Search Results (98)

To enhance the molten salt corrosion resistance of Ni200 alloy plasma arc welds, the welds were subjected to tensile deformation followed by heat treatment. The grain boundary character distribution (GBCD) was analyzed using electron backscatter diffraction (EBSD) in conjunction with orientation imaging microscopy (OIM). A constant-temperature corrosion test at 900 °C was conducted to evaluate the impact of GBCD on the corrosion resistance of the welds. Results demonstrated that after processing with 6% tensile deformation, and annealing at 950 °C for 30 min, the fraction of low-ΣCSL grain boundaries increased from 1.2% in the as-welded condition to 57.3%, and large grain clusters exhibiting Σ3ⁿ orientation relationships were formed. During the heat treatment, an increased number of recrystallization nucleation sites led to a reduction in average grain size from 323.35 μm to 171.38 μm. When exposed to a high-temperature environment of 75% Na₂SO₄-25% NaCl mixed molten salt, the corrosion behavior was characterized by intergranular attack, with oxidation and sulfidation reactions resulting in the formation of NiO and Ni₃S₂. The corrosion resistance of Grain boundary engineering (GBE)-treated samples was significantly superior to that of Non-GBE samples, with respective corrosion rates of 0.3397 mg/cm²·h and 0.8484 mg/cm²·h. These findings indicate that grain boundary engineering can effectively modulate the grain boundary character distribution in Ni200 alloy welds, thereby enhancing their resistance to molten salt corrosion. Full article

The suitability of 347H stainless steel (SS347H) for chloride salt environments is critical in selecting materials for next-generation concentrated solar power (CSP) systems. This study investigated the corrosion behavior of SS347H in a ton-scale purification system with continuously flowing chloride salt under three conditions: exposure to NaCl-KCl-MgCl₂ molten salt vapor, immersion in molten salt, and at the molten salt surface interface. Results revealed that corrosion was most severe in the molten salt vapor, where HCl steam facilitated Cl⁻ reactions with Fe and Cr in the metal, causing dissolution and forming deep corrosion pits. At the interface, liquid Mg triggered displacement reactions with Fe²⁺/Cr²⁺ ions in the salt, depositing Fe and Cr onto the surface, which reduced corrosion intensity. Within the molten salt, Mg’s purification effect minimized impurity-induced corrosion, resulting in the least damage. In all cases, the primary corrosion mechanism involves the dissolution of Fe and Cr, with the formation of minor MgO. These insights provide valuable guidance for applying 347H stainless steel in chloride salt environments. Full article

In response to the growing impact of the climate crisis, many countries are accelerating efforts to develop sustainable and carbon-free energy solutions. This has led to increasing interest in advanced energy storage and conversion technologies, particularly the development of high-temperature molten salt energy systems. Among these, chloride salt-based molten salt systems, which offer excellent thermal properties such as high thermal conductivity, low melting points, and favorable chemical stability, are emerging as strong candidates for thermal energy storage and heat-transfer applications. This study focuses on deriving key thermophysical properties essential for selecting suitable molten salt heat-transfer fluids by examining their eutectic points and thermal stability with respect to various salt compositions. Three chloride mixtures—NaCl-MgCl₂, NaCl-KCl-MgCl₂, and NaCl-KCl-ZnCl₂—were evaluated for potential use in high-temperature molten salt energy systems. Differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) were employed to measure the melting points and thermal stability of molten salts with various compositions near their eutectic regions. Experimental results were compared with predicted eutectic points to assess the thermal performance of each salt mixture. The findings indicate that the NaCl-KCl-MgCl₂ mixture exhibits the most promising characteristics, including a low melting point below 400 °C and superior thermal stability, making it highly suitable as a heat-transfer fluid in high-temperature molten salt energy systems. In contrast, NaCl-KCl-ZnCl₂ was found unsuitable for such applications due to its high hygroscopicity and poor thermal stability. This study provides essential data for selecting optimal molten salt compositions for the efficient and reliable operation of high-temperature molten salt energy systems. Full article

Zeolite Battery Research Africa (ZEBRA) batteries (Na-NiCl₂ solid electrolyte batteries, SEBs) have commercial applications in energy storage due to their low costs and recyclability, long lifetime, and high safety. In commercial ZEBRA batteries, Ni electrode and beta’’-alumina solid electrolyte (BASE) have a more than 70% share of the overall cell material costs. Na-ZnCl₂ all-liquid batteries (ALBs), which replace Ni with abundant and low-cost Zn and BASE electrolyte with molten salt electrolyte, could reduce costs and provide a longer lifetime and higher safety, making their application in grid storage promising. However, compared to SEBs, ALBs are in an early development stage, particularly for their molten salt electrolytes, which have a significant effect on the battery performance. Physical and chemical properties of the salt electrolyte like melting temperatures and solubilities of electrode materials (i.e., Na and Zn metal) are vital for the molten salt electrolyte selection and battery cell design and optimization. In this work, the binary and ternary phase diagrams of salt mixtures containing NaCl, CaCl₂, BaCl₂, SrCl₂, and KCl, obtained via FactSage simulation and DSC measurements, as well as the solubilities of electrode materials (Na and Zn metals), are presented and used for the selection of the molten salt electrolyte. Moreover, various criteria, considered for the selection of the molten salt electrolyte, include high electromotive force (EMF) for suitable electrochemical properties, low melting temperature for large charge/discharge range, low solubilities of electrode materials for low self-discharge, low material costs, and high material abundance for easy scale-up. Based on these criteria, the NaCl-CaCl₂-BaCl₂ and NaCl-SrCl₂-KCl salt mixtures are selected as the two most promising ALB molten salt electrolytes and suggested to be tested in the ALB demonstrators currently under development. Full article

This paper reports the effects of different levels of tensile stress caused by quasi-static loading on the corrosion behavior of T91 steel in a molten salt environment. Corrosion tests were carried out in a molten salt environment with a NaCl:K₂SO₄:Na₂SO₄ ratio of 1:1:8 under different applied stresses. The corrosion behavior was investigated through measurements of the phase composition, oxide morphology, and elementary composition. The results indicated that a low tensile stress promotes the growth of chromium oxides near the substrate and enhances the corrosion resistance, but with an increase in stress, the chromium oxides that formed on the T91 steel are destroyed, accelerating the inward diffusion of sulfur into the substrate to increase corrosion. The mechanism underlying the effects of applied stress and temperature on the corrosion behavior of T91 steel is discussed. Full article

The molten salt reactor is a fourth-generation nuclear power plant considered a long-term eco-friendly energy source with high efficiency and the potential for green hydrogen production. The selection of alloys for such reactors, which can operate for more than 30 years, is a primary concern because of corrosion by high-temperature molten salt. In this study, three Fe- and Ni-based alloys were selected as structural material candidates. Corrosion immersion tests were conducted in NaCl–KCl molten salt for 48 h at 800 °C and 40% RH conditions in an air environment. In the absence of moisture and oxygen removal, ClNaK salt-induced damage was observed in the investigated alloys. The corrosion behavior of the alloys was characterized using various techniques, including scanning electron microscopy, energy-dispersive X-ray spectroscopy, X-ray photoelectron spectroscopy, and Auger electron spectroscopy. The results show that the corrosion process can be explained by salt-induced surface damage, internal ion migration, and depletion to the surface. The corrosion rate is high in SS316L (16Cr-Fe), N10003 (7Cr-Ni), and C-276 (16Cr-Ni), in decreasing order. Based on the corrosion penetration, ion elution, and interfacial diffusion results, C-276 and N10003 are good candidates for structural materials for MSRs. Therefore, Ni-based alloys with high Cr content minimize surface damage and ion depletion in unpurified molten salt environments. This indicates that Ni-based alloys with high Cr content exhibit highly corrosion resistance. Full article

The corrosion properties of 316L stainless steel (316L SS) alloy within molten NaCl-KCl salt were explored through a static immersion experiment carried out at 700 °C under Ar flow for 25, 50, 100, 200, and 400 h. The loss in weight of the corroded 316L SS alloy increased from 0.06 to 1.71 mg/cm², while the maximum corrosion depth increased from 1.71 to 14.09 μm. However, the corrosion rate initially increased from 27.54 μm/year to 93.45 μm/year and then decreased to 47.22 μm/year as the soaking time was increased from 25 to 400 h. The impurities in the molten salts produced corrosive Cl₂ and HCl, which corroded the 316L SS matrix. The accelerated selective Cr dissolution with small amounts of Fe and Ni resulted in intergranular corrosion as the time of corrosion was increased. The depletion depths for Ni, Cr, and Fe at 400 h were found to be 0.87 μm, 3.94 μm, and 1.47 μm, respectively. The formation of Cr and Fe oxides might potentially play a vital role. The grain boundary and outward diffusion of Mo may prevent the outward diffusion of Cr, thereby mitigating alloy corrosion. Therefore, molten chloride salt purification and the selection of stainless steel are crucial for developing future concentrated solar power technologies. The findings of this study provide guidelines for the use of 316L SS in NaCl-KCl salt at high temperatures. Full article

This study presents a metallothermic reduction mechanism for fabricating Nd and Nd–Fe alloys at 850–1050 °C using anhydrous NdCl₃ and Ca, which have relatively low melting points. Our method decreased the process temperature while improving the recovery rate of Nd using the thermodynamic parameters of the CaCl₂–KCl–NaCl and Nd–Fe liquid solutions. To reduce the activity of the product (CaCl₂), the optimal composition of the CaCl₂–KCl–NaCl molten salt was $X_{{CaCl}_2}=0.4(X_{KCl}:X_{NaCl}=6:4)$. The molten metal bath (Nd or Nd–Fe) that formed at the bottom of the reaction zone during Nd and Nd–Fe alloy production absorbed metal particles generated in the molten salt during the reaction, thereby facilitating ingot formation. In Nd produced at 1050 °C using 1.2× the stoichiometric amount (by mass) of Ca, the Nd recovery rate was 97.0%. Moreover, in the Nd–Fe alloys produced at 1050 °C targeting eutectic compositions, the Nd recovery rate was 96.3%. Increased Fe contents in the Nd–Fe liquid solution reduced the Nd recovery rates, and the Nd–Fe alloy (Nd recovery rate: 89.8%) was produced at 850 °C, suggesting the possibility of increasing the energy efficiency of the Nd production process. The Nd–Fe alloy produced through this proposed process could be used as a raw material in the NdFeB strip casting process. Full article

The molten salt chlorination method is one of the two main methods for producing titanium tetrachloride, an important intermediate product in the titanium industry. To effectively improve chlorination efficiency and reduce unnecessary waste salt generation, it is necessary to understand the mechanism of the molten salt chlorination reaction, and consequently this paper conducted studies on the carbon chlorination reaction mechanism in molten salts by combining ab initio molecular dynamics (AIMD) and deep potential molecular dynamics (DeePMD) methods. The use of DeePMD allowed for simulations on a larger spatial and longer time scale, overcoming the limitations of AIMD in fully observing complex reaction processes. The results comprehensively revealed the mechanism of titanium dioxide transforming into titanium tetrachloride. In addition, the presence form and conversion pathways of chlorine in the system were elucidated, and it was observed that chloride ions derived from NaCl can chlorinate titanium dioxide to yield titanium tetrachloride, which was validated through experimental studies. Self-diffusion coefficients of chloride ions in pure NaCl which were acquired by DeePMD showed good agreement with the experimental data. Full article

The sustainability of aquaculture tailwater plays a key role in the aquaculture industry. Photocatalytic degradation of recalcitrant antibiotics in aquaculture tailwater has emerged as a significant research focus, with gCN-based photocatalysis offering a promising approach. To address the issue of inefficient degradation associated with gCN, melamine was modified using NaCl solution, resulting in the synthesis of NaMe-x with distinctive microstructure through molten salt assistance. The ability of NaMe-x to degrade tetracycline hydrochloride (TC-HCl) was examined, including an analysis of its degradation pathway, intermediate products, mechanism, and toxicity of the by-products. The results demonstrated that NaCl-based precursor modification markedly enhanced the degradation capacity of gCN for TC-HCl, achieving a maximum degradation rate of 0.02214 min⁻¹, which is 2.1 times higher than that of unmodified gCN. LC-MS analysis revealed intermediates at various degradation stages, and two potential pathways for TC-HCl degradation in the presence of NaMe-1 were identified. In this process, ·O₂⁻ and ·OH are the reactive radicals that play a dominant role, and their degradation mechanism is thus proposed. It was confirmed by toxicity experiments that the products after the degradation of TC-HCl by NaMe-1 were not significantly toxic to Chlorella vulgaris (p ˃ 0.05). However, it had a significant effect on Vibrio fischeri (p < 0.01). These findings suggest that the synthesis of NaMe-x via melamine precursor modification substantially improves the degradation performance of gCN and enhances the sustainability of aquaculture tailwater. Full article

Concentrated solar power plant (CSP) technology holds significant application value in the renewable energy sector for converting solar radiation into thermal and electrical energy. As a heat storage medium for next-generation solar thermal power stations, chloride salts exhibit strong corrosive effects on structural components. To enhance corrosion resistance of the heated body in molten salt environments, Inconel 625 is modified by incorporating aluminum, which facilitates the formation of a protective oxide film. In this study, High-Aluminum Inconel 625, after cold rolling and solution treatment, was immersed in a NaCl-KCl-MgCl₂ eutectic chloride melt at 650 °C for 200 h. Post-corrosion analysis revealed the formation of an alumina layer on the surface, effectively mitigating corrosion. Increased aluminum content resulted in thicker alumina layers and the formation of oxidation products, such as Cr₂O₃, Fe₂O₃, MoO₂, and MgCr₂O₄ spinel structures, significantly enhancing the alloy’s corrosion resistance. The Inconel 625 cold-rolled plate with 5.31 wt% Al exhibited the best corrosion resistance (3510 μm/year), making it a promising candidate for use in next-generation CSP heat storage and exchange components. Full article

The electrochemical conversion of CO₂ into high value-added carbon materials by molten salt electrolysis offers a promising solution for reducing carbon dioxide emissions. This study focuses on investigating the influence of molten salt composition on the structure of CO₂ direct electroreduction carbon products in chloride molten salt systems. Using CaO as a CO₂ absorber, the adsorption principle of CO₂ in LiCl-CaCl₂, LiCl-CaCl₂-NaCl and LiCl-CaCl₂-KCl molten salts was discussed, and the reasons for the different morphologies and structures of carbon products were analyzed, and it was found that the electrolytic efficiency of the whole process exceeded 85%. Furthermore, cathode products are analyzed through Scanning Electron Microscope (SEM), X-Ray Diffractometer (XRD), Thermal Gravimetric Analyzer (TGA), Raman Spectra and Fourier Transform Infrared (FTIR) techniques with a focus on the content and morphology of carbon elements. It was observed that the carbon content in the carbon powder produced by molten salt electrochemical method exceeded 99%, with most carbon products obtained from electrolysis in the Li-Ca chloride molten salt system being in the form of carbon nanotubes. In contrast, the Li-Ca-K chloride system yielded carbon nanospheres, while a mixture was found in the Li-Ca-Na chloride system. Therefore, experimental results demonstrate that altering the composition of the system allows for obtaining the desired product size and morphology. This research presents a pathway to convert atmospheric CO₂ into high value-added carbon products. Full article

In this paper, the enhancement of thermochemical energy storage by alkali metal chloride salts-doped Ca-based sorbents is revealed by experiments and DFT calculations. The results indicate that NaCl and KCl doping increases the reaction rate and cycle stability. Compared to CaO, the conversion of NaCl-CaO and KCl-CaO after one cycle is increased by 59.1% and 61.9%, respectively. This enhancement originates from the oxygen vacancies generated by Na₂O and K₂O and the significantly increased surface area by CaCl₂ as well as the sintering delay. The synergistic effect between Na₂O, K₂O, and CaCl₂ increases the reaction rate of calcium-based materials. Meanwhile, the penetration of low-viscosity molten NaCl and KCl into the calcium-based materials successfully segregates the CaO grains and allows the calcium-based material to maintain the porous structure after 80 cycles, thus exhibiting a high effective conversion rate. In addition, the KCl-CaO composites show the best combined performance in terms of effective conversion and averaged thermal energy density. This work paves the way for the application of chloride salts-doped calcium-based materials. Full article

In order to enhance the corrosion resistance of tantalum, the double-glow plasma (DGP) metallurgy technique was used to prepare TaC coatings on the tantalum. The morphology, microstructure, and phase constituents of TaC were examined by scanning electron microscopy (SEM) and X-ray diffraction (XRD). Nano-indentation tests were used to evaluate the mechanical properties of the coatings. The specimens were immersed in NaCl-KCl molten salt at 830 °C to evaluate their corrosion resistance. The results showed that the coating prepared by the DGP technique has a thickness of approximately 5 µm, the diffusion layer has a thickness of 2.5 µm, and the nano-indentation hardness is measured to be 17.27 GPa. The high-temperature stable ceramic phase enhances the high-temperature oxidation resistance of pure tantalum (Ta), while the dense corroded surface and oxidation products improve the anti-corrosion property of TaC coatings. Full article

After the high-temperature pretreatment of α-spodumene to induce a phase transition to β-spodumene, a derivative of the silica polymorph keatite, often coexisting with metastable Li-stuffed β-quartz (γ-spodumene)_, the conventional approach to access lithium is through ion exchange with hydrogen using concentrated sulfuric acid, which presents drawbacks associated with the production of low-value leaching residues. As sodium and magnesium can produce more interesting aluminosilicate byproducts, this study investigates Na⁺ ↔ Li⁺ and Mg²⁺ ↔ 2 Li⁺ substitution efficiencies in β-spodumene and β-quartz. Thermal annealing at 850 °C of the LiAlSi₂O₆ silica derivatives mixed with an equimolar proportion of Na endmember glass of equivalent stoichiometry (NaAlSi₂O₆) indicates that sodium incorporation in β-quartz is limited, whereas the main constraint for not attaining complete growth to a Na_0.5Li_0.5AlSi₂O₆ β-spodumene solid solution is co-crystallization of minor nepheline. For similar experiments in the equimolar LiAlSi₂O₆-Mg_0.5AlSi₂O₆ system, the efficient substitution of Mg for Li is observed in both β-spodumene and β-quartz, consistent with the alkaline earth having an ionic radius closer to lithium than sodium. Ion exchange at lower temperatures was also evaluated by exposing coexisting β-spodumene and β-quartz to molten salts. In NaNO₃ at 320 °C, sodium for lithium exchange reaches ≈90% in β-spodumene but less than ≈2% in β-quartz, suggesting that to be an efficient lithium recovery route, the formation of β-quartz during the conversion of α-spodumene needs to be minimized. At 525 °C in a molten MgCl₂/KCl medium, although full LiAlSi₂O₆-Mg_0.5AlSi₂O₆ solid solution is observed in β-quartz, structural constraints restrict the incorporation of magnesium in β-spodumene to a Li_0.2Mg_0.4AlSi₂O₆ stoichiometry, limiting lithium recovery to 80%. Full article