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15 pages, 53267 KiB  
Communication
Tribological Behavior of the Laser Micro-Textured PEEK-1040 Steel Friction Pairs
by Risheng Long, Haiming Wang, Jincheng Hou, Qingyu Shang, Yimin Zhang, Lin Zong and Zhijun Zhang
Polymers 2025, 17(5), 645; https://doi.org/10.3390/polym17050645 - 27 Feb 2025
Abstract
To compare them with PTFE-40# steel tribo-pairs, the tribological properties of textured PEEK-40# (AISI 1040) steel friction pairs were researched under full-film lubrication conditions by manufacturing micro-dimples with different dimensions on the contact surfaces of 1040 steel discs using laser surface texturing (LST). [...] Read more.
To compare them with PTFE-40# steel tribo-pairs, the tribological properties of textured PEEK-40# (AISI 1040) steel friction pairs were researched under full-film lubrication conditions by manufacturing micro-dimples with different dimensions on the contact surfaces of 1040 steel discs using laser surface texturing (LST). After repeated tribological tests, the coefficients of friction (COFs), wear losses, and wear morphologies of the PEEK-1040 steel friction pairs were measured and analyzed. The results show that micro-dimples do not significantly reduce the average COFs of PEEK-1040 steel friction pairs when lubricated with a sufficient amount of hydraulic oil, but they do reduce the wear losses of most groups. When the dimple diameter was 250 μm, the dimple depth was 5 μm, the area ratio was 6.6%, and the mass loss of the 1040 steel disc was reduced by 90% compared to the smooth reference. In comparison to the behavior of the PTFE-1040 steel tribo-pairs, PEEK-1040 steel friction pairs can provide better tribological performance, whether smooth or dimple-textured. This study offers important insights for the design of seals in machinery. Full article
(This article belongs to the Section Polymer Applications)
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<p>(<b>a</b>) Photo of the 1040 steel disc; (<b>b</b>) section view and texture design of the 1040 steel disc; (<b>c</b>) representative 3D morphology of dimple-textured surface of the 1040 steel disc before being re-polished; (<b>d</b>) sectional profile curve of micro-dimples in (<b>c</b>); (<b>e</b>) photo of PEEK ring; (<b>f</b>) section and top views of the PEEK ring.</p>
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<p>COF data of the PEEK-1040 steel friction pairs under full-film lubrication conditions: (<b>a</b>–<b>d</b>) COF curves of T1-T4; (<b>e</b>–<b>h</b>) COF curves of R1-R4; (<b>i</b>–<b>l</b>) COF curves of X1–X4; (<b>m</b>–<b>q</b>) COF curves of X5-1~X5-5; (<b>r</b>) average COFs of 17 groups.</p>
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<p>Representative wear morphologies and wear losses: (<b>a</b>) wear morphologies of the PEEK rings after ultrasonic washing; (<b>b</b>) wear losses of the PEEK rings and 1040 steel discs: (<b>b1</b>) wear losses of T1–T4; (<b>b2</b>) wear losses of R1–R4; (<b>b3</b>) wear losses of X1–X4; (<b>b4</b>) wear losses of X5-1~X5-5.</p>
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<p>Representative three-dimensional wear morphologies of the PEEK rings after ultrasonic washing.</p>
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<p>Representative wear morphologies of the 1040 steel discs after ultrasonic washing and the characteristic infrared absorption peaks of the PEEK transfer film: (<b>a</b>) wear morphologies of the 1040 steel discs; (<b>b</b>) typical infrared spectral characteristics of the PEEK collected on the surface of 1040 steel discs.</p>
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<p>Representative three-dimensional wear morphologies of the 1040 steel discs after ultrasonic washing.</p>
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<p>Representative wear morphologies of the 1040 steel discs with PEEK transfer films before ultrasonic washing.</p>
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16 pages, 3362 KiB  
Article
Effect of Leaching of Ionic Rare Earth Ores on the Permeability Coefficient of Mineral Soil and Its Correlation with the State Parameter
by Run Xiang, Yunzhang Rao, Jiyong Zhang, Laiye Zhang and Zhihua Yang
Metals 2025, 15(3), 258; https://doi.org/10.3390/met15030258 - 27 Feb 2025
Abstract
The permeability of ionic rare is a crucial factor influencing the leaching rate of rare earth elements. In the Gannan region, many ionic rare earth ores exhibit poor permeability and high compressibility compared to sandy soils. The permeability coefficient is a key indicator [...] Read more.
The permeability of ionic rare is a crucial factor influencing the leaching rate of rare earth elements. In the Gannan region, many ionic rare earth ores exhibit poor permeability and high compressibility compared to sandy soils. The permeability coefficient is a key indicator of the hydraulic performance of these ores. Thus, this study investigates the permeability coefficients of ionic rare earth ores with varying fines contents during the leaching process, with a specific focus on analyzing the impact of fines on permeability performance. To provide a comprehensive assessment of the influence of fines, we prepared ionic rare earth ore samples with fines contents of 5%, 10%, 15%, 20%, 25%, and 30%, ensuring that the overall particle size distributions remained consistent with the original gradation. A constant head permeability test was employed to measure the permeability coefficients of these ore samples throughout the leaching process. We specifically examined how varying fines contents influenced permeability across the upper, middle, and lower layers of the ore body, as well as the overall permeability when subjected to both distilled water and magnesium sulfate solutions. To further elucidate the differences in permeability performance among the various rare earth ore samples, we performed a data fitting analysis of the initial permeability coefficients against fines content, uniformity coefficient, average particle diameter, and void ratio. This analysis aims to quantify the fines effect across different rare earth ores and establish correlations among state parameters, such as fines content, and the initial permeability coefficient. Full article
17 pages, 10802 KiB  
Article
Low Brine Shrimp Bio-Toxicity Marine Lubricating Hydraulic Fluid with Ultra-Low Friction Coefficient and Enhanced Frictional Heat Suppression
by Wei Li, Huanyi Chen, Long Chen, Shanqin Ge, Qingzhao Cai, Genxiang Gong, Jinhong Yu, Kazuhito Nishimura, Nan Jiang and Tao Cai
Lubricants 2025, 13(3), 103; https://doi.org/10.3390/lubricants13030103 - 26 Feb 2025
Viewed by 158
Abstract
Hydraulic technology has been instrumental in the extensive application of offshore mechanical equipment, particularly in drilling platforms and ships, where high-performance hydraulic fluids are essential for safe and efficient operations. Addressing the urgent need for water-based hydraulic fluids as an alternative to traditional [...] Read more.
Hydraulic technology has been instrumental in the extensive application of offshore mechanical equipment, particularly in drilling platforms and ships, where high-performance hydraulic fluids are essential for safe and efficient operations. Addressing the urgent need for water-based hydraulic fluids as an alternative to traditional oil-based fluids, this study introduces a novel water-based hydraulic fluid fortified with phytic acid, derived from plant seeds, to achieve low biotoxicity, low coefficient of friction, and reduced frictional heat generation. The integration of phytic acid has significantly enhanced the lubricating performance, reducing the average coefficient of friction to as low as 0.013, as tested by the four-ball tester, which is the lowest value reported to date. Real-time monitoring of the temperature rise of the friction testing apparatus using an infrared thermal imager revealed a 78.6% reduction in temperature increase. Acute toxicity assays using Brine Shrimp demonstrated that the 96 h LC50 value for the water–glycol flame-resistant hydraulic fluid with added phytic acid exceeded 26,304 mg/L, indicating low toxicity. Characterization analyses elucidated the mechanisms underlying the improved tribological properties, highlighting the potential of this eco-friendly fluid for safe and efficient offshore operations. Full article
(This article belongs to the Special Issue Novel Lubricant Additives in 2025)
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<p>(<b>a</b>) Coefficient of friction curves of HFC-PA-0, HFC-PA-1, HFC-PA-2, HFC-PA-4, and HFC-PA-8 under a load of 392 N with a speed of 1200 r/min. (<b>b</b>) The friction coefficient curves of HFC-PA-4 and the internationally leading commercial hydraulic fluid Castrol under the conditions of 392 N and 1200 r/min, (<b>c</b>) Under the test conditions of 392 N and 1200 r/min, the comparison of friction coefficients of lubricants from different literature sources is as follows [<a href="#B31-lubricants-13-00103" class="html-bibr">31</a>,<a href="#B32-lubricants-13-00103" class="html-bibr">32</a>,<a href="#B33-lubricants-13-00103" class="html-bibr">33</a>,<a href="#B34-lubricants-13-00103" class="html-bibr">34</a>,<a href="#B35-lubricants-13-00103" class="html-bibr">35</a>,<a href="#B36-lubricants-13-00103" class="html-bibr">36</a>,<a href="#B37-lubricants-13-00103" class="html-bibr">37</a>,<a href="#B38-lubricants-13-00103" class="html-bibr">38</a>,<a href="#B39-lubricants-13-00103" class="html-bibr">39</a>].</p>
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<p>The experiment was conducted under conditions of a 392 N load and a rotational speed of 1200 revolutions per minute, (<b>a</b>) Temperature curves of lubricants (HFC-PA-4, HFC-PA-0, and Castrol), (<b>b</b>) Thermal images of equipment with HFC-PA-4, HFC-PA-0, and Castrol lubricants.</p>
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<p>(<b>a</b>) Biological toxicity testing method schematic diagram and (<b>b</b>) biological toxicity test results for HFC-PA-4 and Castrol.</p>
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<p>(<b>a</b>) Cross-sectional TEM image of worn surface lubricated by HFC-PA-0, (<b>b</b>) Crystal lattice image at position 3#, (<b>c</b>) Elemental content at different positions corresponding to TEM images, and (<b>d</b>) Corresponding EDX elemental map of TEM images.</p>
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<p>(<b>a</b>) Cross-sectional TEM image of worn surface lubricated by HFC-PA-4, (<b>b</b>,<b>c</b>) Crystal lattice image and diffraction pattern at position 3#, (<b>d</b>) Elemental content at different positions corresponding to TEM images, (<b>e</b>) Corresponding EDX elemental map of TEM images.</p>
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<p>XPS spectra of the steel balls wear track surface when using HFC-PA-4 solution as a lubricant: (<b>a</b>) Overview, (<b>b</b>) C 1s, (<b>c</b>) P 1p, (<b>d</b>) O 1s, and (<b>e</b>) Fe 2p. The applied load during the friction test was 392 N, the rotational speed was 1200 r/min, and the test duration was 1800 s.</p>
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<p>Lubrication film on the worn surface lubricated by HFC-PA-4: (<b>a</b>) TOF-SIMS mass spectrum and (<b>b</b>) TOF-SIMS imaging of positive and negative ions. (The mass spectrometry area mapping is 150 μm × 150 μm).</p>
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<p>(<b>a1</b>,<b>a2</b>) SEM images of wear tracks lubricated by HFC-PA-0 and their magnified edges, (<b>b1</b>,<b>b2</b>) SEM images of wear tracks lubricated by HFC-PA-4 and their magnified edges, (<b>c</b>) SEM images of fine particles after HFC-PA-4 lubrication for 7.5, 15, 30, and 60 min, (<b>d1</b>,<b>d2</b>) 2D and 3D images of fine particles under AFM, (<b>d3</b>) Statistical analysis of fine particle sizes, (<b>d4</b>) Height profile of four selected fine particles, (<b>e</b>) EDS mapping of fine particles on a silicon wafer under SEM, and (<b>f</b>) EDS mapping of fine particles under TEM.</p>
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<p>(<b>a</b>) Schematic diagram of the four-ball friction test, (<b>b</b>)The possible superlubrication mechanism of HFC-PA-0, (<b>c</b>) The possible superlubrication mechanism of HFC-PA-4.</p>
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22 pages, 704 KiB  
Review
Using Pilot Plants as a Didactic Resource to Facilitate the Acquisition of Technical Competences in the Urban Water Cycle in Vocational and Higher Education
by Albert Canut-Montalva, Carlos Rizo-Maestre and Joaquín Martínez-López
Water 2025, 17(5), 675; https://doi.org/10.3390/w17050675 - 26 Feb 2025
Viewed by 112
Abstract
The technical training associated with urban water cycle management has a markedly multidisciplinary character. In Spain, training in this field to cover the different professional profiles involved in urban water management ranges from specific intermediate and higher Vocational Education and Training Programmes to [...] Read more.
The technical training associated with urban water cycle management has a markedly multidisciplinary character. In Spain, training in this field to cover the different professional profiles involved in urban water management ranges from specific intermediate and higher Vocational Education and Training Programmes to related subjects included in various university degrees, as well as specialised master’s degrees in a very specific discipline involved in water management. Paradoxically, the companies in the sector are finding it difficult to find intermediate and higher technicians with training in line with their current needs to meet the challenges they must face in order to manage the sewerage and supply networks as efficiently as possible. It is necessary to incorporate, in Vocational Education centres, innovative methods and means that facilitate the acquisition of the skills required by key sectors for sustainability, such as urban water management. The incorporation of resources that help students to understand complex concepts in this field through the operation of pilot-scale equipment and installations that simulate those they will encounter in their professional performance can be of great value in facilitating the acquisition of the desired competences. In this work, a bibliographical review of the use of pilot plants for teaching purposes, in relation to technical aspects involved in the field of urban water management circumscribed to urban supply and sanitation networks, is carried out in order to assess the degree of their implementation as a training resource, which aspects are most frequently addressed, and the contribution they make to the improvement of teaching–learning processes. Full article
(This article belongs to the Special Issue Water: Economic, Social and Environmental Analysis)
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<p>Semantic fields of prospective search terms in Spanish.</p>
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<p>Semantic fields prospective search terms in English.</p>
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<p>Selection process of articles for literature review.</p>
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21 pages, 3175 KiB  
Article
Bio-Hybrid Films from Chirich Tuber Starch: A Sustainable Approach with Machine Learning-Driven Optimization
by Eyyup Karaogul, Gencay Sarıışık and Ahmet Sabri Öğütlü
Sustainability 2025, 17(5), 1935; https://doi.org/10.3390/su17051935 - 24 Feb 2025
Viewed by 389
Abstract
This study investigates the potential of Chirich (Asphodelus aestivus) tuber, one of Turkey’s natural resources, for sustainable bio-hybrid film production. Bio-hybrid films developed from Chirich tuber starch in composite form with polyvinyl alcohol (PVOH) were thoroughly examined for their physical, mechanical, [...] Read more.
This study investigates the potential of Chirich (Asphodelus aestivus) tuber, one of Turkey’s natural resources, for sustainable bio-hybrid film production. Bio-hybrid films developed from Chirich tuber starch in composite form with polyvinyl alcohol (PVOH) were thoroughly examined for their physical, mechanical, and barrier properties. During the production process, twin-screw extrusion and hydraulic hot pressing methods were employed; the films’ optical, chemical, and barrier performances were analyzed through FT-IR spectroscopy, water vapor permeability, solubility, and mechanical tests. To evaluate the films’ durability against environmental factors and model their properties, advanced computational model algorithms such as Gradient Boosting Regression (GBR), Random Forest Regression (RFR), and AdaBoost Regression (ABR) were utilized. The results showed that the GBR algorithm achieved the highest accuracy with 99.92% R2 and presented the most robust model in terms of sensitivity to environmental factors. The results indicate that Chirich tuber-based bio-hybrid films exhibit significantly enhanced mechanical strength and barrier performance compared to conventional corn starch-based biodegradable polymers. These superior properties make them particularly suitable for industrial applications such as food packaging and medical materials, where durability, moisture resistance, and gas barrier characteristics are critical. Moreover, their biodegradability and potential for integration into circular economy frameworks underscore their environmental sustainability, offering a viable alternative to petroleum-derived plastics. The incorporation of ML-driven optimization not only facilitates precise property prediction but also enhances the scalability of bio-hybrid film production. By introducing an innovative, data-driven approach to sustainable material design, this study contributes to the advancement of bio-based polymers in industrial applications, supporting global efforts to mitigate plastic waste and promote environmentally responsible manufacturing practices. Full article
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<p>Flowchart of the multi-step methodology applied for the development and characterization of bio-hybrid films.</p>
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<p>Heatmap of the correlation matrix showing the relationships between the mechanical, physical, barrier, optical, and chemical properties of bio-hybrid films.</p>
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<p>Frequency distributions for the tensile strength (TS), tensile modulus (TM), density (D), water absorption (WA), water vapor permeability (WVP), and carbonyl index (CI) parameters of bio-hybrid films.</p>
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<p>Importance ranking of parameters for bio-hybrid films not exposed to environmental conditions (% Importance Distribution).</p>
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<p>Importance ranking of parameters for bio-hybrid films exposed to environmental conditions (% Importance Distribution).</p>
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<p>Prediction performance of advanced computational models for bio-hybrid films’ technical properties after exposure to environmental conditions (The red dashed line represents the ideal prediction line (y = x), where predicted values perfectly match actual values. The proximity of data points to this line indicates model accuracy, with deviations reflecting prediction errors.).</p>
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24 pages, 1170 KiB  
Review
A Review on Biohydrogen Production Through Dark Fermentation, Process Parameters and Simulation
by Babak Mokhtarani, Jafar Zanganeh and Behdad Moghtaderi
Energies 2025, 18(5), 1092; https://doi.org/10.3390/en18051092 - 24 Feb 2025
Viewed by 120
Abstract
This study explores biohydrogen production through dark fermentation, an alternative supporting sustainable hydrogen generation. Dark fermentation uses organic waste under anaerobic conditions to produce hydrogen in the absence of light. Key process parameters affecting hydrogen yield, including substrate type, microorganism selection, and fermentation [...] Read more.
This study explores biohydrogen production through dark fermentation, an alternative supporting sustainable hydrogen generation. Dark fermentation uses organic waste under anaerobic conditions to produce hydrogen in the absence of light. Key process parameters affecting hydrogen yield, including substrate type, microorganism selection, and fermentation conditions, were examined. Various substrates, such as organic wastes and carbohydrates, were tested, and the role of anaerobic and facultative anaerobic microorganisms in optimizing the process was analyzed. The research also focused on factors such as pH, temperature, and hydraulic retention time to enhance yields and scalability. Additionally, the study modelled the process using ASPEN Plus software 14. This simulation identifies the bottle necks of this process. Due to the lack of available data, modelling and simulation of the described processes in ASPEN Plus required certain approximations. The simulation provides insight into the key challenges that need to be addressed for hydrogen production. Future research should indeed explore current limitations, such as substrate efficiency, process scalability, and cost-effectiveness, as well as potential advancements like the genetic engineering of microbial strains and improved bioreactor designs. Full article
(This article belongs to the Special Issue Sustainable Development of Fuel Cells and Hydrogen Technologies)
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<p>Schematic diagram of the pathways of hydrogen production by dark fermentation.</p>
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<p>A simplified block diagram for hydrogen production with a dark fermentation process.</p>
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<p>Process overview for hydrogen production with ASPEN Plus.</p>
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19 pages, 6375 KiB  
Article
Development and Testing of the Adaptive Control System for Profiling Grain Header
by Yi Niu, Ruixue Li, Wei Liu, Kai Rong, Haoxuan Hong and Guohai Zhang
Agriculture 2025, 15(5), 473; https://doi.org/10.3390/agriculture15050473 - 22 Feb 2025
Viewed by 213
Abstract
In the harvesting operation, the stubble height of the grain is a vital parameter index in the combined harvesting operation; if the stubble is too high or too low, it will directly affect the harvesting quality and the service life of the header. [...] Read more.
In the harvesting operation, the stubble height of the grain is a vital parameter index in the combined harvesting operation; if the stubble is too high or too low, it will directly affect the harvesting quality and the service life of the header. At present, the profiling control system can only control the lift of the header in the vertical direction but not the horizontal direction and the angle of the cutter profiling. This study proposes a contouring control strategy and system for grain harvesting by analyzing the designed contouring adjustment mechanism and simulating the control method and hydraulic system through Amesim2404 software to simulate and analyze the control method and hydraulic system. Finally, different forward speeds of the harvester (5, 7, 9, and 11 km/h) and other cutting heights of the harvester were analyzed based on static and field tests and different stubble heights (100, 150, 200, and 250 mm) on the test indexes. The results of the field test showed that for different operating speeds, the error between the mean value of stubble height and the target value was small, the absolute error was less than 2 mm, the mean value of the coefficient of variation of stubble height was 4.53%, and the mean value of control accuracy is 94%. The developed adaptive control system of the profiled grain header has high precision and stability, which can provide a reference for the all-terrain profiling control technology of the combined harvester header deck. Full article
(This article belongs to the Section Agricultural Technology)
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<p>Schematic diagram of the adaptive profiling adjustment mechanism. 1. Lifting hydraulic cylinder; 2. overbridge; 3. cutting angle adjusting hydraulic cylinder; 4. horizontal swinging hydraulic cylinder; 5. header; 6. angle sensor; 7. fixing bracket; 8. profiling rod; 9. sensor driving plate; 10. connecting rod; 11. driving rod; and 12. adjusting device.</p>
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<p>Kinematic modeling of the regulating mechanism in the vertical direction.</p>
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<p>Kinematic modeling of the regulating mechanism in the horizontal direction.</p>
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<p>(<b>a</b>) Kinematic modeling of affine mechanisms. (<b>b</b>) Computational model for conversion of affine angles to sensor acquisition angles.</p>
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<p>Leveling strategy for profiling grain header control system.</p>
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<p>Schematic diagram of the hydraulic system of the imitation row grain header. 1. Double-acting hydraulic cylinders; 2. one-way speed control valves; 3. check valves; 4. safety valves; 5. switching valves; 6. three-position four-way solenoid operated proportional valves; 7. two-position three-way solenoid operated proportional valves; 8. solenoid relief valves; 9. accumulators; 10. decompression valves; 11. buffer valves; 12. hydraulic pumps; and 13. oil tanks.</p>
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<p>Joint simulation modeling of hydraulic systems. Hydraulic module and 2D mechanical module for joint simulation are used to analyze the header lifting ram cylinder, horizontal oscillating ram cylinder, and front and rear floating ram cylinder motion patterns, and evaluate the dynamic.</p>
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<p>Lifting hydraulic cylinder simulation analysis results.</p>
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<p>Cutting angle hydraulic cylinder simulation analysis results.</p>
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<p>Horizontal hydraulic cylinder simulation analysis results.</p>
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<p>Prototype field test and data collection.</p>
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<p>Static test results for profiling cutter elevation statistics.</p>
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<p>Statistical results of field trial data.</p>
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17 pages, 2131 KiB  
Article
Leveraging Biomineralization in Repurposed Stirred Reactors for Mn/Zn Removal from Mine Water: Insights from a Laboratory-Scale Study
by Fumiya Kurogi, Peiyu Liu and Naoko Okibe
Minerals 2025, 15(3), 211; https://doi.org/10.3390/min15030211 - 22 Feb 2025
Viewed by 309
Abstract
This study developed a semi-passive treatment system for manganese (Mn)- and zinc (Zn)-containing mine water by repurposing a neutralization tank into a biologically active stirred reactor. Laboratory-scale experiments demonstrated efficient removal of Mn2+ (>97%) and Zn2+ (>80%) with hydraulic retention times [...] Read more.
This study developed a semi-passive treatment system for manganese (Mn)- and zinc (Zn)-containing mine water by repurposing a neutralization tank into a biologically active stirred reactor. Laboratory-scale experiments demonstrated efficient removal of Mn2+ (>97%) and Zn2+ (>80%) with hydraulic retention times (HRTs) as short as 6 h—significantly faster than traditional passive systems. XRD and XANES analyses identified the predominant formation of birnessite, a layered Mn oxide, during Mn2+ oxidation, with Zn co-treatment promoting the precipitation of Zn-containing carbonates. Despite decreasing crystallinity of birnessite over time, microbial activity, dominated by Mn-oxidizing genera, such as Sphingomonas, Pseudonocardia, Sphingopyxis, Nitrospira, and Rhodobacter, persisted in the presence of Zn2+, ensuring system stability. Importantly, the low leachability of Mn and Zn from the resulting sludge in TCLP tests confirmed its environmental safety and potential for reuse. By leveraging existing infrastructure and microbial biomineralization, this system bridges the gap between passive and active treatments, significantly reducing treatment footprints and operational costs. These findings highlight the potential of repurposing mine water treatment tanks as a scalable, cost-effective solution for sustainable mine water remediation. Full article
(This article belongs to the Special Issue Microbial Biomineralization and Organimineralization)
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<p>Schematic diagram of the continuous-flow stirred tank reactor system. The system consists of a feed tank supplying synthetic mine water via a pump (P) to the stirred tank reactor with a retention volume of 200 mL. The reactor contains a biologically active Mn-sludge layer at the bottom, facilitating microbial oxidation of Mn<sup>2+</sup>. A mesh filter (0.154 mm) at the outlet prevents the escape of Mn-sludge particles. Treated water flows into the collection tank for final discharge or further analysis. The reactor operates at room temperature (20–30 °C), with a stirring speed of 100 rpm. The hydraulic retention time (HRT) varied between 10 and 4 h.</p>
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<p>Changes in key parameters in inlet (○, ▽) and outlet (●, ▼) liquid samples of the Mn-system (black) and Mn/Zn-system (red): (<b>a</b>) total Mn concentrations, (<b>b</b>) total Zn concentrations, (<b>c</b>) pH, (<b>d</b>) Mn removal efficiency, (<b>e</b>) bicarbonate concentrations, and (<b>f</b>) redox potential (Eh vs. SHE). Dashed horizontal lines indicate Japan’s effluent standards (ESs) for Mn and Zn concentrations (<b>a</b>,<b>b</b>). Hydraulic retention times (HRTs) are indicated above the plots.</p>
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<p>Changes in XRD peaks of solid samples in the Mn/Zn-system on Days 0, 58, and 85. B, birnessite ((Na, Ca, K)<sub>0.5</sub> Mn<span class="html-italic"><sup>III,IV</sup></span><sub>2</sub> O<sub>4</sub>·1.5 H<sub>2</sub>O; PDF#00–013-0105); Z, hydrated zinc carbonate hydroxide Zn<sub>4</sub>CO<sub>3</sub>(OH)<sub>6</sub>∙H<sub>2</sub>O (PDF#00–011-0287) or Zn<sub>5</sub>(CO<sub>3</sub>)<sub>2</sub>(OH)<sub>6</sub> (PDF#00–019-1458)); C, calcium carbonate (CaCO<sub>3</sub>; PDF#01–075-4553); and Q, quartz (SiO<sub>2</sub>; PDF#01–085-0865).</p>
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<p>Changes in Mn oxidation states (bar graph; left axis) and ATP concentrations (circles; right axis) in (<b>a</b>) Mn-system and (<b>b</b>) Mn/Zn-system. White bars represent Mn<sup>2+</sup>, black bars represent Mn(III), and gray bars represent Mn(IV). The average oxidation state (AOS) of Mn is shown below the plots, while hydraulic retention time (HRT) conditions are indicated above the plots. ATP concentrations, reflecting microbial activity over time, are illustrated with gray circles in the Mn-system (<b>a</b>) and white circles in the Mn/Zn-system (<b>b</b>).</p>
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<p>Taxonomic composition of microbial communities at the order level in the original Mn-sediment [<a href="#B34-minerals-15-00211" class="html-bibr">34</a>] and during the experimental systems. (<b>a</b>) Mn-system on day 12 and day 43. (<b>b</b>) Mn/Zn-system on day 12 and day 43. The proportions of microbial orders are displayed as relative abundances (%), highlighting shifts in community composition over time and between systems. Detailed numerical data are provided in <a href="#app1-minerals-15-00211" class="html-app">Supplementary Table S1</a>.</p>
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28 pages, 7937 KiB  
Article
The Effects of Lime and Cement Addition on the Compaction and Shear Strength Parameters of Silty Soils
by Andrzej Gruchot, Katarzyna Kamińska and Agnieszka Woś
Materials 2025, 18(5), 974; https://doi.org/10.3390/ma18050974 - 21 Feb 2025
Viewed by 248
Abstract
This article presents the results of laboratory tests of compaction parameters and shear strength of silty soils with and without the addition of hydraulic binder in the form of lime and/or cement. The tests were carried out on samples formed with an optimum [...] Read more.
This article presents the results of laboratory tests of compaction parameters and shear strength of silty soils with and without the addition of hydraulic binder in the form of lime and/or cement. The tests were carried out on samples formed with an optimum moisture content and with 0, 3, 5, and 8% hydraulic binder added to the dry mass of the soil. The soil samples were examined after 7 and 14 days of air–water treatment without and with freeze–thaw cycles. It was found that the addition of lime and cement caused changes in the compaction parameters. This effect depended to a large extent on the type of binder, and also on the grain size composition of the tested soil. The tests showed that the shear strength and the parameters describing it, i.e., the angle of internal friction and cohesion, were high and largely depended on the type of binder and the sample treatment method, as well as its duration. The obtained results indicate that the use of hydraulic binders was an effective method of surface stabilization. Improving soil properties based on the addition of a hydraulic binder is a beneficial method for the environment from the viewpoint of sustainable development and reducing CO2 emissions because it does not require the use of, e.g., soil replacement. Using the SHAP algorithm, it was found that normal stress, initial moisture content, and curing time of the samples were the main input features that influenced the shear strength. Full article
(This article belongs to the Section Mechanics of Materials)
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<p>Samples of coarse silt with added cement during treatment after 10 out of 28 days of air–water treatment (photo by K. Kamińska).</p>
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<p>Grain size curve of the tested silty soils.</p>
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<p>Compaction curves of the tested silty soils with or without hydraulic binder: (<b>a</b>) Si, Sandomierz; (<b>b</b>) saclSi, Kraków, addition of cement; (<b>c</b>) CSi, Wieliczka, addition of lime; (<b>d</b>) CSi, Wieliczka, addition of cement.</p>
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<p>Dependence of the optimum moisture content and maximum bulk density of the skeleton of the tested silty soils on the type and addition of hydraulic binder.</p>
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<p>Shear strength line of the tested silty soils without the addition of binder.</p>
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<p>Shear strength line of the tested soils with the addition of binder and without and with treatment.</p>
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<p>Sample of coarse silt with addition of 3% lime after 7 days of air–water treatment immediately after shearing (visible shear surface) (photo by K. Kamińska).</p>
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<p>Dependence of the internal friction angle and cohesion on the moisture content of silt.</p>
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<p>The effects of the type and addition of binder and the type and time of treatment on the values of internal friction angle and cohesion of the tested silty soils.</p>
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<p>Correlation matrix of measured parameters. Gravel, Sand, Silt, Clay [%]—fraction content, MDD [g∙cm<sup>−3</sup>]—maximum dry density, OMC [%]—optimum moisture content, MC [%]—moisture content, D [g∙cm<sup>−3</sup>]—bulk density, DD [g∙cm<sup>−3</sup>]—dry density, CI [-]—compaction index, Addition of binder [%], Treatment time [days], Freeze–Thaw Cycles [times], Normal stress [kPa], Shear stress (strength) [kPa], initial, final—before, after tests.</p>
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<p>Comparison of shear strength values obtained from tests and those predicted using XGBoost.</p>
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<p>Graphical analysis of results for averages of SHAP values (legend description of the vertical axis the same as for <a href="#materials-18-00974-f010" class="html-fig">Figure 10</a>).</p>
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<p>SHAP value bee graph: Feature 0—kind of soil; Feature 1—location of soil collection; Feature 2—content of gravel fraction [%]; Feature 3—content of sand fraction [%]; Feature 4—content of silt fraction [%]; Feature 5—content of clay fraction [%]; Feature 6—MDD, maximum dry density [g∙cm<sup>−3</sup>]; Feature 7—OMC, optimum moisture content [%]; Feature 8—MC, initial moisture content [%]; Feature 9—MC, final moisture content [%]; Feature 10—BD, initial bulk density before [g∙cm<sup>−3</sup>]; Feature 11—BD, final bulk density [g∙cm<sup>−3</sup>]; Feature 12—DD, initial dry density [g∙cm<sup>−3</sup>]; Feature 13—DD, final density after [g∙cm<sup>−3</sup>]; Feature 14—CI, initial compaction index [-]; Feature 15—CI, final compaction index [-]; Feature 16—type of binder; Feature 17—Addition of binder [%]; Feature 18—care time [days]; Feature 19—freeze–thaw cycles [times]; Feature 20—normal stress [kPa].</p>
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<p>Waterfall graph of SHAP values (legend description of the vertical axis the same as for <a href="#materials-18-00974-f013" class="html-fig">Figure 13</a>).</p>
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32 pages, 4816 KiB  
Review
Geoenvironmental Engineered Structures for Water Protection: Challenges and Perspectives for Sustainable Liners
by Leonardo Marchiori, Antonio Albuquerque, Luis Andrade Pais, Maria Eugênia Gimenez Boscov and Victor Cavaleiro
Sustainability 2025, 17(5), 1850; https://doi.org/10.3390/su17051850 - 21 Feb 2025
Viewed by 178
Abstract
Geoenvironmental engineered barriers, such as geotechnical and hydraulic layered structures called liners, are essential for protecting the environment from pollution. Liners are usually compacted clay liners (CCL), geomembranes (GM), geosynthetic clay liners (GCL), or a combination of these liners (composite liners), which require [...] Read more.
Geoenvironmental engineered barriers, such as geotechnical and hydraulic layered structures called liners, are essential for protecting the environment from pollution. Liners are usually compacted clay liners (CCL), geomembranes (GM), geosynthetic clay liners (GCL), or a combination of these liners (composite liners), which require significant attention concerning materials, techniques, and procedures to perform adequately. This work reviews the function of geotechnical and hydraulic barriers as liners and highlights the lack of investigation and problematic aspects of them. In addition, the work provides an overview of the literature around earthworks which are liners’ specific configurations, such as landfills, dams, ponds, wastewater lagoons, and vertical barriers. Furthermore, the main investigations, issues, and perspectives are demonstrated, and are discussed alongside the trending research areas and sustainable new materials. This work highlights different directives in several countries for liner construction standards and testing program specifications, analyzing their economic aspects. The main studies on the subject have been compiled, and a bibliometric analysis was performed. Thus, this paper concludes by pointing out gaps in the research regarding alternative materials and structures within geoenvironmental investigations on liners, and signposts future scientific threads related to sustainable development. Full article
(This article belongs to the Special Issue Geoenvironmental Engineering and Water Pollution Control)
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<p>Bibliometric analysis keywords’ research mechanism (<b>a</b>) co-occurrence map, (<b>b</b>) the main subject area chart, (<b>c</b>) year, and (<b>d</b>) countries of the 778 Scopus documents.</p>
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<p>Bibliometric analysis keywords’ research mechanism (<b>a</b>) co-occurrence map, (<b>b</b>) the main subject area chart, (<b>c</b>) year, and (<b>d</b>) countries of the 778 Scopus documents.</p>
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<p>AIG images of (<b>a</b>) a landfill, (<b>b</b>) an earth dam, (<b>c</b>) a wastewater lagoon, and (<b>d</b>) a dumpsite.</p>
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<p>Typical cross-section, according to [<a href="#B44-sustainability-17-01850" class="html-bibr">44</a>,<a href="#B45-sustainability-17-01850" class="html-bibr">45</a>,<a href="#B46-sustainability-17-01850" class="html-bibr">46</a>].</p>
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<p>Chemical structure of (<b>a</b>) PFAS, (<b>b</b>) PBDE, (<b>c</b>) PCB, (<b>d</b>) BPA, and (<b>e</b>) heavy metals harmful to humans in black, and toxic in large quantities in gray.</p>
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<p>According to the literature, evaluation cycles for forever chemical contaminants.</p>
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<p>Typical single-layer liner cross-section (<b>a</b>) and liner design’s directives from different countries regarding k and thickness (t) (<b>b</b>).</p>
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<p>Geosynthetic types and acronyms.</p>
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21 pages, 3060 KiB  
Article
Improving Lime-Based Restoration Mortars: Effect of Type and Utilization Rate of Binder and Aggregate
by Tuğçe İsafça-Kaya, Yahya Kaya, Naz Mardani, Ali Mardani and Adem Doğangün
Materials 2025, 18(5), 961; https://doi.org/10.3390/ma18050961 - 21 Feb 2025
Viewed by 239
Abstract
Lime-based mortars, frequently used in historic structures, are classified as hydraulic and non-hydraulic according to how they gain strength. In the past, various methods were used to improve the strength and durability properties of lime-based hydraulic mortars such as Khorasan mortar. Today, in [...] Read more.
Lime-based mortars, frequently used in historic structures, are classified as hydraulic and non-hydraulic according to how they gain strength. In the past, various methods were used to improve the strength and durability properties of lime-based hydraulic mortars such as Khorasan mortar. Today, in studies carried out to increase the strength of lime-based mortars, the effects of binders, aggregates, and additives, which are the basic components of the mortar, are examined. In this study, the mechanical properties of Khorasan mortar mixtures, which are frequently used in the restoration of historical structures, were examined under the influence of different parameters. In particular, the effects of variables such as aggregate type and ratio (river sand and crushed brick), binder type and ratio (natural hydraulic lime, metakaolin, and blast furnace slag), and water/total dry material ratio on the strength of mortars were investigated experimentally. In the experimental study, two different aggregate types (river sand and crushed brick) were used in 1/3 and 1/2 ratios, and three different binders (natural hydraulic lime, metakaolin, and blast furnace slag) were used in different ratios. The water-to-total-dry-material ratios were set at 0.2 and 0.25. Standard test samples were then created from the prepared mortar mixtures, and their flexural and compressive strengths were assessed at 28 and 56 days. A statistical analysis of the experimental data was conducted using the Taguchi method, allowing for a detailed examination of how the different parameters influenced the strength of the mortars. Through this analysis, the optimal mixture ratios that maximized mortar strength were successfully identified. Full article
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<p>Khorasan mortar used as a floor covering in the Aigai archaeological site (<b>a</b>); Khorasan plaster used in the transition elements of an Ottoman bath in Türkiye (<b>b</b>) [<a href="#B9-materials-18-00961" class="html-bibr">9</a>].</p>
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<p>Main and sub-variables taken into consideration when creating mortar mixtures.</p>
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<p>Mortar mixtures prepared within the scope of this study: (<b>a</b>) fresh state (<b>b1,b2</b>) hardened state.</p>
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<p>Flexural (<b>a</b>) and compressive (<b>b</b>) strength values of mortar specimens at 28 and 56 days. The full names of the abbreviations listed in the figure are as follows: natural hydraulic lime (NHL), metakaolin (M), blast furnace slag (BFS), crushed brick (CB), river sand (RS).</p>
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<p>Optical microscope images of mortar–crushed brick adhesion.</p>
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<p>Influence levels and significance graph of effective parameters for compressive strength (<b>a</b>) according to S/N ratio and (<b>b</b>) according to mean values. The full names of the abbreviations listed in the figures are as follows: natural hydraulic lime (L), metakaolin (M), blast furnace slag (BFS), crushed brick (CB).</p>
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<p>ANOVA model fit.</p>
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<p>Comparison of linear regression model with experimental results on compressive strength.</p>
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<p>Comparison of second-order regression model with experimental results on compressive strength.</p>
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17 pages, 5105 KiB  
Article
Comparison of Hydraulic Fracturing and Deflagration Fracturing Under High-Temperature Conditions in Large-Sized Granite
by Hengtao Yang, Yan Zou, Bing Bai, Huiling Ci, Tiancheng Zhang, Zhiwei Zheng and Hongwu Lei
Appl. Sci. 2025, 15(5), 2307; https://doi.org/10.3390/app15052307 - 21 Feb 2025
Viewed by 265
Abstract
Fracturing is an indispensable technique in geothermal energy development. Large-sized model tests of different fracturing methods are crucial for evaluating the fracturing effect and extrapolating the results to field applications. For common hydraulic and deflagration fracturing methods, 40 × 40 × 40 cm [...] Read more.
Fracturing is an indispensable technique in geothermal energy development. Large-sized model tests of different fracturing methods are crucial for evaluating the fracturing effect and extrapolating the results to field applications. For common hydraulic and deflagration fracturing methods, 40 × 40 × 40 cm3 granite samples were used to carry out fracturing tests under high-temperature conditions in this paper. Through the analysis of the fracturing parameters and multiscale fracture morphology, a series of key findings were summarized. Deflagration fracturing is more intense, notably unaffected by the principal stress difference, and is capable of generating fracture spaces tens of times larger than those created by hydraulic fracturing. Furthermore, high temperatures tend to produce more fracture zones rather than continuous cracks during hydraulic fracturing. In contrast, deflagration fracturing yields simpler and more regular fractures in granite at high temperatures. Finally, the influence of the borehole number and the quantity of the deflagration agent on the fracturing effect are briefly discussed. These findings provide valuable insights for enhancing reservoir stimulation in geothermal systems. Full article
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<p>The schematic and physical diagram of the model experimental device for HDR fracturing. (<b>a</b>) Schematic diagram of test device connection; (<b>b</b>) Model experimental platform for large-sized samples; (<b>c</b>) The hand-operated pump; (<b>d</b>) ISCO plunger pump, produced by Teledyne ISCO (Lincoln, NE, USA); (<b>e</b>) The computer for control and data acquisition.</p>
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<p>Processing of the large-sized sample. (<b>a</b>) Drilling of granite sample, (<b>b</b>) processed granite sample.</p>
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<p>Schematic diagram of borehole sealing for (<b>a</b>) hydraulic fracturing and (<b>b</b>) deflagration fracturing.</p>
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<p>A demonstration of the surface damage of rock samples.</p>
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<p>The damage distribution diagram of the sample after hydraulic fracturing, (<b>a</b>–<b>d</b>) correspond successively to the four cases H1–H4. The red lines in the figure represent exposed cracks, and the red circles indicate localized damage zones.</p>
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<p>Observation of specimen failure. (<b>a</b>) Hydraulic fracturing cracks observed under a portable microscope; (<b>b, c</b>) damage zone revealed by tracer-based seepage visualization.</p>
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<p>The curves of fluid pressure within the wellbore, the injection rate, and the sample temperatures with time in each experiment, (<b>a</b>–<b>d</b>) correspond successively to the four cases H1–H4. The numbers in the figure, such as ①, represent some specific time points during the injection.</p>
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<p>The 3DEC model and the boundary conditions. The three-dimensional half-model on the left represents the simulated rock mass itself, with stress and fixed displacement boundary conditions. The two-dimensional plane on the right is the separately displayed flowplane, with free and constant flow boundary conditions.</p>
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<p>Fluid pressure within the wellbore changes with time. The insets depict the fluid pressure distribution across the flowplane at different time points, which also reflect the fracture state of the fracture plane.</p>
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<p>The fracture distribution diagram of the sample after deflagration fracturing: (<b>a</b>–<b>d</b>) correspond successively to the four cases D1–D4.</p>
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<p>Three-dimensional visualization model of fractures induced by two different fracturing methods: (<b>a</b>) for hydraulic fracturing, these subfigures correspond, from left to right, to H1–H4; (<b>b</b>) for deflagration fracturing, these subfigures correspond, from left to right, to D1–D4.</p>
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<p>Fluid pressure within the wellbore changes with time when the tensile strength of the fracture plane is 1 × 10<sup>3</sup> Pa.</p>
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16 pages, 6145 KiB  
Article
Real-Time Scanning Curve of Soil–Water Characteristic Curve for Sustainability of Residual Soil Slopes
by Abdulroqeeb Mofeyisope Daramola, Alfrendo Satyanaga, Babatunde David Adejumo, Yongmin Kim, Zhai Qian and Jong Kim
Sustainability 2025, 17(5), 1803; https://doi.org/10.3390/su17051803 - 20 Feb 2025
Viewed by 282
Abstract
The scanning curve of the soil–water characteristic curve (SWCC) represents the intermediate paths followed by soil as it transitions between the initial drying and main wetting cycles. The alternating occurrence of climatic conditions, such as rainfall and evaporation in different regions globally, provides [...] Read more.
The scanning curve of the soil–water characteristic curve (SWCC) represents the intermediate paths followed by soil as it transitions between the initial drying and main wetting cycles. The alternating occurrence of climatic conditions, such as rainfall and evaporation in different regions globally, provides a valuable framework for understanding how these dynamics influence the scanning curve. Monitoring the scanning curve can provide valuable insights for managing water resources and mitigating the impacts of drought, contributing to environmental sustainability by enabling more precise agricultural practices, promoting water conservation, and supporting the resilience of ecosystems in the face of climate change. It enhances sustainability by enabling data-driven designs that minimize resource use, reduce environmental impact, and increase the resilience of slopes to natural hazards like landslides and flooding. Available studies to determine the scanning curve of SWCC are limited and mostly conducted in the laboratory. This study aims to determine the real-time measurement of the scanning curve of SWCC for unsaturated soil. The research focuses on assessing the hysteresis behavior of residual soil slope from old alluvium through a combination of field instrumentation and laboratory testing. The pore size distribution was derived from the initial drying and main wetting SWCC. Field monitoring (scanning curve) indicates measurable deviations from the experimental results, including a 10% lower saturated water content and a 25% lower air-entry value. This study demonstrates the potential for field-based determination of scanning curves. It highlights their role in improving the prediction of the hydraulic behavior of residual slopes during varying climatic conditions. Full article
(This article belongs to the Special Issue Disaster Prevention, Resilience and Sustainable Management)
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<p>Study area and geological formation of Singapore.</p>
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<p>Field monitoring layout of the residual slope at Buangkok Link.</p>
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<p>Laboratory experiment of drying and wetting soil–water characteristic curve of Buangkok Link soil.</p>
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<p>Estimated drying and wetting pore size distribution of Buangkok Link soil.</p>
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<p>Daily and cumulative daily rainfall in Buangkok Link between 1 October 2019 and 4 April 2020.</p>
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<p>Rainfall distribution with soil volumetric water content between October 2019 and April 2020 at the crest of the Buangkok Link slope.</p>
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<p>Rainfall distribution with soil volumetric water content between October 2019 and April 2020 at the toe of the Buangkok Link slope.</p>
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<p>Rainfall distribution with soil suction between 1 October 2019 and 4 April 2020 at the crest of the Buangkok Link slope.</p>
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<p>Rainfall distribution with soil suction between October 2019 and April 2020 at the toe of the Buangkok Link slope.</p>
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<p>Variation in soil volumetric water content at the crest of Buangkok Link slope between 2 and 7 January.</p>
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<p>Variation in soil volumetric water content at the toe of Buangkok Link slope between 2 and 7 January.</p>
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<p>Variation in soil suction at the crest of Buangkok Link slope between 2 and 7 January.</p>
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<p>Variation in soil suction at the toe of Buangkok Link slope between 2 and 7 January.</p>
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<p>Scanning curve of soil–water characteristic curve.</p>
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20 pages, 14270 KiB  
Article
Hydrodynamic Loads on Rectangular Bridge Decks at Very Low Proximity in Fixed and Movable Beds
by Michele Palermo, Ajit Kumar, Huan Wei and Stefano Pagliara
Water 2025, 17(5), 617; https://doi.org/10.3390/w17050617 - 20 Feb 2025
Viewed by 162
Abstract
Bridges positioned near riverbeds experience complex interactions between flow dynamics and structural geometry, significantly affecting hydrodynamic loading and stability. This study analyzes the effect of deck proximity to the bed on pressure distribution and hydrodynamic loading, including drag and lift forces. Experimental tests [...] Read more.
Bridges positioned near riverbeds experience complex interactions between flow dynamics and structural geometry, significantly affecting hydrodynamic loading and stability. This study analyzes the effect of deck proximity to the bed on pressure distribution and hydrodynamic loading, including drag and lift forces. Experimental tests were conducted in a rectangular channel using a scaled bridge deck model, varying deck positions, flow conditions, and upstream–downstream water depth levels. To the best of the authors’ knowledge, for the first time, a comparative analysis of hydrodynamic loads on bridge decks was conducted using both rigid and deformable granular beds. Pressure distributions on the front, rear, and bottom faces of the deck were measured using transducers sensors. Our findings corroborate that changes in Reynolds number have minimal impact on the deck drag and lift coefficients, under identical submergence conditions, whereas both coefficients decrease with the Froude number for both bed types. More importantly, the analysis of experimental evidence unveiled some interesting aspects pertaining to the physics of the phenomenon, allowing us to provide the following, unprecedented results: (1) lift and drag coefficients significantly decrease with proximity, exhibiting much higher values than those reported in the literature for larger clearance; (2) under identical hydraulic conditions (both upstream and downstream of the deck), drag and lift coefficients are significantly amplified by the presence of rigid beds compared to granular beds; and (3) the scour evolution alters the effective deck proximity, resulting in time-dependent hydrodynamic loads acting on the deck. Full article
(This article belongs to the Section Hydraulics and Hydrodynamics)
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<p>Pictures of deck under (<b>a</b>) fully (<span class="html-italic">P<sub>r</sub></span> = 0.67) and (<b>b</b>) partially submerged conditions (<span class="html-italic">P<sub>r</sub></span> = 0.67).</p>
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<p>Diagram sketch of experimental setup with fixed bed: (<b>a</b>) top view, (<b>b</b>) upstream view (section <span class="html-italic">A</span>-<span class="html-italic">A</span>’), (<b>c</b>) bottom view, (<b>d</b>) downstream view (section <span class="html-italic">B</span>-<span class="html-italic">B</span>’), and (<b>e</b>) side view (section <span class="html-italic">C</span>-<span class="html-italic">C</span>’).</p>
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<p>Diagram sketch of experimental setup with movable bed: (<b>a</b>) top view, (<b>b</b>) upstream view (section <span class="html-italic">A</span>-<span class="html-italic">A</span>’), (<b>c</b>) bottom view, (<b>d</b>) downstream view (section <span class="html-italic">B</span>-<span class="html-italic">B</span>’), and (<b>e</b>) side view (section <span class="html-italic">C</span>-<span class="html-italic">C</span>’).</p>
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<p>Extreme configurations tested in this study. <span class="html-italic">Max. h<sub>u</sub></span> is maximum upstream level, <span class="html-italic">Min</span>. <span class="html-italic">h<sub>u</sub></span> is minimum upstream level, <span class="html-italic">Max. h<sub>d</sub></span> is maximum downstream level, and <span class="html-italic">Min. h<sub>d</sub></span> is minimum downstream level.</p>
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<p>Scheme of forces relative to methods M1 (in black) and M2 (in red). Selected <span class="html-italic">CV</span> is represented with bold, dashed lines.</p>
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<p>Comparison of drag force computed with methods M1 and M2.</p>
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<p><span class="html-italic">C<sub>D</sub></span> as function of <span class="html-italic">h</span>* for tests with fixed bed: (<b>a</b>) effect of <span class="html-italic">ΔH*</span> for tests with <span class="html-italic">P<sub>r</sub></span> = 0.67 and <span class="html-italic">R<sub>eD</sub></span> ≈ 40,000 along with data derived from [<a href="#B3-water-17-00617" class="html-bibr">3</a>] (M &amp; G in legend); (<b>b</b>) effect of <span class="html-italic">R<sub>eD</sub></span> for tests with <span class="html-italic">P<sub>r</sub></span> = 0.67; and (<b>c</b>) effect of <span class="html-italic">P<sub>r</sub></span> for all tests with fixed bed. <span class="html-italic">C<sub>D</sub></span> as function of <span class="html-italic">h</span>* for tests with movable bed: effect of (<b>d</b>) Δ<span class="html-italic">H</span>* for tests with <span class="html-italic">P<sub>r</sub></span> = 0.47 and <span class="html-italic">R<sub>eD</sub></span> ≈ 30,000 along with data derived from [<a href="#B3-water-17-00617" class="html-bibr">3</a>] (M &amp; G in legend); (<b>e</b>) effect of <span class="html-italic">R<sub>eD</sub></span> for tests with <span class="html-italic">P<sub>r</sub></span> = 0.67. (<b>f</b>) Effect of <span class="html-italic">P<sub>r</sub></span> for all tests with both fixed and movable beds.</p>
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<p><span class="html-italic">C<sub>D</sub></span> and <span class="html-italic">C<sub>L</sub></span> as functions of various hydraulic and geometric parameters. Empty and dashed bars indicate values of proximity at initial and equilibrium configurations of same test, <span class="html-italic">P<sub>r</sub></span> and <span class="html-italic">P<sub>r</sub></span>′, respectively. Black, red, and blue colors refer to tests with <span class="html-italic">F<sub>r</sub></span> ≈ 0.2, 0.3, and 0.4, respectively.</p>
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<p><span class="html-italic">C<sub>D</sub></span> as function of <span class="html-italic">P<sub>r</sub></span> for tests with (<b>a</b>) fixed and (<b>b</b>) movable bed, including data points of tests by [<a href="#B1-water-17-00617" class="html-bibr">1</a>] (indicated with K et al. in legend). (<b>c</b>) Δ<span class="html-italic">H</span>* and (<b>d</b>) <span class="html-italic">C<sub>D</sub></span> as function of <span class="html-italic">F<sub>r</sub></span> for tests with fixed bed.</p>
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<p><span class="html-italic">C<sub>L</sub></span> as function of <span class="html-italic">h</span>* for tests with fixed bed: (<b>a</b>) effect of Δ<span class="html-italic">H</span>* for tests with <span class="html-italic">P<sub>r</sub></span> = 0.67 and <span class="html-italic">R<sub>eD</sub></span> ≈ 40,000 along with data derived from [<a href="#B3-water-17-00617" class="html-bibr">3</a>] (M &amp; G in legend); (<b>b</b>) effect of <span class="html-italic">R<sub>eD</sub></span> for tests with <span class="html-italic">P<sub>r</sub></span> = 0.67; and (<b>c</b>) effect of <span class="html-italic">P<sub>r</sub></span> for all tests with fixed bed. <span class="html-italic">C<sub>L</sub></span> as function of <span class="html-italic">h</span>* for tests with movable bed: (<b>d</b>) effect of Δ<span class="html-italic">H</span>* for tests with <span class="html-italic">P<sub>r</sub></span> = 0.67 and <span class="html-italic">R<sub>eD</sub></span> ≈ 30,000 along with data derived from [<a href="#B3-water-17-00617" class="html-bibr">3</a>] (M &amp; G in legend); (<b>e</b>) effect of <span class="html-italic">R<sub>eD</sub></span> for tests with <span class="html-italic">P<sub>r</sub></span> = 0.67. (<b>f</b>) Effect of <span class="html-italic">P<sub>r</sub></span> for all tests with both fixed and movable beds.</p>
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<p><span class="html-italic">C<sub>L</sub></span> as function of <span class="html-italic">P<sub>r</sub></span> for tests with (<b>a</b>) fixed and (<b>b</b>) movable beds, including data points of tests by [<a href="#B1-water-17-00617" class="html-bibr">1</a>] (indicated with K et al. in legend).</p>
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<p>Comparison of dynamic pressure distributions in axial direction for Test 13 and 23 conducted under similar hydraulic conditions (<span class="html-italic">P<sub>r</sub></span> = 0.67, <span class="html-italic">h</span>* = 1.4, <span class="html-italic">F<sub>r</sub></span> ≈ 0.2) and with (<b>a</b>) fixed and (<b>b</b>) movable beds. Red lines represent measured pressures, and number indicates value of pressure in mm of water.</p>
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<p><span class="html-italic">C<sub>D</sub></span> versus <span class="html-italic">C<sub>L</sub></span> for selected tests conducted under similar hydraulic conditions and proximities. Symbols in black represent fixed bed conditions while symbols in red represent movable bed conditions.</p>
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<p>Comparison of pressure head oscillations pertaining to Test 13 and 23 for: (<b>a</b>) fixed and (<b>b</b>) movable beds at front sensor 8; (<b>c</b>) fixed and (<b>d</b>) movable beds at rear sensor 16; (<b>e</b>) fixed and (<b>f</b>) movable beds at bottom sensor 10.</p>
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<p>Pressure head evolution measured by sensor 9 for Test 3.</p>
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18 pages, 5366 KiB  
Article
Regenerative Structural Fatigue Testing with Digital Displacement Pump/Motors
by Win Rampen, Marek J. Munko, Sergio Lopez Dubon and Fergus Cuthill
Actuators 2025, 14(3), 103; https://doi.org/10.3390/act14030103 - 20 Feb 2025
Viewed by 228
Abstract
Historically, a large fraction of fatigue testing of both components and structures has been performed using hydraulic actuators. These are typically driven by servo-valves, which are in themselves very inefficient. But, as most tests involve elastically stressing mechanical components, a lot of stored [...] Read more.
Historically, a large fraction of fatigue testing of both components and structures has been performed using hydraulic actuators. These are typically driven by servo-valves, which are in themselves very inefficient. But, as most tests involve elastically stressing mechanical components, a lot of stored energy could be recovered. Unfortunately, servo-valves are not regenerative—simply metering out fluid in order to relax the system prior to the start of the next cycle. There is much to be gained with a more intelligently controlled system. The FastBlade facility in Scotland uses a new type of regenerative test hydraulics. Digital displacement pump/motors (DDPMs), originated by Artemis Intelligent Power, now Danfoss Scotland, are used to load and unload the test structure directly via hydraulic rams. The DDPMs are driven by induction motors supplied by three-phase frequency converters, each with a very loose speed correction target, such that they can speed up or slow down according to the instantaneous torque exerted by the load. The rotating assembly of the induction motor and DDPM is designed to have sufficient inertia so as to function as a kinetic energy storage flywheel. The loading energy is then cyclically transferred between the rotating inertia of the motor/DDPM and the spring energy in the test structure. The electric motor provides sufficient energy to maintain the target average cyclical shaft speed of the DDPM whilst the bulk of the system energy oscillates between the two storage mechanisms. Initial tests (at low load) suggest that this technique requires only 30% of the energy previously needed. FastBlade is a unique facility built by the University of Edinburgh and Babcock, with support from the UK EPSRC, conceived as a means of testing and certifying turbine blades for marine current turbines. However, this approach can be used in any cyclical application where elastic energy is stored. Full article
(This article belongs to the Special Issue Actuation and Control in Digital Fluid Power)
Show Figures

Figure 1

Figure 1
<p>Simplified schematic of a regenerative hydraulic loading circuit with reversing energy flows.</p>
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<p>Cross-section of an early DDP, illustrating basic conformation and components.</p>
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<p>Rendering of loading frame, jacking actuators, strong wall, and test specimen at FastBlade.</p>
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<p>Photo of the actual FastBlade facility with a short specimen blade on the test.</p>
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<p>Photo of the undercroft where the four Artemis/Danfoss DDPMs are housed. The main level decking can be seen at the top of the photo, and the side of the loading frame is visible on the extreme right.</p>
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<p>A simplified schematic of the hydraulic loading system, consisting of an oil reservoir, a DDPM unit, an adjustable pressure compensated flow control valve, a loading jack, and a load cell.</p>
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<p>Traces of both the flywheel speed and the desired load acting on the specimen specimen deflection showing the energy exchange, both in amplitude and phase. The two vertical lines represent the phase shift, showing the maximum flywheel speed to be slightly leading to the minimum displacement.</p>
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<p>Regeneration test, where power to the VLT is cut at 5 s. (<b>a</b>) The loading cycle continues, slightly diminishing in amplitude cycle by cycle until transferred energy sinks to 1/3rd of the initial amount after 25 cycles. (<b>b</b>) Motor speed slows after power is cut at 5 s. If loading is also stopped, then the system runs down following the smooth red trace. If loading continues, then the speed reduction is slightly faster. The small difference in speed decay illustrates the high round-trip efficiency of the loading system. (<b>c</b>) The energy that is being cycled between the flywheel and load also diminishes with time, but not in a way that might be recognised as a logarithmic decrement. For the first 3 s, after power is cut to the VLT, loading energy remains relatively constant since the flywheel can source the required energy in the time available. As flywheel speed drops, the energy that can be transferred also diminishes.</p>
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<p>The relation between the power losses and the angular velocity of a DDPM for four operating modes: low pressure (LP), medium pressure (MP), high pressure (HP), and idle.</p>
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<p>Sankey diagram for the loading portion of the cycle. It can be seen from the change in speed during the loading cycle that 2.2 kJ given up by the flywheel during its deceleration are passed through to the strain energy in the specimen, and the VLT makes up the rest, as well as supplying the various parasitic losses in the circuit.</p>
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<p>Sankey diagram for the unloading phase of the cycle. Here, 3.37 kJ of energy are given up by the relaxing test specimen and directed to help accelerate the flywheel. The VLT once again makes up for losses.</p>
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<p>Relative cycle input energy for the FastBlade DDPM regenerative system compared to a calculated approximation for a conventional proportional valve with a variable pump and accumulator supply.</p>
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