Search Results (55)

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

Recently, due to the rapid increase in the demand for artificial graphite, there has been a strong need to improve the productivity of artificial graphite. In this study, we propose a new efficient process by eliminating the carbonation stage from the existing process. The conventional graphite manufacturing process usually involves a series of stages: the pulverization of needle-type coke, the granulation of pitch and coke premix, carbonation, graphitization, and surface treatment to compensate voids formed within particles. The process seems time-consuming and costly. Therefore, in our proposed shortened process, we have eliminated the carbonization stage. Instead of petroleum-derived pitch, coal tar pitch was employed. Coal tar pitch has a lower softening point than binder pitch. Apart from the cost-effectiveness of the process, it has enhanced the properties of artificial graphite by a uniform coating using a lower amount of hard carbon. In addition, the whole manufacturing time and cost was reduced by 12 h and 20% due to the skipped manufacturing step, respectively. It was observed that the artificial graphite produced by the newly proposed shortened process had improved physical properties related to the density and graphitization degree, and also showed an improvement in electrochemical performance. Raman 3D mapping and the electrochemical evaluation of artificial graphite were mainly used to compare the physical properties. This shortened process not only reduces the manufacturing cost, but also contributes to the improved performance of lithium-ion battery anode material. Full article

Chloride ions readily react with organic matter and other ions, resulting in the formation of disinfection by-products (DBPs) that exhibit heightened levels of toxicity, carcinogenicity, and mutagenicity. This study creatively employed waste walnut shells as self-templates and low-cost magnesium bicarbonate as a rigid template to successfully synthesize multifunctional porous carbon derived from walnut shells. Employing a series of characterization techniques, it was ascertained that the porous carbon material (WSC/Mg) synthesized via the dual-template method exhibited a distinct layered microscopic surface structure, with a predominance of C and O elements on the surface. The material displayed a high degree of graphitization, significant specific surface area, and abundant oxygen-containing surface functional groups. The incorporation of magnesium bicarbonate as a hard template improved the structure of the walnut shell porous carbon, resulting in a significant enhancement in mass transfer efficiency for the target product on the adsorbent and a substantial improvement in removal efficiency. In comparison with walnut shell-derived carbon using only self-templating, WSC/Mg exhibited a 17.26-fold increase in adsorption capacity for 2,4-dichlorophenol. Furthermore, even after four adsorption–desorption cycles, WSC/Mg-12 maintained an adsorption efficiency above 90%. It is remarkable that WSC/Mg-12 demonstrated exceptional resistance to interference from natural organic matter and pH variations. Moreover, the adsorbed saturated WSC/Mg-12 effectively treated real coke wastewater, resulting in an 80% color removal rate, 20% COD removal rate, and 15% ammonia nitrogen removal rate. In conclusion, this study presents an innovative approach for cost-effective and versatile porous carbon materials with extensive applications in water environment purification and biomass utilization. Full article

Carbon-based electrodes have recently been most widely used in P-MFC due to their desirable properties such as biocompatibility, chemical stability, affordable price, corrosion resistance, and ease of regeneration. In general, carbon-based electrodes, particularly graphite, are produced using a complex process based on petroleum derivatives at very high temperatures. This study aims to produce electrodes from bio-pitch and charcoal powder as an alternative to graphite electrodes. The carbons used to manufacture the electrodes were obtained by the carbonisation of Robinia pseudoacacia and Azadirachta indica wood. These carbons were pulverised, sieved to 50 µm, and used as the raw materials for electrode manufacturing. The binder used was bio-pitch derived from coconut shells as the raw materials. The density and coking value of the bio-pitch revealed its potential as a good alternative to coal-tar pitch for electrode manufacturing. The electrodes were made by mixing 66.50% of each carbon powder and 33.50% of bio-pitch. The resulting mixture was moulded into a cylindrical tube 8 mm in diameter and 80 mm in length. The raw electrodes obtained were subjected to heat treatment at 800 °C or 1000 °C in an inert medium. The electrical resistivity obtained by the four-point method showed that N1000 has an electrical resistivity at least five times lower than all the electrodes developed and two times higher than that of G. Fourier-transform infrared spectroscopy (FTIR) was used to determine the compositional features of the samples and their surface roughness was characterised by atomic force microscopy (AFM). Charge transfer was determined by electrical impedance spectroscopy (EIS). The FTIR of the electrodes showed that N1000 has a spectrum that is more similar to that of G compared to the others. The EIS showed the high ionic mobility of the ions and therefore that N1000 has a higher charge transfer compared to G and the others. AFM analysis revealed that N1000 had the highest surface roughness in this study. Full article

The synergy effect of high K-low Ca-high Si biomass ash-based model system (BAMS) on the synthesis gas output and reaction characteristics of petroleum coke (PC) steam gasification process was studied using three biomass ash (BA) components, KCl, SiO₂, and CaCO₃, which were used as the model compounds. In the ternary model system, the steam gasification experiment of PC was conducted using a fixed bed reactor and gas phase chromatography. The synergistic effects of binary and ternary components in the ternary model system on the gasification of PC were obtained. These investigations were based on the data from the gas analysis and examined the gasification reaction process, syngas release behavior, and reaction characteristics. This study examined the effects of binary and ternary components in the ternary model system on the evolution of semi-char structure during PC gasification. This correlation revealed the synergistic effect of the model system on PC gasification. Scanning electron microscope (SEM) and Raman spectroscopy were used to characterize the structure and surface microstructure of the gasification semi-char. The results showed that the yields of different gases in the ternary model system were in H₂ > CO > CO₂. Compared with single PC gasification, the yields of H₂, CO, syngas, and carbon conversion were increased by 29.42 mmol/g, 20.40 mmol/g, 56.68 mmol/g, and 0.35, respectively. All other components in the ternary model system with high K-low Ca-high Si demonstrated catalytic effect, except for SiO₂ and the Ca-Si system, which showed inhibitory effects on syngas release and reaction features. Integrating SEM and Raman spectroscopic analyses, it was elucidated that CaCO₃ and KCl diminished the degree of graphitization in semi-char through interactions with the carbonaceous matrix. This phenomenon facilitated the gasification process and exhibited a synergistic effect. Secondly, SiO₂ will react with CaCO₃ and KCl, producing inert silicates and inactivating these compounds, leading to the decline of catalysis. Full article

The elimination of tar impurities from biomass gasification by catalytic steam reforming can provide clean syngas for downstream biofuel synthesis (Fischer–Tropsch). The effects of key operating parameters in CH₄/tar steam reforming were investigated. Ni-Co/Mg(Al)O catalyst performance was tested at model conditions (10/35/25/25/5 wt% CH₄/H₂/CO/CO₂/N₂), changing the temperature (650–800 °C), steam-to-carbon ratio (2–5), tar loading (10–30 g/Nm³), and tar composition (toluene, 1-methylenaphthalene, and phenol). Complete tar elimination was achieved under all conditions, at the expense of catalyst deactivation by coke formation. Post-operation coke characterization was obtained with TPO-MS, Raman spectroscopy, and STEM analysis, providing vital insight into coke morphology and location. Critical low-temperature and high-tar loading limits were identified, where rapid deactivation was accompanied by increasing amounts of hard coke species. A coke classification scheme is proposed, including strongly adsorbed surface carbon species (soft coke A), initial scattered carbon filaments (hard coke B1.1), filament clusters and fused filaments (B2), and strongly deactivating bulk encapsulating coke (B3), formed through progressive filament cluster graphitization. High-molecular-weight tar was found to enhance the formation of strongly deactivating metal-particle-encapsulating coke (B1.2). The results contribute to the understanding of coke formation in the presence of biomass gasification tar impurities. Full article

Currently, a power-to-gas technology that obtains electrolytic hydrogen from renewable energy sources, synthesizes it with carbon dioxide, and converts it to methane has received a great deal of attention. It is called methanation, but there are few studies examining alternative substances to replace the raw material of hydrogen. Since hydrogen does not exist naturally, it is important to find other substances that react with carbon dioxide. We focus on flammable gases formed in oil refineries and petrochemical plants. In this study, based on chemical equilibrium calculations of the so-called NASA-CEA, we tested several gases including flammable and nonflammable gases by reacting them with carbon dioxide. Some of them are included in flare stacks. The reactants in the present gas conversion were H₂O, CH₃OH, C₂H₅OH, NH₃, CH₃CN, CH₃N₂CH₃, C₃H₈O (1-propanol), C₃H₈O (2-propanol), C₂H₆, C₂H₄, C₃H₈, C₃H₆, C₃H₄ (allene), C₃H₄ (propine), C₆H₅OH, (CH₃COOH)₂, HCOOH, HF, HCl, HBr, H₂S, HNO₃, and SiH₄. The results show that substances with more hydrogen atoms per mol of reactant, such as C₃H₈, CH₃N₂CH₃, and SiH₄, can produce more synthetic methane. One more finding is that graphite due to coking increases proportionately to the number of carbon atoms in the chemical formula. Full article

An innovative process for preparing silicon carbide (SiC) from acid leaching residue of ferronickel slag through a carbon–thermal reduction process was proposed in this study. The results indicate that the acid leaching residue is an ideal silicon source for SiC preparation according to its high amorphous silica content of 84.20% and fine particle size of d₅₀ = 29.16 μm. Compared with carbon black, activated carbon, and graphite, coke is the more appropriate carbon source for SiC preparation. A micron-size SiC powder with grade of 88.90% and an average particle size (d₅₀) of 44.68 μm can be obtained under the following conditions: the mass ratio of coke to leaching residue as 1.2:1, in an air atmosphere, reducing at 1600 °C for 3 h, following by decarbonizing at 700 °C for 4 h. The XRD, SEM and FTIR analyses show that the prepared powder is 3C-SiC and belongs to the β-SiC crystal type. Based on thermodynamic analysis and micromorphology observation, it can be concluded that with amorphous silica as the silicon source, the carbon–thermal synthesis of SiC powder follows both the solid–solid reaction mechanism and the gas–solid mechanism. The SiC created through solid–solid reaction is primarily nucleated in situ on amorphous SiO₂, with a size close to that of the original acid-leaching slag, while the SiC generated according to the gas–solid mechanism mainly nucleates heterogeneously on the surface of carbon particles, resulting in a smaller particle size and mostly adhering to the surface of solid–solid nucleated SiC particles. This study provides a feasible method for the effective utilization of amorphous silica, which is also significant for the efficient consumption of the vast acid leaching residue. Full article