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Publications
Publications (97)
In this work a three phase 3D mathematical model was developed using the Volume Of Fluid (VOF) algorithm, which is able to accurately describe the cavity geometry and size as well as the liquid
flow
patterns created when a gas jet impinges on a two phase liquid
free surface. These phenomena are commonly found in steelmaking operations such as in...
In this work a fundamental Eulerian mathematical model was developed to
simulate fluid flow in a water physical model of an aluminum ladle
equipped with impeller for degassing treatment. The effect of critical
process parameters such as rotor speed, gas flow rate on the fluid flow
and vortex formation was analyzed with this model. Commercial CFD co...
Gas jets play a key role in several steelmaking processes as in the Basic Oxygen Furnace (BOF) or in the Electric Arc Furnace (EAF). They improve heat, mass and momentum transfer in the liquid bath, improve mixing of chemical species and govern the formation of foaming slag in EAF. In this work experimental measurements are performed to determine t...
The effect of the presence of two different primary phases on the microstructural characteristics and solidification kinetics
of Pb-Sn eutectic was analyzed using Fourier thermal analysis method (FTA) and microstructural characterization. Three Pb-Sn
alloys, a hypoeutectic, an eutectic, and a hypereutectic alloy, were melted in an electric furnace...
Zn-Ag-Cu alloys have recently attracted attention as alloy candidates for biomedical applications, but, to date, they have not achieved the required mechanical properties. To improve the mechanical properties of Zn-Ag-Cu-base alloys, in this work, the effects of the presence of increasing amounts of Ag and Cu as alloying elements on the properties...
In this work, the Planar Laser-Induced Fluorescence (PLIF) technique is applied to study the effect of the number of nozzles, their radial position and the gas flow rate on the thermal mixing during the secondary steel refining under non-isothermal conditions in a water model. In the physical model, three burners have been used to simulate the arc...
This work studied the effects of the angle between nozzles, oil thickness, gas flow ratio, and gas flow rate on mixing time and open eye area in a physical model of a gas stirred ladle with dual plugs. The effect of the variables under study was determined using a two‐level factorial design. Particle image velocimetry (PIV) was used to establish, t...
Particle image velocimetry (PIV) and planar laser-induced fluorescence (PLIF) are synergically used to study from first principles the relative importance of the mass transport mechanisms governing the mixing of tracers in a physical model of a gas-stirred ladle. A scaled 1/17th physical model of a 200 ton prototype is used to obtain flow patterns...
A 1/17th water physical model of a 200-ton steel ladle furnace with a single gas injection was used to simulate bath heating using a single burner to mimic the heat flux due to electric arcs in the industrial steel ladle. Two phases were considered, using water to simulate the molten steel and air to simulate the argon injection at a flow rate of 1...
Ladle refining plays a crucial role in the steelmaking process, in which a gas stream is bubbled through molten steel to improve the rate of removal of impurities and enhance the transport phenomena that occur in a metallurgical reactor. In this study, the effect of dual gas injection using equal (50%:50%) and differentiated (75%:25%) flows was stu...
In this work, a new computer-aided cooling curve analysis method (CA-CCA) called metal/mold energy balance method (MEB) is presented. Its originality relies on taking into account the thermal history, the mass, and the heat capacity of both the sample and the mold containing it, for the determination of the latent heat of fusion and the evolution o...
The planar laser-induced fluorescence (PLIF) technique was implemented to measure mixing time in a 1/17 water model of a 200-ton ladle furnace. The results were compared to those obtained using the conventional method of pH probes. PLIF determinations were done at two different planes, and pH probe determinations were performed at two different loc...
In this work, the effects of equal (50%/50%) or differentiated (75%/25%) gas flow ratio, gas flow rate, and slag thickness on mixing time and open eye area were studied in a physical model of a gas stirred ladle with dual plugs separated by an angle of 180°. The effect of the variables under study was determined using a two-level factorial design....
Mixing phenomena in metallurgical steel ladles by bottom gas injection involves three phases namely, liquid molten steel, liquid slag and gaseous argon. In order to numerically solve this three-phase fluid flow system, a new approach is proposed which considers the physical nature of the gas being a dispersed phase in the liquid, while the two liqu...
An experimental study of the gas‐liquid dynamics in a water model of an aluminum ladle was conducted. The rotor degassing performance was evaluated for two commercial rotor‐injector devices compared to a new rotor design. In this work, the influence of the turbulent properties of the flow fields on the bubble size distribution is analyzed for a bet...
In this work is described a new cooling curve analysis method focused on the experimental determination of the latent heat of phase changes and phase transformation kinetics.The method analyses the cooling process of a metallic sample, initially liquid that is contained into a cylindrical metallic mold, both of known weight, thermally isolated at i...
Ladle refining plays a key role in achieving the quality of the steel since in this reactor temperature and chemical composition is adjusted, elimination of non-metallic inclusions is performed, and also deoxidation and desulphurization are operations taking place in the refining process. Specifically, the metal-slag mass exchanges have not receive...
The hydrodynamic performance of a gas-stirred ladle is analyzed experimentally, through a factorial experimental design, through physical modeling and particle image velocimetry techniques, to find the effects of the nozzle position, and its number, the gas flow rate and the presence or not of an oil layer on the flow velocity field, the turbulent...
Recent studies on aluminum degassing [1, 2] show that although the impeller speed and the gas flow rate are important process variables in terms of the productivity and operational costs, the impeller design is also a key design parameter influencing the productivity and the quality of the aluminum in foundry shops. In this work, an improved design...
A mathematical model was developed to describe the hydrodynamics of a batch reactor for aluminum degassing utilizing the rotor-injector technique. The mathematical model uses the Eulerian algorithm to represent the two-phase system including the simulation of vortex formation at the free surface, and the use of the RNG k-ε model to account for the...
Ladle refining plays a key role in achieving the quality of the steel. Specifically the metal-slag mass exchange is studied through a scaled water physical model
in which thymol, a solute, is added to the water (steel) and silicon oil (slag) picks up the thymol, while the ladle is agitated with the central gas injection and samples of water were ta...
The hydrodynamic performance of a stirred ladle, for an aluminum degassing system in turbulent regime, is analyzed experimentally. This study explores the dynamic flow features due to the bubble dispersion on the gas–liquid flow. Diverse impellers with geometrical differences are tested with the purpose of comparing the influence in the flow behavi...
A physical model of a batch aluminum degassing reactor equipped with the rotor-injector technique was used to measure deoxidation kinetics of water, assuming that this kinetics is similar to dehydrogenization of aluminum. Performances of three different impeller designs were tested with the model, two of them available commercially, while the third...
A very realistic 1:17 scale physical model of a 140-ton gas-stirred industrial steel ladle was used to evaluate flow patterns measured by Particle Image Velocimetry (PIV), considering a three-phase system (air-water-oil) to simulate the argon-steel-slag system and to quantify the effect of the slag layer on the flow patterns. The flow patterns were...
In this study a process analysis of the melting process of solid particles in a bath of same composition is performed using both experimental information and theoretical computations. An experimental setup was used to measure the thermal histories and to follow the evolution with time of the size of solid metallic spherical particles being melted i...
A methodology is proposed to obtain the grain growth coefficients operating during solidification of a near eutectic Al-Ni alloy from data on solid fraction evolution, latent heat of solidification and., volume grain density. These parameters are obtained using Newton Thermal Analysis
(NTA), metallographic methods and the Free Growth Method (FG)....
Mathematical and physical models of water deoxidation in a batch aluminum degassing reactor using the rotor-injector technique were developed. The mathematical model was successfully validated against measured degassing kinetics. The physical model was employed to perform a process analysis using a two-level factorial experimental design to determi...
A mathematical model is developed to describe deoxidation of water in a physical model of a batch aluminum degassing reactor equipped with the rotor-injector technique, assuming that deoxidation kinetics of water is similar to dehydrogenization of liquid aluminum. Degassing kinetics is described by using mass transport and mass balance principles b...
In this work a methodology is applied to describe quantitatively grain growth during solidification of a near eutectic Al-Cu alloy using cooling curves, volume grain density and solid fraction evolution data. The methodology assumes free grain growth before impingement and an exponential dependence of the grain growth rate on undercooling. Informat...
A study of the fluid flow in a mixing device proposed to dissolve alloying elements in iron baths is performed through a mathematical model in order to predict the best operating conditions for a proper melting/dissolution of solid alloying particles. The mathematical model consists in the mass and momentum conservation equations (continuity and Tu...
In this work the thermal and kinetic analysis of the cooling and solidification of a near eutectic Al-Cu alloy is performed using inverse thermal and solidification kinetics analysis. The Fourier thermal analysis is applied to experimental cooling curves to obtain data on solid fraction evolution and latent heat of solidification. Inverse thermal a...
Melting of Direct Reduced Iron (DRI) pellets in Electric Arc Furnaces (EAF) in steelmaking production is a common practice worldwide. Mathematical models are proper tools to study the phenomena involved in melting DRI. In this work we develop a mathematical model to predict melting kinetics of DRI in a liquid slag bath. The model is successfully va...
In the current study a transparent water physical model was developed to study fluid flow and turbulent structure of aluminum ladles for degassing treatment with a rotating impeller and gas injection. Flow patterns and turbulent structure in the ladle were measured with the particle image velocimetry technique. The effects of process parameters suc...
The purpose of this work was to explore the differences in solidification kinetics between unmodified and Sr modified eutectic Al-Si alloy as revealed by Fourier Thermal Analysis (FTA) and grain-growth kinetics characterization. Thermal analysis were performed in cylindrical stainless steel cups coated with a thin layer of boron nitride, using two...
In the present work, the effect of Bi in the lead free yellow brass alloy is studied, due to a crack formation during the solidification process. Visual inspections, optical microscopy (OM) and scanning electron microscopy (SEM/EDS) studies were carried out, also simulations in ProCast v.2008 were made in order to determine the failure analysis. Re...
The aim of this work was to explore changes in the solidification kinetics associated with the presence of modified and nonmodified Al-Si eutectic in Al-Si alloys, as revealed by Newton thermal analysis (NTA). Hypoeutectic and near eutectic Al-Si melts with different Sr contents were produced in silicon carbide crucibles. The addition of strontium...
In this work, a 3D numerical simulation using a Euler-Euler-based model implemented into a commercial CFD code was used to simulate fluid flow and turbulence structure in a water physical model of an aluminum ladle equipped with an impeller for degassing treatment. The effect of critical process parameters such as rotor speed, gas flow rate, and th...
The purpose of this work is to compare the results obtained from three methodologies intended to estimate kinetic parameters describing quantitatively the grain growth during equiaxed eutectic solidification in order to identify the best procedure to characterize grain growth kinetics. A heat transfer / solidification kinetics model is implemented...
A full scale water physical model of an aluminum degassing crucible was built to analyze the effect of changing the point of gas injection, from the conventional location, through the shaft, to an injection underneath impeller, on the performance of three rotor designs, based on the oxygen kinetic elimination from water by N2 injection, similar to...
In this work a methodology to measure kinetic parameters to describe grain growth during equiaxed eutectic solidification is proposed. This methodology includes the numerical processing of two cooling curves and requires input data concerning the number of grains per unit volume. In addition, free grain growth before impingement and an exponential...
Gas injection in metallurgical vessels is an important tool to improve chemical and thermal mixing. Chemical mixing has been extensively studied in the past 40 years, however, thermal mixing is still poorly understood. This work reports a mathematical model developed to describe the effect of the number and position of porous plugs on thermal and c...
Samples with hook cracks were analyzed in order to find their origin. For that purpose, samples were analyzed by using optical and scanning electron microscopes. WDX-microanalyses performed in areas close to and into the crack detected the presence of a spinel, which showed a MgAl2O4 stoichiometry. In order to find the origin of this spinel, analys...
The effects of two variables on the NiAl intermetallic compound were studied: 1) copper macroalloying additions and 2) rapid solidification processing. For that purpose, several NiCuAl alloys were vacuum induction melted and rapidly solidified by using a copper wheel, rotating at 15 m/s, under an argon atmosphere. Chemical analysis of as-rapidly so...
The purpose of this work is to explore the capability of Fourier Thermal Analysis (FTA) to detect differences in solidification kinetics between unmodified and Sr modified eutectic Al-Si alloy obtained from the same base alloy. Experimental melts are produced in silicon carbide crucibles using an electrical resistance furnace and burdens of A356 al...
The purpose of this work was to determine the capability of Newton Thermal Analysis (NTA) to detect differences in solidification kinetics between non modified and Sr modified Al-Si alloys obtained from the same base alloy. Hypoeutectic and near eutectic melts were produced in silicon carbide crucibles using an electrical resistance furnace and bur...
Experimental trials were carried out using a green sand mold test casting for ductile iron (DI) designed according to pressure control risering method (PCR). The system is composed by a gating system connected to a blind riser feeding a cubic casting through a rectangular neck. The system was used to explore the effect of pouring temperature and C...
Previous works attempting to simulate DC arcs have assumed the plasma gas to be composed by 100% air, consequently, the arc region has been represented by solving the equations that govern the process, i.e. heat and mass conservation equations coupled to the turbulent Navier-Stokes equations. A real plasma gas is composed by a complex mixture of se...
Solidification of a simple casting made of ductile iron is mathematically modeled in this work. The model is able to numerically simulate the cooling rate and solidification of the whole casting system composed by a cubic piece, a blind riser connected through a rectangular neck, and immersed in a green sand mold. The center of the neck acts as a v...
In order to explore the effect of the presence of SiC particles on dendritic coherency during solidification of Al–Si based metallic alloys, a factorial fractional two levels experimental design was implemented to allow an identification of the main effects of the particle content, silicon content, grain refinement, and cooling rate on the solid fr...
In this work a fundamental Eulerian mathematical model is developed to simulate fluid flow and mixing phenomena in aluminum ladles equipped with an impeller for dehydrogenization treatment. The effect of rotating speed and type of impeller, depth of immersion, and gas flow rate, on the mixing behavior and vortex formation is analyzed with this mode...
This work was intended to explore the reliability of the Newtonian thermal analysis method as a tool for the quantification of the amount of alloy microconstituents formed during solidification as observed at room temperature in alloy systems without phase transformations in the solid state. This technique was applied to three hyper eutectic Pb–Sn...
In this work a fundamental Eulerian mathematical model was developed to study fluid flow and mixing phenomena in aluminum ladles equipped with impeller for deshidrogenization treatment. The effect of critical process parameters such as rotor speed, depth of immersion, gas flow rate, and type of rotor on the mixing behavior and vortex formation was...
In this work a fundamental Eulerian mathematical model was developed to study fluid flow and mixing phenomena in aluminum ladles equipped with impeller for deshidrogenization treatment. The effect of critical process parameters such as rotor speed, depth of immersion, gas flow rate, and type of rotor on the mixing behavior and vortex formation was...
The purpose of this work is to analyze the capability of Newton Thermal Analysis (NTA) to detect differences of the solidification kinetics between eutectic gray and ductile irons obtained from the same base alloy. The NTA experimental output has been analyzed with a simple micro-macro modeling approach. The outcome of this work suggests that NTA h...
The purpose of this work is to explore the effect of the presence of two different primary phases on the microstructure and solidification kinetics of Pb-Sn alloys. The experimental results have been compared with predictions obtained from the Newton Thermal Analysis of cooling curves generated by a conventional heat transfer-solidification kinetic...
The microstructural and mechanical properties of an ultra-clean low carbon steel sheet with 0.035% Cr have been evaluated. The isothermal recrystallization kinetics at 800°C is analyzed by using the Kolomogorov-Johnson-Mehl-Avrami (KJMA) equation. The obtained results indicate that Cr retards the recrystallization kinetics owing to the presence of...
A Ni57Fe18Al25 alloy is produced by vacuum induction melting under an argon atmosphere and gravity cast into a copper chill mould. Ingots of 2 × 10 × 50 mm are re-heated at 1100°C for 24 hours and hot rolled until a 25 % reduction is reached. Immediately, hot rolled plates are heat treated at 1100°C for 1 hour and water cooled to room temperature....
This work explores the feasibility of using the Newton Thermal Analysis method (NTA) as an alternative technique for quantitative determination of the relative volume fractions of the microconstituents formed during solidification of three hypereutectic Pb-Sn alloys. The results suggest that NTA has a good potential as a quantitative microstructure...
The distribution of solute in α-Al matrix of directionally solidified Al–5.3at.% (12wt.%) Zn master alloy with additions of 5.5–11.5at.% (4.6–9.2wt.%) Mg was determined and predicted according to the model for dendrite solidification of multicomponent alloys with unequal liquid diffusion coefficients. Predictions showed a good agreement with experi...
The resulting microstructure obtained in solidified Al–Zn–Mg alloys was characterized and predicted using the vertical section in 5.3 at.% Zn of the ternary Al–Zn–Mg phase diagram together with thermal analysis data and multicomponent equations for dendrite and intermetallic growth. In addition, results of characterization and prediction of microst...
Decorative properties of aluminum-molibdenum alloys have been analyzed as a function of chemical composition and applied heat treatment. These decorative application are due exclusively for their nanostructure nature. The alloys were prepared at room temperature by DC magnetron sputtering technique in argon atmosphere at different deposition time t...
Decorative properties of aluminum-molibdenum alloys have been analyzed as a function of chemical composition and applied heat treatment. These decorative application are due exclusively for their nanostructure nature. The alloys were prepared at room temperature by DC magnetron sputtering technique in argon atmosphere at different deposition time t...
An addition of Ti or Ti/B is an accepted technique to produce cast aluminum alloys having fine grain size and superior mechanical properties. Present investigation focuses on the role of grain refinement treatment on the SiC particle distribution in Al-7 wt.% Si-10 vol.% SiCp cast composites and also on the degree of refinement of matrix microstruc...
The aim of this work was to explore the effect of the presence of SiCp on the solidification kinetics and the microstructural characteristics of A356/SiCp cast composites by using the Fourier thermal analysis (FTA) method. The tests were performed in order to identify changes in the solidification kinetics of the metal matrix that could be caused b...
The effect of additions of Sr (in the range 0.05–0.5%) on the microstructural characteristics of Al–7wt.% Si–10vol.% SiCp composites have been studied. Optical microscopy (OM), SEM, EDS, WDS microanalysis techniques and X-ray diffraction powder techniques have been used for the characterization of the composites. It was found that Sr concentrations...
An analysis of the structure obtained in gravity chill cast Al-Zn-Mg ingots was carried out. The microstructure consisted of α-dendrites, τ-intermetallic in solid solution and eutectic in interdendritic regions. The electrochemical behavior of alloys in both cast and heat-treated conditions was investigated in 3% NaCl solution. Results showed that...
The aim of this work is to explore the feasibility of the computer aided thermal analysis as a tool for SiCp content quantification in molten Al–Si/SiCp composites. This technique was applied to three cases of interest: (1) the metal matrix alloy A356, without SiCp particle reinforcement, (2) A356/8% SiCp MMC and (3) A356/18% SiCp MMC. Tests were p...
This work shows the results obtained of the microstructural analysis by optical microscopy (OM) and scanning electron microscopy (SEM-EDX) and its relationship with the mechanical properties of Al–7Si–0.5Cu, Al–7Si–1.5Cu, Al–7Si–0.5Ni and Al–7Si–1.0Ni cast alloys. These cast alloys were manufactured in two conditions: nonmodified and modified with...
This work carries out an analysis of the structure obtained in gravity chill cast Al-5.3 at. % Zn with additions of 5.3, 6.5, 7.5 and 11.5 at. % Mg, The as-cast microstructure consisted of α-Al dendrites, the intermetallic τ in α-Al solid solution and eutectic α+τ in interdendritic regions. The electrochemical behavior of alloys in both as-cast and...
In the present research, Al-Zn-Mg alloys were vacuum induction melted and gravity cast into steel molds. Ingots were microstructurally
and electrochemically characterized to evaluate their performance as Al-sacrificial anodes for cathodic protection of structures
exposed to marine environments. The microstructure observed in as-cast ingots consiste...
The synthesis and bending strength of nanocrystalline β-phase NiAl intermetallic compound macroalloyed with copper are discussed in this paper. Nanocrystalline NiCuAl powders were prepared by mechanical alloying of elemental Ni, Al and Cu powders under argon atmosphere. The alloyed nanocrystalline powders were consolidated by double action pressing...
The purpose of this work was to explore the effect of the presence of different quantities of SiCp on the cooling curve characteristics, latent heat released and solidification kinetics, associated with the cooling and solidification of Al-Si/SiCp composites produced by the stir casting process. An increase in SiCp content in A356/SiCp metal matrix...
The purpose of this work was to explore the effect of the presence of different quantities of SiCp on the cooling curve characteristics, latent heat released and solidification kinetics, associated with the cooling and solidification of Al-Si/SiCp composites produced by the stir casting process. An increase in SiCp content in A356/SiCp metal matrix...
Several steel plates in the as-hot rolled plus cooled condition were studied, in order to evaluate the impact of the steelmaking route and the controlled thermomechanical processing plus the cooling media, on the resulting microstructure and mechanical properties of steel plates, which will be processed to produce large diameter steel pipes with so...
This study carried out a characterization of chill-cast NiAl alloys with copper additions, which were added to NiAl, such
that the resulting alloy composition occurred in the β-field of the ternary NiAlCu phase diagram. The alloys were vacuum induction
melted and casted in copper chill molds to produce ingots 0.002 m thick, 0.020 m wide, and 0.050...
In order to investigate the effect of Cu-macroalloying and rapid solidification processing on NiAl intermetallic compounds, six alloys were studied. Four alloy compositions were inside the β-NiAl field, one alloy composition was in the upper limit of the β-NiAl field and one was far from this β-NiAl field going to the (β-NiAl–Cu3Al) field. Lattice...
The solution treatment of an as-cast ASTM F-75 alloy was investigated. Microstructural evolution was followed during thermal processing, in particular with regard to the content and type of carbides formed. To evidence any probable carbide transformations occurring during the heating stage, as well as to clarify their effect on the carbide dissolut...
Three ultra-low carbon/titanium (Ti) added steels in the as-annealed condition were evaluated in order to determine their mechanical properties, in terms of the percentage elongation and the Lankford value, as well as their corrosion behaviour. The examination of the processed steels form part of a research program that has the objective of develop...
The aim of this work is to explore the phenomenology that describes the local solid formation and heat transfer occurring during sand cast alloys solidification in order to propose an explanation to the observed changes of local microstructural characteristic lengths in hypoeutectic and eutectic Al–Si based alloys. Microstructural observations are...
A series of ultra low carbon/Ti added steels were produced with the aim of evaluating the steelmaking route and processing conditions of slabs, in order to achieve mechanical properties on resulting annealed sheets adequate for automotive applications. Characterization of microstructure was carried out in the as-cast, deformed and annealed specimen...
An API 5L X-70 grade steel for large diameter pipeline application with sour gas resistance was developed. The resulting Fe–C–Mn–Nb slabs were controlled rolled and accelerated cooled. In most of the slabs, mechanical properties equivalent to the above grade were broadly achieved. However, despite achieving excellent mechanical properties, during t...
Recently, Fourier thermal analysis (FTA) has been proposed as a suitable technique to obtain information about local solidification
kinetics in casting alloys. In this work, FTA was applied to a near-eutectic aluminum-silicon cast alloy in order to seek
experimental evidence supporting the solidification kinetics obtained from this method. Also, a...
A new method for the modification of aluminum-silicon eutectic using sodium salts has been developed. The proposed method eliminates the problem of fading associated with the conventional modification in the ladle. The fundamentals of the method and some relevant aspects related to its industrial implementation are discussed. Also, the results obta...
A coupled heat transfer and solidification kinetics model is employed to predict the thermal history, the solidification kinetics and the secondary interdendritic arm spacing as a function of the radial position within cylindrical A356 alloy sand castings. The model predictions are compared with experimental results by using, for the solidification...
Corrosion of reinforcing steel can seriously limit the service life of concrete structures in marine applications. Chloride diffusion is one of the two major problems causing this phenomenon, increasing when the concrete is exposed to a marine environment in coastal areas. The service life of a structure may be divided into two general phases: an i...
A low carbon Al-killed/Ti-added steel was processed in a Mexican steel company as a part of a research program which has the scope of developing ultra low carbon steels for automotive applications. Microstructural characterization of slab in the as-cast and re-heated conditions prior to the rolling operations is presented, giving emphasis to the nu...
In order to explore the behavior of ductile iron (DI) liquid melts producing a good casting free of shrinkage defects, using the pressure controlled risering method (PCR) in green sand molds, experiments have been carried out using three DI alloys with carbon equivalent (C.E.) values corresponding to hypoeutectic, eutectic and hyper eutectic alloys...
A full scale water physical model of an aluminum degassing crucible was used to analyze the kinetics and removal efficiency of dissolved oxygen from water by N 2 injection, similar to hydrogen removal from liquid aluminum. Different process parameters were studied, such as impeller design (two impellers designs were used, named "B" and "C"), rotati...
