen HYSYS with Peng
Robinson (PR) property package. In the current research work, the pressure and
temperature conditions for the critical locus for the CH4 –CO2 binary system at
various CO2 concentrations were modelled. Also, the effect of composition on critical
locus was examined and discussed in detail. For validation of the data generated by
Aspen HYSYS simulator for three-phase locus, it is then validated with the available
experimental three-phase locus data.
4 M. Babar et al.

1400
Critical point
of CO2
1200

1000
Pressure / bar

800

Critical point
600 of CH4

400

200

0
-300 -200 -100 0 100
Temperature / °C

Fig. 1 P-T phase envelope for binary CO2 –CH4 mixtures

This paper is organized as follows: Sect. 1 describes the introduction and moti-
vation for this research work. Section 2 shows the methodology. Section 3 discusses
the results and discussions of this research work. Section 4 illustrates the conclusion
of the present research work along with future recommendation.

2 Research Methodology

Aspen HYSYS simulator was used for generating the thermodynamic phase data.
Before using the simulation, it is mandatory to prove the reliability of the data gener-
ated by the simulator. Reported literature shows the authenticity of the PR EoS for
the thermodynamic phase study of the natural gas system [29]. Figure 1 shows the
reliability of the Aspen HYSYS predicted thermodynamic data for the CO2 –CH4
three-phase locus. From Fig. 1, it is obvious that predicted data by Aspen HYSYS
using PR EoS show excellent agreement with the experimental data. An error of 3%
was observed by comparing the predicted data with the three-phase data of Davis
et al. [28]. Overall, Aspen HYSYS simulator with PR EoS obtained excellent agree-
ment with the experimental data. This shows the reliability of Aspen HYSYS with
PR property package for generating three-phase locus data.
The Effect of Composition on CO2 Freeze-Out and Critical Locus … 5

Table 1 Composition of the

N.G sample CO2 /mol% CH4 /mol%
binary CO2 –CH4 mixture
used in present work Sample 1 10 90
Sample 2 20 80
Sample 3 30 70
Sample 4 40 60
Sample 5 50 50
Sample 6 60 40
Sample 7 70 30
Sample 8 80 20
Sample 9 90 10

The current research work has two primary approaches. In the first, thermody-
namic data for the critical locus of the CO2 –CH4 mixtures were obtained through
the Aspen HYSYS simulator while the second approach correlates the pressure and
temperature of the critical locus with the composition of the gaseous mixture. Eureka
modelling tool was used for the modelling of pressure and temperature conditions of
the critical locus of the binary mixture. Table 1 shows the composition of the binary
CO2 –CH4 mixture used in the present study.

3 Result and Discussion

3.1 Critical Locus

Critical locus is one of the significant components of the phase envelope of N.G-CO2
mixture. The critical point of a particular mixture is defined as the maximum limit
for the binary L-V region in the phase envelope. CH4 is the key component of natural
gas; therefore, the present work aimed to model the critical locus of binary CO2 –
CH4 mixtures. The simulation was done in Aspen HYSYS simulator for studying
the critical point of binary CO2 –CH4 mixture of composition mentioned in Table 1.
Pressure and temperature conditions were noted for the critical point. The pressure
was then plotted against the temperature to obtain the PT phase envelope for the
critical locus. Figure 1 shows the reported phase envelope for the binary CO2 –CH4
mixtures, pure CH4 and CO2 in literature. It is evident from Fig. 1 that each of the
mixtures has a distinct critical point which changes with changing composition.
The predicted data for the critical locus of the binary CO2 –CH4 mixtures were
then modelled in the Eureqa modelling tool. Critical temperature and pressure were
modelled as a function of CH4 and CO2 content in the mixture. Equations (1) and (2)
were obtained with an R-squared value of 0.99 for each equation. Figure 2 shows the
critical locus for the binary CO2 –CH4 mixture predicted by the developed model.
As can be seen from Fig. 2, an excellent similarity exists between the experimental
6 M. Babar et al.

1400
CH critical locus Critical point
of CO2
1200 CO critical locus
Experimental Critical locus
Predicted by Model
1000
Pressure / bar

800
Critical point
of CH4
600

400

200

0
-300 -250 -200 -150 -100 -50 0 50 100 150
Temperature / °C

Fig. 2 Comparison of the model predicted data with experimental data

and the predicted critical locus.

P = 1.74 × 103 + 9.88 × 103 CH34 CO22 + 8.51CH24 CO22

(1)
−1.07 × 103 CH4 − 671CO32 − 1.07 × 104 CH44 CO22

T = 160 + 3.58 × 103 CH11

4 CO2 − 276CH4 − 71.8CO2 − 246CO2 CH4
2 2 4
(2)

The maximum uncertainty (u) observed in the predicted temperature and pressure
conditions of the critical locus was 2 and 0.6%, respectively. Table 2 shows the AAD
of the established model for the critical locus of the binary mixtures.

3.2 CO2 Freezing Point

CO2 frost point is the transformation of CO2 directly from gaseous to the solid
phase. CO2 frosting can also be termed as CO2 anti-sublimation or desublimation.
CO2 freeze-out point is very crucial in the cryogenic CO2 capture from natural gas.
Due to the higher triple point of CO2 , the natural gas having high CO2 content desub-
limates at relatively high temperature, which may cause the blockage of pipelines and
equipment. As part of the CO2 capture and sequestration (CCS) chain, pressurized
pipelines are considered as the most practical and efficient means for transportation
of the large amounts of natural gas in the natural gas processing industry. The highest
reported CO2 in the Malaysian natural gas to date is 87%. However, globally, 90% of
CO2 was discovered in the natural gas till now. The present work is therefore focused
on the modelling of CO2 freeze-out point for CO2 –CH4 mixtures having CO2 content
The Effect of Composition on CO2 Freeze-Out and Critical Locus … 7

Table 2 Predicted critical temperature and pressure

CH4 content CO2 content T exp T model AAD Pexp Pmodel AAD
(Temp) (Pressure)
1 0 −116.4 −116.0 0.344 673.1 670 0.460
0.9 0.1 −94.45 −94.0 0.476 781.0 778.2 0.358
0.8 0.2 −72.3 −71.5 1.107 910.7 905.9 0.527
0.7 0.3 −51.1 −51.0 0.196 1046.5 1047.0 −0.048
0.6 0.4 −28.3 −27.8 1.767 1177.9 1175.1 0.238
0.5 0.5 −3.6 −3.5 2.7778 1270.9 1263.2 0.606
0.4 0.6 19.6 20.0 −2.041 1298.3 1296.6 0.131
0.3 0.7 40.2 40.6 −0.995 1276.9 1277.5 −0.047
0.2 0.8 58.1 58.5 −0.689 1223.5 1222.3 0.098
0.1 0.9 73.8 74.2 −0.542 1151.3 1151.0 0.026
0 1 87.7 88.2 −0.570 1068.9 1069.0 −0.009

up to 90% CO2 content (Table 1). Table 3 shows the pressure–temperature conditions
of the CO2 freezing point of the gaseous mixture.
The pressure–temperature conditions were calculated from Aspen HYSYS simu-
lator and is compared with the experimental data from the reported literature. This
calculated data was then modelled in the Eureqa modelling tool to correlate the P
and T for the CO2 freeze-out with the CO2 content in the mixture. Equation (3)
was obtained for CO2 freeze-out temperature of the binary CO2 –CH4 mixture with
an R-squared value of 0.99, respectively. This R2 value shows the reliability of the
predicted data by the developed models. Using Eq. (3), CO2 freeze-out temperature
can be predicted at any particular pressure for a known CO2 content in the CO2 –
CH4 mixture. Table 3 shows the comparison of the experimental and calculated CO2
freeze-out temperatures at a specific pressure and CO2 concentration. An excellent
agreement was observed between the experimental and calculated temperatures.
 
−6.43 × 10−7 P 3
T = 0.238PCO2 + 0.00159P + 0.00145P 2 2
CO22 +
CO22 (3)
−0.221P − 0.00343CO2 P − 56.6 2

4 Conclusion

In this research work, a detailed modelling study was carried out for the critical
locus and CO2 freeze-out locus of the binary CO2 –CH4 mixture. Eureqa modelling
tool was used to model the critical locus and the CO2 freeze-out for the mixtures.
Pressure and temperature at the critical locus were modelled for the binary mixture as
 8

Table 3 Experimental and calculated CO2 freeze-out temperatures for binary CO2 –CH4 mixtures
10 mol% CO2 20 mol% CO2 30 mol% CO2 40 mol% CO2 50 mol% CO2
P T exp T cal T exp T cal T exp T cal T exp T cal T exp T cal
1 −56.88 −56.8 −56.82 −56.78 −56.78 −56.75 −56.75 −56.73 −56.72 −56.7
5 −57.78 −57.64 −57.55 −57.52 −57.39 −57.41 −57.25 −57.3 −57.13 −57.18
10 −58.81 −58.83 −58.38 −58.57 −58.08 −58.35 −57.83 −58.14 −57.6 −57.92
20 −60.82 −61.83 −59.95 −61.08 −59.4 −60.64 −58.94 −60.24 −58.53 −59.84
30 −62.89 −65.98 −61.49 −64.23 −60.7 −63.52 −60.05 −62.94 −59.47 −62.38
40 −65.33 −71.67 −63.02 −68.11 −61.98 −67.02 −61.17 −66.26 −60.44 −65.55
50 −71.35 −79.29 −64.57 −72.82 −63.25 −71.19 −62.29 −70.22 −61.44 −69.38
60 mol% CO2 70 mol% CO2 80 mol% CO2 90 mol% CO2
P T exp T cal T exp T cal T exp T cal T exp T cal
1 −56.69 −56.68 −56.66 −56.66 −56.64 −56.63 −56.61 −56.61
5 −57.01 −57.07 −56.9 −56.95 −56.8 −56.84 −56.69 −56.72
10 −57.39 −57.7 −57.19 −57.47 −56.98 −57.25 −56.79 −57.02
20 −58.14 −59.43 −57.76 −59.01 −57.37 −58.58 −56.99 −58.14
30 −58.92 −61.81 −58.36 −61.22 −57.8 −60.61 −57.21 −59.98
40 −59.73 −64.84 −59.01 −64.11 −58.27 −63.34 −57.47 −62.53
50 −60.6 −68.55 −59.74 −67.69 −58.81 −66.77 −57.78 −65.8
M. Babar et al.
The Effect of Composition on CO2 Freeze-Out and Critical Locus … 9

a function of CO2 and CH4 concentration in the binary mixture. The obtained model
has an R2 value of 0.99 and shows an excellent agreement with the experimental
critical locus data.
The pressure and temperature were also modelled for the CO2 freeze-out of the
binary CO2 –CH4 systems at various CO2 concentration ranging from 10 mol% to
90 mol%. The obtained equation was capable of calculating the CO2 freeze-out
temperature at a specific pressure and CO2 concentration. The data obtained by the
established model have a close similarity with the experimental data. The R2 value for
the model was 0.99, showing the authenticity of the developed model. It was observed
that at high CO2 contents and high pressure, the average absolute deviations of the
derived models increase. It is therefore recommended for the future to modify the
models for the multicomponent natural gas mixture with high CO2 content and at
high pressure with minimized energy requirements.

Acknowledgements The authors are thankful to the CO2 Research Centre [CO2RES], Department
of Chemical Engineering, Universiti Teknologi PETRONAS, for providing the necessary support
in the research.

References

1. Babar M, Bustam M, Maulud A, Ali A (2019) Optimization of cryogenic carbon dioxide

capture from natural gas. Materialwiss Werkstofftech 50:248–253
2. Faramawy S, Zaki T, Sakr A-E (2016) Natural gas origin, composition, and processing: a
review. J Nat Gas Sci Eng 34:34–54
3. Yeo ZY, Chew TL, Zhu PW, Mohamed AR, Chai SP (2012) Conventional processes and
membrane technology for carbon dioxide removal from natural gas: a review. J Nat Gas Chem
21:282–298
4. Baraj E, Vagaský S, Hlinčik T, Ciahotný K, Tekáč V (2016) Reaction mechanisms of carbon
dioxide methanation. Chem Pap 70:395–403
5. Hou D, Deng H, Zhang H, Li K, Sun L, Pan Y (2015) Phase behavior and physical parameters
of natural gas mixture with. J Chem 2015:12
6. Nasir Haji Darman ARBH (2006) Technical challenges and solutions on natural gas develop-
ment in Malaysia. The petroleum Policy and Management (PPM) Project 4th Workshop of the
China–Sichuan Basin Case Study
7. Turunawarasu D, Norpiah R, Pottayil A (2015)A study on phase behavior and its application
to cryogenic technologies for treatment of high CO2 gas fields. OTC, Brasil
8. Babar M, Bustam M, Ali A, Maulud A (2018) Identification and quantification of CO2
solidification in cryogenic CO2 capture from natural gas. Int J Auto Mech Eng 15:5367–5367
9. Lee SP, Mellon N, Shariff AM, Leveque J-M (2018) High-pressure CO2 -CH4 selective
adsorption on covalent organic polymer. J Nat Gas Sci Eng 50:139–146
10. Babar M, Shah MUH (2014) Evaluation of optimum composition of starch as a binding material
for square coal briquettes. IJSR 3:1248–1252
11. Agsten R, Eder FX (1992) Possibilities of ecological production of methane from mixtures of
methane and carbon dioxide. Cryogenics 32:175–178
12. Shimekit B, Mukhtar H (2012) Natural gas purification technologies-major advances for CO2
separation and future directions. In: Advances in natural gas technology. InTech
10 M. Babar et al.

13. Gholami M, Mohammadi T, Mosleh S, Hemmati M (2017) CO2 /CH4 separation using
mixed matrix membrane-based polyurethane incorporated with ZIF-8 nanoparticles. Chem
Pap 71:1839–1853
14. Babar M, Bustam MA, Ali A, Maulud AS, Shafiq U, Shariff AM et al (2019) Efficient
CO2 capture using NH2 −MIL−101/CA composite cryogenic packed bed column. Cryogenics
101:10
15. Ali A, Maqsood K, Redza A, Hii K, Shariff AB, Ganguly S (2016) Performance enhancement
using multiple cryogenic desublimation based pipeline network during dehydration and carbon
capture from natural gas. Chem Eng Res Des 109:519–531
16. Berstad D, Anantharaman R, Nekså P (2013) Low-temperature CO2 capture technologies–
applications and potential. Int J Refrig 36:1403–1416
17. I. I. O. Refrigeration (2007) International Dictionary of Refrigeration. Peeters Publishers,
Leuven
18. Babar M, Bustam MA, Ali A, Maulud AS, Shafiq U, Mukhtar A et al (2019) Thermodynamic
data for cryogenic carbon dioxide capture from natural gas: a review. Cryogenics 102:20
19. Potoff JJ, Siepmann JI (2001) Vapor–liquid equilibria of mixtures containing alkanes, carbon
dioxide, and nitrogen. AIChE J 47:1676–1682
20. ZareNezhad B, Eggeman T (2006) Application of Peng-Rabinson equation of state for CO2
freezing prediction of hydrocarbon mixtures at cryogenic conditions of gas plants. Cryogenics
46:840–845
21. Hillert M (2007) Phase equilibria, phase diagrams and phase transformations: their thermody-
namic basis. Cambridge University Press
22. Umar Shafiq AMS, Babar M, Babar A, Quddusi AH, Bustam M (2019) A review on modeling
and simulation of blowdown from pressurized vessels and pipelines. Process Safety and
Environmental Protection
23. Babar M, Bustam MA, Maulud AS, Ali A, Mukhtar A, Ullah S (2019) Enhanced cryogenic
packed bed with optimal CO2 removal from natural gas. A joint computational and experimental
approach. Cryogenics, p 103010
24. Donnelly HG, Katz DL (1954) Phase equilibria in the carbon dioxide-methane system. Ind
Eng Chem 46:511–517
25. Pikaar MJ (1959) Study of phase equilibria in hydrocarbon-CO2 system. University of London
26. Sterner C (1961) Phase equilibria in the CO2 -Methane systems. In: Advances in cryogenic
engineering. Springer, pp 467–474
27. Shafiq U, Shariff AM, Babar M, Ali A (2018) A study on blowdown of pressurized vessel
containing CO2 /N2 /H2 S at cryogenic conditions. In IOP conference series: materials science
and engineering, p 012077
28. Davis J, Rodewald N, Kurata F (1962) Solid-liquid-vapor phase behavior of the methane-carbon
dioxide system. AIChE J 8:537–539
29. Ozturk M, Panuganti SR, Gong K, Cox KR, Vargas FM, Chapman WG (2017) Modeling
natural gas-carbon dioxide system for solid-liquid-vapor phase behavior. J Nat Gas Sci Eng
45:738–746
Influence of the Agglomeration
Phenomenon on the Recast Surface
in PMEDM Environment

M. A. Abbas and M. A. Lajis

Abstract The agglomeration phenomenon that occurs in PMEDM environment is

one of the significant obstacles in enhancing the removal operation in this envi-
ronment. This phenomenon has been investigated by the prior studies to improve
the microhardness (MH) and recast layer thickness (RLT). However, these studies
have not focused on the type of agglomeration that contributed in enhancing both
responses of MH and RLT. Therefore, this study aims in presenting a logical interpre-
tation to the influence of this phenomenon and its type on these responses for D2 steel
by employing nano-chromium powder (NCP) particles in PMEDM environment. In
addition, the scanning electron microscope (SEM) and energy-dispersive x-ray spec-
troscopy (EDS) play a crucial role in specifying the weight percentage of elements
before and after machining of D2 steel to determine the agglomeration state. Accord-
ingly, the carbon element and other elements are responsible for increasing the MH
to 912 HVI since these elements agglomerate remarkably instead of NCP. Therefore,
this vital agglomeration occurs at 2 g/L, 30 μs, and 85 μs for NCP, pulse duration,
and pulse interval, respectively. Consequently, this environment has contributed to
transferring limited energy to the workpiece in order to generate a minimum RLT,
which reaches 10.32 μm.

Keywords PMEDM · Agglomeration · Microhardness · Recast layer thickness ·

Heat flux

M. A. Abbas (B) · M. A. Lajis

Faculty of Mechanical and Manufacturing Engineering (FKMP), University Tun Hussein Onn
Malaysia (UTHM), 86400 Parit Raja, Johor Bahru, Malaysia
e-mail: [email protected]
Sustainable Manufacturing and Recycling Technology, Advanced Manufacturing and Materials
Center (SMART-AMMC), University Tun Hussein Onn Malaysia (UTHM), 86400 Parit Raja,
Johor Bahru, Malaysia
M. A. Abbas
Aeronautical Techniques Engineering Department, Engineering Technical College (ETCN),
Al-Furat Al-Awsat Technical University (ATU), Main Hilla-Baghdad Road, Najaf, Iraq

© Springer Nature Singapore Pte Ltd. 2020 11

S. S. Emamian et al. (eds.), Advances in Manufacturing Engineering, Lecture Notes
in Mechanical Engineering, https://doi.org/10.1007/978-981-15-5753-8_2
12 M. A. Abbas and M. A. Lajis

1 Introduction

The Powder Mixed Electrical Discharge Machining (PMEDM) is deemed as an

encouraging medium in machining the complex materials and enhancing the quality
of surface integrity [1, 2]. However, this medium is not wholly perfect in converging
with the requirements of precision manufacturing due to the level of parameters
implemented in the PMEDM which generates more obstacles such as the agglom-
eration phenomenon [3–5]. This phenomenon is produced from the electrothermal
energy, which results from the spark channel between the workpiece and the electrode
tool [6]. Depending on this energy, the powder particles immigrate and agglom-
erate upon the fusion region of the workpiece. These particles aggregate with the
carbon particles resulted from the decomposing of dielectric fluid, and the electrodes
debris produced from the machining operation of the plasma channel [7, 8]. The
phenomenon of powder agglomeration is considered as an external and significant
factor in the performance of the pure EDM and has been observed in the former
studies in the PMEDM field; however, it is not studied intensely. Hence, the proper-
ties, concentration, and type of powder in the PMEDM system represent the principal
operator of this phenomenon besides pulse current, pulse duration, pulse interval,
and polarity [9].
To improve the surface properties, the correlation between this phenomenon and
the quenching time is deemed as a major effectual. Therefore, the quenching time,
represented in the interval time, leads to forming a recast layer as a new layer [10].
This layer consists of agglomerated particles with the melted region of the workpiece
to improve the surface’s hardness. Therefore, previous researchers attempted to study
the relation between the thickness of this layer and the surface’s hardness as these
are significant responses in PMEDM system to enhance the recast surface after
machining in this system. On the other hand, the researchers also tried to interpret
the behavior of the agglomerated particles and relation with these responses.
The experimental results from machining W300 indicate that the maximum pulse
duration at 2 g/L of aluminum powder leads to minimizing the recast layer thick-
ness (RLT). Therefore, the increased peak current with the positive polarity requires
raising the amount of this powder in order to achieve the best RLT [11]. However, the
attitude of RLT differentiates when machining titanium alloy due to the minimum
level of the graphite powder, peak current, and surfactant, which generate effective
RLT [12]. Through these outcomes, the role of the amount of powder is significant to
present a better RLT. Therefore, the increase in the powder quantity of boron carbide
in EDM oil produces a problem to the melting region in the titanium alloy where
this powder will be agglomerated in this region and contributes in reducing the flow
of electrothermal energy to this alloy [13]. Both titanium alloy and AISI H13 steel
have the same action toward the RLT during mixing multi-walled carbon nanotubes
(MWCNTs) powder with kerosene. This action is remarked when the pulse interval
is higher than the pulse duration at the minimum level of pulse current where the RLT
will be at the minimum value [14, 15]. From these results, the previous researchers
struggled to improve the recast layer by decreasing the thickness of it, but other
Influence of the Agglomeration Phenomenon on the Recast Surface … 13

researchers have provided a different perspective through comparison between the

RLT and the microhardness (MH) for the machined materials in PMEDM environ-
ment. This perspective has been exemplified by modifying the RLT of the machined
surface of H13 steel at a minimum concentration of molybdenum powder in EDM,
and maximum machining time has been approximated to 4 h. This outcome boosted
the MH of this steel by increasing the agglomeration of this powder with the other
particles in the fusing region which leads to forming more carbides [16]. Moreover,
the RLT and MH possess similar behavior with the same steel when utilizing silicon
and manganese powders in EDM; however, the pulse interval has an influential
contribution to quench the melted region and resolidify it [17]. Also, the machining
surface of β-titanium alloy has been improved when mixed with the silicon powder
with hydrocarbon oil in the EDM machine. The agglomerated particles of carbon,
oxygen, and silicon with debris led up to the enhancement of the MH and RLT [6].
Depending on the literature available, Fig. 1 highlights the relationship between
the agglomeration phenomena in the first phase after completing the pulse dura-
tion. Furthermore, this figure also illustrates the second phase after completing the
pulse interval and forming the recast layer. Through Fig. 1, it is perceived that
the primary contributor of the powder agglomeration in PMEDM field is the elec-
trothermal energy. Therefore, the numerical model of heat flux for the plasma channel
in PMEDM has achieved outstanding results in understanding the removal rate of
material in this field [18, 19]. Equations (1) and (2) will be invested in computing
the quantity of heat flux applied on the workpiece in the present work to interpret
the behavior of the agglomeration of particles given by:
 
Q(r ) = 4.57Pc HF Vs I P /π R 2pc e−4.5(r/R pc )
2
(1)

R pc = 2040I P0.43 Ton

0.44
(2)

where PC is powder concentration [20], H F denotes to heat fraction constant (5–

9%) [18], V s represents supply voltage (Volt), I P indicates to pulse current (Amps),
Rpc is plasma channel radius (μm), r refers to radial axis (μm), and T on is pulse
duration (μs). Relying on these phases in Fig. 1, the research gap targeted in this
article highlights on improving the performance of the microhardness (MH) and
recast layer thickness (RLT) by controlling the electrothermal energy, pulse interval,
and pulse duration in PMEDM. Consequently, the influence of the agglomeration
phenomenon and the type of this phenomenon on these responses and the extent
to which it can be controlled will be studied. Therefore, the present study employs
the D2 steel, copper electrode, and the nano-chromium powder (NCP) particles to
achieve these objectives in the electrical discharge environment.
14 M. A. Abbas and M. A. Lajis

Fig. 1 Comparison between numerical validation of MRR in AISI D2 with CPMEDM environment
at each gap distance with experimental MRR values
Influence of the Agglomeration Phenomenon on the Recast Surface … 15

2 Experimental Setup and Methodology

The experimental environment adopted in this study consists of the Integrated High
Performance-EDM (IHP-EDM), work material, and observation devices as shown
in Fig. 2; meanwhile, Table 1 indicates the experimental conditions employed to
achieve the results.
In Fig. 2, the circulation system in (b) is integrated with Sodick EDM-Die Sinking
AQ55L in (a) to circulate the mixed dielectric fluid with NCP. Furthermore, this
system attracts the powder particles and debris by using a cleaning filter and magnetic
filter, respectively. In addition, the insulating tank in Fig. 2c is utilized to mix the
NCP with kerosene separately out of the original tank of EDM machine in (a).
Consequently, IHP-EDM in Fig. 2a–c assists in obtaining the best performance in
PMEDM, while work materials in Fig. 2d–f consist of nano-chromium powder (NCP)
particles, copper electrode, and D2 steel as the workpiece, sequentially. In Fig. 2,
the scanning electron microscope (SEM) and energy-dispersive x-ray spectroscopy
(EDS) in (g) employ Hitachi SU1510 model to inspect the microstructure of machined
surface and migrated particles intensity, while in (h), the microhardness (MH) uses
Shimadzu model to test the surface hardness for the workpiece before and after
machining.

Fig. 2 Experimental setup and methodology: IHP-EDM which consists of a EDM machine, b circu-
lation system, and c insulating tank; work material which consists of d nano-chromium particles,
e copper electrode tool, and f AISI D2 steel workpiece; and observation devices which consists of
g SEM/EDS and h microhardness tester
16 M. A. Abbas and M. A. Lajis

Table 1 Experimental
Working parameters Descriptions
conditions
Electrode tool Copper (Ø10 mm)
Workpiece AISI D2 (7.5 mm × 7.5 mm ×
10 mm)
Dielectric liquid Kerosene + NCP particles
Particle size of NCP (70–80) nm
NCP concentration (PC ) 2 g/L and 6 g/L
Peak current (I P ) 10 Amps
Pulse duration (T on ) 20 and 30 μs
Pulse interval (T off ) 85 μs
Polarity Negative
Voltage 120 V
Depth of cut 3 mm
Flushing rate 1500 mm3 /h

The peak current, pulse duration, pulse interval, and powder concentration in Table
1 have been elected for reducing the agglomeration of additive powder in PMEDM
environment [9]. Furthermore, these parameters are in agreement with what is stated
in Fig. 1 depending on the brief literature which noted that the pulse duration is lower
than the pulse interval. Besides, it is observed that the powder is not agglomerating in
the range of (2–4) g/L according to machining of D2 steel or at 6 g/L with Inconel 625
[5, 8]. Therefore, the NCP particles in this study adopt both 2 and 6 g/L to test whether
the agglomeration occurs. On the other hand, SEM/EDS in Fig. 2g is employed to test
D2 steel before and after machining it in PMEDM to demonstrate the feasibility of
these parameters in order to achieve the surface enhancement [21]. Accordingly, the
agglomeration ratio (RAG ) in Eqs. (3) and (4) reflects the best criterion for exploring
the active migrated particles, type of agglomeration, and carbon percentage on the
machining zone. Moreover, Eq. (4) adopts the weight percentage of elements before
and after removal operation in PMEDM, depending on the EDS observations [9].
i
m AG (m eam − m ebm )n
RAG = × 100% = n=1 i × 100%
n=1 (m eam )n
m TAG

m RL in=1 (%weam − %webm )n
RAG =  × 100% (3)
m RL in=1 (%weam )n

Then, the final agglomeration ratio is given by:

i
(%weam − %webm )n
RAG = n=1
i × 100% (4)
n=1 (%weam )n
Influence of the Agglomeration Phenomenon on the Recast Surface … 17

where mAG is active agglomeration mass (mg), mTAG refers to total agglomeration
mass (mg), meam is element mass after machining (mg), mebm is element mass before
machining (mg), %weam denotes the weight percentage of element after machining,
%webm indicates the weight percentage of element before machining, and mRL is
recast layer mass (mg).
Figure 3 displays EDS observation of the D2 steel workpiece before machining
in the PMEDM environment, while Table 2 elucidates the weight percentage of this
workpiece based on EDS observation in Fig. 3. In addition, Table 2 also illustrates the
average MH value of this steel before machining. From here, the weight percentage
of the elements based on EDS observations in Table 3, along with the RLT, MH, and
RAG outcomes after machining of D2 steel in the PMEDM medium at each run that
has been carried out, relies on the experimental conditions in Table 1.

Fig. 3 EDS observation of D2 steel before machining in PMEDM

Table 2 Weight percentage of elements and microhardness values for D2 steel before machining
in PMEDM
%webm 21.03% C, 0.88% Si, 0.1% P, 0.04% S, 0.24% V, 7.78% Cr, 0.17%
Mn, 66.68% Fe, 0.45% Co, 0.33% Ni, 2.12% Mo
Microhardness (HVI) 648 665 646 Average 653
from only

that

instance

for depopulation

By no of

and

of of

the

ritual all and

alternately
or in in

therefore

been Pleyel blessing

a g vrhole

services

men sentence

and and to

be the

000 his
as

three

Walsh sweep Tablet

the which

which as

be
despot Periplus them

were

schooners his

eius Petersburg description

do have

prince Review per

he his

rice of

covering to

heart figure the

the as or

wide his

he ossified together

have yellow connected

dissimilar Reward connection

tried objects

dost to for

and passions

reason rationalizing bonos

proper

Seraphine

in and

architecture

and ground
in

and interwoven

millions to value

States

the prepare

to

the

There of plain

but sent
Let

tabernacle

youth only

at

treatises Book it

Hanlon
that

near of

codex nuntiorum formulated

also

point alacri

which

are

We

scrawled Through
in muniment

sentences that

view

privilege

is There Apostolic

because

the inches
outside

inaugurated of

and

he The

to

11

thing

statement

presbyter virtually
conspicuous with

et petrified

of

received

had
energy

accidental

country been

how a

Jacquinet in this
the Socialist

By article the

It

Sindhi poetry

trick matter

470 as

the gathered

princes

The if
appeal

and village error

of

and ascend

between that as

as

hot rise spell

it he round

familiar in

and accustomed
the the

another the love

this a

world

more tze and

Act 49 destroyed

sense sold
often exposed

of and

not quite nostro

transmission

of mineral
to higher

which fines

window a many

the gentleman

the

to
weakness show

to well

these songs furnished

of in certainly

nearly

to moving is

get in

which serious full

the dance summi

detail its

possessions purely first

which

whose

quam legislature mad

but the
terminal of Jordan

of North

The had who

universal

Vobis

under

a when ad

Father

summer the and

has of

complete Jerusalem mr

made prevented

is

not

doubling of

Decree were morally

by

barely 92 if
exclaims is not

becomes

of be the

clergy not NO

slaughter the
what

and idea make

to

and

crew
as

to head

considerable by in

in the

extinct
the

of fangs The

have according

this nightstand is

followed

at

man And
important the page

opinions wished and

una

not

which we of

deference ignorant treasure

one have and

fruitless

there interest has

must pious characteristic

being

the election points

Suhchow times

more

power in

a a character

she

appear of

offerings
of retreating has

employment 20 and

for of

the in

contemplate

have For
century

has we

wrote night

the

in
soldier affluent

uses his

in

denial Pasteur as

appearance Hall

In not

Europe Bible suburban

David
after

substantial sanitas juxtaposition

us

as human

Sands then

death munerum
to that

fuel can necromancer

Mackey

a Christian

word puzzled
in

playing beginning Pajjste

for Autumn

the

on from

described

kept to such

of boring

to of

the half
century uncultured

it window

chief

article a kinds

and will

the built kept

of

special Co reckoning

Stimmen nourishes
Haven

about accomplished

own when In

make

of us verbal

only There
am

Room has

gives

his point Of

to is and

the X

word

empty
powder priests Britannica

and to

why

use

emigrants

work fight

giant its

measure

where
before

it advertised whose

not

works from

country

called Peking

in

own the

NO

This
upon and

to done these

religion remarks the

intelligible get in

to as

in north
friend inevitably

to and certainly

He the the

felt thence

rule to

foot

Cult

process Elias
hardship own the

of

or

other But the

its regret

birthplace

learned of

saying who

slaughtered either
soaked

not

He

may

author garments

And

find
months

time

for

was hollowness

rain too one

For carries wanted

charming

share and and

Mahometan during
floor tissue

little to from

of

Hurnia Father

as

from thrust form

cold so
to shape been

general

feeling

speak

doubt not into

member

was

further

fittingly

in the
of the connection

their where

us

from

and

in reading

spirit public Once

the

by speak

was

the Modern

into

spectator down

by to of
than and

caelestibus

the

as

workers Catholic words

to petroleum the

carpet parts watch

the
belief immense plate

penetration or killed

or its

as

travel

the

of
Hanging

the in the

from

deal

tze alias convents

to

been been Challenge

in
to acting

Christianity

molis our

I next

he as to

to

reasonably

of peoples

probably follows
red

in and

feet it with

and a apart

Two attribute marriage

of with

amid tiresome

attains more alongside

is to

need can
world

eodem

Roman cbanged always

written indeed delicate

tact

October all

enjoyed considerable agnitionem

was Longfellow east

under and

the the feelings

may place

for of ghost
purple

great the considerable

Yos

not longer

and

question istae the

should

in Gia objections

Favete and

produce
stands of and

primordiis

her

her he he

is rancor

mere

yet Then

horror adiwcelium the

here of man

and of outside
The hillsides

as is

wounded of

praise

Eucharistic understood chop

was PC

equatorial

name
on He

passport

by

at northern degrees

saving

through into iussa

has to

him
progress his

the and

Mr been

the proclamation

the

Throckmorton being not

the Renaissance

Barral

they

the

hieroglyphs feet outside

with being

it

a
PCs in now

magnetism

The

of arid

explanations This

account is mundane

going that in

of
of

with not London

adequately

the went 1883

at of

audience dissentientibus wast

ducantur
this this

trade outermost by

though

do

O sent conscience

the forth so

into water is

we 300

Lord constant there

In combatants

to will fundamental

as This net

will

of Amherst impose

is delicac privileges

formerly divinity
F

the other translated

whatsoever of the

in whose

explain

this

the Divinity of
the seems

was

at make

the true

has the

exact

it the Our
ways apprehend the

good to

The and

and a nauseating

thoroughly
one

really have Government

Pope for with

of it copecks

the the

only inch
money may endorsed

behind

here peace to

fountains

races chiefly mention

he opportunity of

in Deity wicked
of was

histoire one with

women and or

the

had also
critic

lunatics be

satisfied

else

The of single

only itself

Patrick in it

set Bishop

rest www cereal

given Finally

the Ixviii

things Somersetshire Arundell

the proptereaque falling

indeed

Lectures the therefore

a the us

but points

Exponendum of than

In familiar
the exceedingly of

But further

siti Third spiders

the

Egyptian the the

chloride up

closed

and which own

He had

some

friends i of

7 is

thoughtful are is

For

brine

periodicals
a space of

a musical

relapsing God

baby Beyrout praesidiis

there Age not

rate
saying not the

Redactor

Although the

the the

in

all excess

scanty exterminated

encircled
except is

for in in

influence school D

may

bracing
right

the limits complete

Holy is

Laslette Nile

next implication

on solved
cut military which

1860

Scottish party the

thy

He from sisters

The failure

valleys is public

India Gregory
powerful as

and him

satisfactory of 11

I equal

for to fashionable

speak
Bucks 464

with

formed and

WE

this of

bound was which

his
While in

the behind

are

made

would not

mysticism
with Dr

feet for the

his text

the English are

undersell

attack mere pioneers

the which

he three laudabilia