Search Results (62)

The modification of road bitumen using micro-sized carbonaceous materials offers a promising route to enhance pavement performance; however, the influence of microdispersed coke derived from coal and petroleum sources has not been sufficiently clarified. In this study, coal and petroleum coke from Pavlodar Petrochemical Plant LLC (Pavlodar, Kazakhstan) were mechanochemically activated and used as the modifiers for BND 100/130 bitumen, produced by Asphaltbeton 1 LLC (Almaty, Kazakhstan). X-ray diffraction and scanning electron microscopy were used to determine the structure and morphology of the resulting coke powders. Standard tests and the Superpave Multiple Stress Creep and Recovery (MSCR) methodology were used to determine the physico-mechanical and rheological properties of the modified binders. Microdispersed granular coke powders produced after mechanochemical activation had a minimum average particle diameter of 8.28 µm (petroleum coke) and 16.64 µm (coal coke), and were mainly an amorphous carbon phase with traces of graphite. Addition of 1 wt.% microdispersed coke resulted in better performance of binder and an enhancement in grades of BND 100/130 to BND 70/100, in line with ST RK 1373-2013. MSCR testing showed that Jnr_3.2 is between 2.0–3.0 kPa⁻¹, which is in the S category of AASHTO M 332-20. This study showed how micro-sized coal and petroleum coke can be effectively used as a high-carbon modifier in bitumen, which reflects the possibility of their practical use in asphalt pavements that are subjected to normal traffic conditions. Full article

Linear alkylbenzene (LAB) is the main raw material used to make biodegradable detergents, and its production process is based on aromatic alkylation. HY zeolites that have undergone controlled dealumination and desilication have led industrial standards amongst solid acid catalysts because of their controllable acidity and hierarchical pore structure. Coke formation in such systems can assume a dual role, which is dependent on its condition. Though the over-deposition is known to cause deactivation by blocking the micropores, Bronsted acid-site masking, and diffusion collapse, the low-level deposition could also be done to increase the monoalkylate selectivity by the pore mouth catalysis, steric modulation, and selective suppression of secondary alkylation pathways. The critical review is done on the structural-kinetic interaction that determines the coke evolution in HY-based catalysts. In order to moderate the acid-site density and enhance hydrothermal stability, dealumination (Si/Al optimization of about 2.5 to 30–100) occurs, but to reduce deep-pore coke formation, desilication (interconnected mesopores) is created. The bimodal porosity and regulated acidity are found to be synergistic, as hierarchical HY zeolites produced through successive cycles of steam and alkaline treatments not only show LAB selectivity in excess of 90% but also exhibit much longer catalyst lifetimes. Quantitative research on the beneficial coke regime revealed that it was composed of about 36 wt% hydrogen-rich species, which were localized at the pore mouths, hence enhancing monoalkylation selectivity by 15–40%. Beyond a critical transition window (e.g., 8–12 wt.%), coke formation to condensed polyaromatic and graphitic products leads to fast deactivated coke formation, which is due to percolation limits and transport-controlled kinetics. More advanced techniques of characterization of the coke, e.g., temperature-programmed oxidation (TPO), ²⁷Al MAAS NMR, and UV-Raman spectroscopy, indicate how the coke is changed to highly structured graphitic deposits of high oxidation activation energy. Activity recovery of 85–98% is obtained in regeneration processes, including controlled oxidative calcination, microwave-based and plasma-based processes, and thermal management protocols, and it would be determined by the chemistry of the coke, its spatial distribution, and the regeneration protocols. This paper has developed a mechanistic coke control system by cross-tuning the acidity and development of an effective pore network, which led to a sustainable aromatic alkylation reaction with minimal activity loss, high selectivity, and long life. Full article

The purity of titanium sponge is crucial for determining the performance of final titanium alloys, underscoring the importance of impurity control in its precursor, TiCl₄. Among these impurities, VOCl₃ is particularly challenging to remove due to its similar boiling point and complete miscibility with TiCl₄. Although organic reagents are widely employed for vanadium removal, their complex compositions complicate the identification of key active components. This study systematically compares the vanadium removal efficiency of six organic compounds bearing different functional groups. Results demonstrate that 1-dodecene exhibits superior performance, achieving a VOCl₃ removal efficiency of 93.35%. Mechanistic studies reveal that 1-dodecene initially undergoes cyclization to form cyclododecane, followed by aromatization and subsequent carbonization through stacking, dehydrogenation, and coking, ultimately yielding partially graphitized amorphous carbon. In this process, VOCl₃ interacts not only with the incompletely carbonized organic precursor but also directly with the alkenes. These findings elucidate the reaction pathway and central role of linear α-alkenes in vanadium removal, providing a theoretical foundation for developing efficient and stable vanadium removal agents. Full article

The COREX smelting-reduction route is a representative non-blast furnace technology, but its scale-up is hindered by insufficient gas and liquid permeability in the melter gasifier. To improve the gas and liquid permeability of the melter gasifier, coke is charged together with an iron-bearing material to partly replace lump coal to increase the burden voidage. The charged coke undergoes successive physical and chemical attacks that progressively weaken its strength, finally reducing the coke particle size and impairing overall burden permeability. Drilling “in situ” coke samples from the tuyere zone is an effective method to study coke behaviors inside a working melter gasifier. This work obtained tuyere coke samples by direct coke sample drilling during a melter gasifier blow-out and then systematically investigated the coke deterioration behaviors in the melter gasifier. The results show that the mean particle size decreased from an initial 50.3 mm to 31.6 mm at the tuyere, evidencing the severe fragmentation of coke. Basic oxides and alkali metals in the coke ash increased, indicating alkali recycling and enrichment occurred in the melter gasifier. Microcrystalline structure analysis of coke revealed a high degree of graphitization. Furthermore, coke degradation was further accelerated by both alkalis trapped in the coke pores and slag infiltration into the pores. This study clarifies the properties of the coke in the tuyere of the COREX melter gasifier and provides a theoretical basis for its operational optimization. Full article

This work introduces ultrafast high-temperature graphitization (UHG) as an effective method to synthesize graphite with significantly reduced processing times of about 100 s and reduced consumed energy, as opposed to conventional methods that require several days at 2800 K. This novel process achieves graphitization of up to 90% within a few minutes due to the accelerated kinetics occurring at temperatures as high as 3400 K. Samples processed using UHG attained stable cyclic capacities of 350 mAh/g, which is fully comparable to commercially available graphite. Finite Element Simulations were also used to calculate the energy consumption for a scaled-up configuration, and it was found that the UHG approach reaches ultra-low energy consumption, requiring only 2.4 MJ/kg for the direct conversion of coke into graphite. By minimizing the duration of high-temperature processing and employing localized heating, UHG is envisioned to mitigate some of the challenges associated with traditional Acheson furnaces that have been in use for more than a century. Full article

The article presents a method of measurement and a test stand for determining the specific electrical resistivity of granular carburizing materials most commonly used in foundry practice. The research was conducted for synthetic graphites (GS) and petroleum cokes (KN) using a test stand proposed by the authors of the study and protected by a patent. It was shown that this measurement method allows for a clear distinction between the tested materials. For synthetic graphites, specific resistivities in the range of 35.9–144.5 μΩ·m were obtained, while for petroleum cokes the range was 172.1–1390 μΩ·m. The main aim of the study was to determine whether there is a correlation between the measured electrical resistivity of the tested materials and the carburization efficiency obtained in melting experiments. Therefore, the article also presents the course and results of studies on the process of cast iron melting in laboratory induction furnaces, where the carburizing material was introduced into the induction furnace with a fixed charge. Carburization efficiencies obtained for synthetic graphite ranged from 86.6% to 94.4%, and from 65.5% to 85.31% for petroleum coke. Based on the measurement results, a statistical analysis was carried out, yielding a relationship with a coefficient of determination R² = 0.92. The research confirmed the possibility of a quick assessment of carburizers in terms of their assimilation degree by molten metal. This is valuable information both for scientific research and industrial applications. The presented results form part of ongoing studies aimed at explaining the differences occurring within a given group of materials (petroleum cokes and synthetic graphites). Full article

The service life of graphite anodes—key consumables in the Pr/Nd fluoride molten salt electrolysis process—directly governs production continuity, cost-efficiency, and supply chain stability. This study systematically evaluated five industrial-grade anodes produced from different raw materials and processes. Multimodal characterization—combining macroscopic and microscopic morphology, SEM/EDS, XRD, Raman, and physical property analysis—was employed to correlate initial anode properties with corrosion-induced morphological and mass changes during electrolysis. The results show that the raw material quality and preparation methods synergistically regulate both the crystal structure and microstructure, thereby governing the corrosion behaviour and mass loss. Anodes #2 and #3, which were fabricated from high-quality petroleum coke and subjected to full densification and graphitization, exhibited high graphitization (93.7–94.5%), large crystallites (59.6–64.5 nm), minimal defects (low I_D/I_G), and suppressed microporosity, leading to the lowest mass loss (10.2 ± 0.8 kg and 10.6 ±0.9 kg). In contrast, anodes #1, #4, and #5, made from recycled graphite without graphitization, contained abundant structural defects and large pores and led to greater morphological changes and quality losses. Moreover, for recycled graphite anodes, the presence of large pores and cracks is one of the important reasons for their failure. This work clarifies the “process–microstructure–mass loss” relationship in graphite anodes for Pr/Nd electrolysis, offering key insights for designing high-performance anodes and advancing sustainable rare earth production. Full article

This work examines the effect of gadolinium (Gd) promotion on nickel-based SBA-16 catalysts for the dry reforming of methane (DRM), with the goal of improving syngas production by optimizing catalyst composition and operating conditions. Catalysts with varying Gd loadings (0.5–3 wt.%) were synthesised using co-impregnation. XRD, N₂ physisorption, FTIR, XPS, and H₂-TPR–CO₂-TPD–H₂-TPR were used to examine the structural features, textural properties, surface composition, and redox behaviour of the catalysts. XPS indicated formation of enhanced metal–support interactions, while initial and post-treatment H₂–TPR analyses showed that moderate Gd loadings (1–2 wt.%) maintained a balanced distribution of reducible Ni species. The catalysts were tested for DRM performance at 800 °C and a gas hourly space velocity (GHSV) of 42,000 mL g⁻¹ h⁻¹. 1–2 wt.% Gd-promoted catalysts achieved the highest H₂ (~67%) and CO yield (~76%). Response surface methodology (RSM) was used to identify optimal reaction conditions for maximum H₂ yield. RSM predicted 848.9 °C temperature, 31,283 mL g⁻¹ h⁻¹ GHSV, and a CH₄/CO₂ ratio of 0.61 as optimal, predicting a H₂ yield of 96.64%, which closely matched the experimental value of H₂ yield (96.66%). The 5Ni–2Gd/SBA-16 catalyst exhibited minimal coke deposition, primarily of a graphitic character, as evidenced by TGA–DSC and Raman analyses. These results demonstrate the synergy between catalyst design and process optimization in maximizing DRM efficiency. Full article

This study presents a sustainable upcycling strategy to convert “Pit,” a carbon-rich coke oven by-product from steel manufacturing, into high-purity graphite for use as an anode material in lithium-ion batteries. Despite its high carbon content, raw Pit contains significant impurities and has irregular particle morphology, which limits its direct application in batteries. We employed a multi-step, additive-free refinement process—including jet milling, spheroidization, and high-temperature graphitization—to enhance carbon purity and structural properties. The processed Pit-derived graphite showed a much-improved particle size distribution (D50 reduced from 25.3 μm to 14.8 μm & Span reduced from 1.72 to 1.23), increased tap density (from 0.54 to 0.80 g/cm³), and reduced BET surface area, making it suitable for high-performance lithium-ion batteries anodes. Structural characterization by XRD and TEM confirmed dramatically enhanced crystallinity after graphitization (graphitization degree increasing from ~13 for raw Pit to 95.7% for graphitized Pit at 3000 °C). The fully processed graphite (denoted S_Pit3000) delivered a reversible discharge capacity of 346.7 mAh/g with an initial Coulombic efficiency of 93.5% in half-cell tests—comparable to commercial artificial graphite. Furthermore, when composited with silicon oxide to form a hybrid anode, the material achieved an even higher capacity of 418.0 mAh/g under high mass loading conditions. These results highlight the feasibility of transforming industrial coke waste into value-added electrode materials through environmentally friendly physical processes. The upcycled graphite anode meets industrial performance standards, demonstrating a promising route toward circular economy solutions in both the steel and battery industries. Full article

This research investigates a novel hybrid E-glass fiber coated with a thin amorphous carbon (coke) layer, referred to as GF@C, designed to enhance the affinity of fiber with a polymer matrix. Acrylonitrile butadiene styrene (ABS), an engineering thermoplastic, was selected as the matrix to form the composite. The carbon coating was produced by pyrolyzing a lubricant oil (Lo) layer applied to the glass fiber strands. To promote the formation of graphite crystallites during carbonization, a small amount (x wt.% of Lo) of coronene (Cor) was added to Lo as a dopant. The resulting doped fibers, denoted GF@C_Lo-Cor(x%), were embedded in ABS at 70 wt.%, leading to significant improvements in mechanical properties. At the optimal doping level (x = 5), the composite achieved a Young’s modulus of 1.02 GPa and a tensile strength of 6.96 MPa, substantially higher than the 0.4 GPa and 3.81 MPa observed for the composite with the pristine GF. This enhancement is attributed to a distribution of graphite crystallites and their graphitization extent in the carbon coating, which improves interfacial bonding and increases chain entanglement. Additionally, GF@C_Lo-Cor(x%)–ABS composites (x = 0 and 5) exhibit significantly higher dielectric constant–temperature profiles than GF–ABS, attributed to the formation of diverse chain adsorption states on the C-coating. Full article

In the methylation of pseudocumene with methanol over IM-5 zeolite, the yield of durene can be enhanced. However, poorer stability of the catalytic activity was observed, especially at a higher methanol/pseudocumene ratio. In this paper, conventional characterization methods (XRD, XRF, TGA, SEM, physical adsorption, OH-IR, NH₃-TPD, and Py-IR) were used to characterize fresh and deactivated IM-5 zeolite and ZSM-5. FT-IR, XPS, TG-MS, GC-MS, FT-ICR MS, and NMR were employed to characterize deactivated IM-5 zeolite. It was found that the deactivation of IM-5 zeolite was mainly due to the severe coverage of acidic sites and pore channels by carbon deposits. The carbon deposits within the internal surface had a higher abundance, mainly in the form of linear unsaturated chain-like structures with a high degree of unsaturation. The carbon deposits on the external surface were mainly polycyclic aromatic hydrocarbons with alkyl side chains and a high degree of saturation, accompanied by unreacted methanol. Moreover, graphitized carbon existed on both the internal and external surfaces, which made the conventional coke-burning regeneration method unable to restore the activity of the post-reaction IM-5 zeolite. This work had certain reference significance for modulating the acidity and pore channels of zeolite catalysts, thus improving the activity and stability of the catalysts and extending their service life. Full article

Pyrolysis is an important methodology for achieving efficient and clean utilization of coal. Lump coal pyrolysis demonstrates distinct advantages over pulverized coal processing, particularly in enhanced gas yield and superior coke quality. As a critical parameter in lump coal pyrolysis, particle size significantly influences heat transfer and mass transfer during pyrolysis, yet its governing mechanisms remain insufficiently explored. This research systematically investigates pyrolysis characteristics of the low-rank coal from Ordos, Inner Mongolia, across graded particle sizes (2–5 mm, 5–10 mm, 10–20 mm, and 20–30 mm) through pyrolysis experiments. Real-time central temperature monitoring of coal bed coupled with advanced characterization techniques—including X-ray diffraction (XRD), Raman spectroscopy, Brunauer–Emmett–Teller (BET) analysis, scanning electron microscopy (SEM), gas chromatography (GC), and GC–mass spectrometry (GC-MS)—reveals particle-size-dependent pyrolysis mechanisms. Key findings demonstrate that the larger particles enhance bed-scale convective heat transfer, accelerating temperature propagation from reactor walls to the coal center. However, excessive sizes cause significant intra-particle thermal gradients, impeding core pyrolysis. The 10–20 mm group emerges as optimal—balancing these effects to achieve uniform thermal attainment, evidenced by 20.99 vol% peak hydrogen yield and maximum char graphitization. Tar yield first demonstrates a tendency to rise and then decline, peaking at 14.66 wt.% for 5–10 mm particles. This behavior reflects competing mechanisms: enlarging particle size can improve bed permeability (reducing tar residence time and secondary reactions), but it can also inhibit volatile release and intensify thermal cracking of tar in oversized coal blocks. The BET analysis result reveals elevated specific surface area and pore volume with increasing particle size, except for the 10–20 mm group, showing abrupt porosity reduction—attributed to pore collapse caused by intense polycondensation reactions. Contrasting previous studies predominantly focused on less than 2 mm pulverized coal, this research selects large-size (from 2 mm to 30 mm) lump coal to clarify the effect of particle size on coal pyrolysis, providing critical guidance for industrial-scale lump coal pyrolysis optimization. Full article

PTFE/C composite targets were ablated using a pulsed electron beam of different energies to evaluate the suitability of this technique for composite coating deposition. Composite materials with two different carbon fillers and their contents (graphite—10 wt.% and coal coke—35 wt.%) were used. A PTFE target was used as reference material. The chemical and physical structure of the coatings was investigated using FTIR, XPS, and XRD. The topography was investigated using optical microscopy, SEM, and AFM. In addition, the contact angle and surface energy of the coatings were evaluated. It was shown that the presence of carbon particles in the polymer matrix decreased the deposition rate but greatly reduced the degradation of PTFE. It is hypothesized that the high content of conductive particles reduces the capability of the pulsed electron beam process to maintain the integrity of the filler particles during the coating deposition process. Full article

The growing demand for high-performance and cost-effective composite materials necessitates advanced computational approaches for optimizing their composition and properties. This study aimed at the application of machine learning for the prediction and optimization of the functional properties of composites based on a thermoplastic matrix with various fillers (two types of fibrous, four types of dispersed, and two types of nano-dispersed fillers). The experimental methods involved material production through powder metallurgy, further microstructural analysis, and mechanical and tribological testing. The microstructural analysis revealed distinct structural modifications and interfacial interactions influencing their functional properties. The key findings indicate that optimal filler selection can significantly enhance wear resistance while maintaining adequate mechanical strength. Carbon fibers at 20 wt. % significantly improved wear resistance (by 17–25 times) while reducing tensile strength and elongation. Basalt fibers at 10 wt. % provided an effective balance between reinforcement and wear resistance (by 11–16 times). Kaolin at 2 wt. % greatly enhanced wear resistance (by 45–57 times) with moderate strength reduction. Coke at 20 wt. % maximized wear resistance (by 9−15 times) while maintaining acceptable mechanical properties. Graphite at 10 wt. % ensured a balance between strength and wear, as higher concentrations drastically decreased mechanical properties. Sodium chloride at 5 wt. % offered moderate wear resistance improvement (by 3–4 times) with minimal impact on strength. Titanium dioxide at 3 wt. % enhanced wear resistance (by 11–12.5 times) while slightly reducing tensile strength. Ultra-dispersed PTFE at 1 wt. % optimized both strength and wear properties. The work analyzed in detail the effect of PTFE content and filler content on composite properties based on machine learning-driven prediction. Regression models demonstrated high R-squared values (0.74 for density, 0.67 for tensile strength, 0.80 for relative elongation, and 0.79 for wear intensity), explaining up to 80% of the variability in composite properties. Despite its efficiency, the limitations include potential multicollinearity, a lack of consideration of external factors, and the need for further validation under real-world conditions. Thus, the machine learning approach reduces the need for extensive experimental testing, minimizing material waste and production costs, contributing to SDG 9. This study highlights the potential use of machine learning in polymer composite design, offering a data-driven framework for the rational choice of fillers, thereby contributing to sustainable industrial practices. Full article

Ilmenite concentrate has emerged as the key titanium raw material for exploitation and utilization, playing a crucial role in the preparation of metallic titanium and titanium dioxide. However, the presence of impurities such as Fe, Ca, and Mg in ilmenite concentrate severely restricts its economic utilization and environmentally friendly applications. In our previous research, a novel process was proposed to prepare TiCl₄ from high-Ca- and Mg-containing ilmenite through carbothermal reduction and boiling chlorination. Nevertheless, the employment of graphite as a reducing agent and hydrochloric acid for metallic iron separation led to elevated production costs. The aim of this study was to explore an alternative and more cost-effective method. Petroleum-derived coke was used as the reducing agent to investigate the feasibility of producing titanium oxycarbide from ilmenite concentrate via carbothermal reduction and magnetic separation. The results showed that petroleum-derived coke is capable of reducing ilmenite concentrate to coral-shaped TiC_xO_y under high-temperature conditions. However, an approximate 100 °C increment in temperature is required to reach an equivalent reduction efficiency compared with graphite. The X-ray diffraction (XRD) analysis results of the reduced products reveal that complete reduction of ilmenite concentrate by petroleum-derived coke can only be achieved when the reduction process is conducted at 1600 °C for 3 h or at 1500 °C for 5 h. The reduced product obtained at 1600 °C, characterized by a substantial presence of dense Ti₂O₃, exhibits a significantly coarser particle size after 30 minutes of ball milling in contrast to the reduced product obtained at 1200 °C, which is rich in M₃O₅ anosovite. Magnetic separation results showed that the reduction product at 1200 °C could not have metallic iron removed by magnetic separation at 1.2 T, while the reduction product at 1600 °C could yield a non-magnetic charge rich in Ti₂O₃ and TiC_xO_y with an iron content as low as 2 ± 0.03 wt.%, which fully meets the requirements for producing TiCl₄ by boiling chlorination. Overall, these research results offer a new approach for the low-cost production of TiCl₄ from ilmenite concentrate with high levels of Ca and Mg impurities through boiling chlorination. Full article