Search Results (197)

Large-scale reuse of copper tailings can mitigate environmental hazards and recover strategic elements; this work investigates the feasibility of producing foam glass-ceramics with high copper-tailing content (>70 wt%) by tuning the CaO/SiO₂ ratio to couple melt viscosity and crystallisation. The comprehensive utilisation of these tailings helps mitigate environmental pollution and enhance resource efficiency. In this study, foam glass-ceramics with varying CaO/SiO₂ ratios were synthesised through melt quenching followed by foaming heat treatment. The effects of different CaO/SiO₂ ratios on the foaming behaviour, crystallisation, and microstructure were investigated using DSC, FTIR, viscosity, XRD, SEM, and CT. The results indicate that increasing the CaO/SiO₂ ratio disrupts the three-dimensional network structure of the glass, which lowers the glass viscosity and influences the bubble size and distribution in the foam glass-ceramics. Additionally, the increased CaO content promotes crystal precipitation and enhances the compressive strength of the foam glass-ceramics. At a CaO/SiO₂ mass ratio of 0.22, the foam glass-ceramics exhibited the lower bulk density (240 kg/m³) and thermal conductivity (0.07 W/m·K). The materials also demonstrated good water absorption and compressive strength. This study highlights the potential of using copper tailings in foam glass-ceramics to improve their overall performance, offering promising energy-saving and environmentally friendly solutions. Full article

Silicon carbide (SiC) and SiC fiber-reinforced SiC matrix composites (SiC/SiC) are receiving renewed attention for use in next-generation fusion reactors due to their ability to withstand extreme conditions, including high temperatures, neutron irradiation, and plasma interactions. General Atomics Electromagnetic Systems (GA-EMS) has demonstrated significant progress in scaling up the fabrication of SiC/SiC, achieving high mechanical uniformity and meeting dimensional requirements in components up to 12 feet in length. Key developments are discussed including scale-up of the chemical vapor infiltration (CVI) process from lab-scale to full sized parts, high-dose (100 dpa) irradiation testing, nuclear-grade ceramic joining technologies, and production-focused quality control with the collective aim to establish SiC/SiC as a reliable solution for structural and functional components in fusion systems. Beyond manufacturing, the paper addresses supply chain barriers, particularly the limited availability and high cost of nuclear-grade SiC fiber. GA-EMS is developing a novel SiC fiber production method based on a thermochemical cure step that is anticipated to reduce costs compared to traditional approaches. Additionally, advancements in engineered SiC materials, such as SiC foams and tungsten-graded SiC composites, are discussed as promising solutions for specific fusion reactor components. Full article

Municipal solid waste incineration (MSWI) fly ash is classified as hazardous waste due to its enrichment of heavy metals and dioxins. This article systematically reviews its generation pathways, physicochemical characteristics, and potential environmental risks, based on the literature from 2010 to 2025 sourced from Web of Science, Scopus, ScienceDirect and China National Knowledge Infrastructure. Emphasis is placed on heavy metal stabilization, dioxin degradation and resource recovery from MSWI fly ash. The mechanisms, technical advantages, and application limitations of three mainstream detoxification, including solidification/stabilization, extraction and thermal treatment, were emphasized. For instance, geopolymer achieves >99.6% Pb immobilization and electrodialytic removal rates of Cd up to 98%, while vitrification reduces the MSWI fly ash volume by >50%. A comprehensive exploration of MSWI fly ash resource utilization was conducted, covering the preparation of ceramic tiles, synthesis of glass ceramic and glass ceramic foams, processing of road substrates, and modification of cement-based composite materials. The current technological system still faces challenges such as high costs, excessive energy consumption, and secondary pollution. Future research should focus on developing green, low-carbon, and low-cost processes, improving long-term environmental stability of products and strengthening pollution source reduction control. Full article

Oily substances (oils, greases, lubricants, etc.) are among the most persistent pollutants for water. They mix with water to form emulsions that contaminate large volumes. Therefore, this project evaluated the use of porous systems (polyurethane foam) modified with polydimethylsiloxane-modified silica (SiO₂/DMS) hybrid ceramics as filtration membranes at the laboratory scale for vegetable oil. The polyurethane foam was modified using sol solutions with various SiO₂/PDMS ratios obtained via the sol–gel method. Tetraethyl-orthosilicate (TEOS) was used as the silica precursor. Three different polydimethylsiloxane chains were employed as the organic fragment: polydimethylsiloxane hydroxyl terminated (DMS-CH₃), aminopropyl-terminated polydimethylsiloxane (DMS-N), and copolymer polydiphenylsiloxane-polydimethylsiloxane hydroxyl terminated (PDS). The siloxane chain was added at a concentration of 20–40% w/w. The modification of the porous system was determined using different characterization techniques, including infrared spectroscopy, which was used to observe the main functional groups. Optical microscopy and SEM were used to identify the hybrid ceramic deposited into the pore structure of the polyurethane sponge. Contact angle measurements revealed the hydrophobic character of the modified material. The removal capacity was evaluated by using vegetable oil as a representative oily contaminant, with values ranging from 43.42 to 96.78 g of oil per gram of adsorbent. In the case of gasoline, removal capacities between 27 and 54 g were observed. This study demonstrated the influence of hydrophobicity on vegetable oil removal, confirming that higher hydrophobicity leads to greater adsorption capacity. Nevertheless, the use of a viscous contaminant introduced challenges in the extraction process from the PS/SiO₂-DMS system. Despite this limitation, the material maintained adequate removal performance for up to five reuse cycles. On the other hand, the removal capacity depends on the amount of polysiloxane chain in the ceramic, as well as the functional group, exhibiting the following behavior: DMS-N < DMS-CH₃ < PDS. This study demonstrates that hydrophobicity is a key property for enhancing the removal capacity of oily substances. Moreover, the control of intermolecular interactions further strengthens this effect, as evidenced in the PS/SiO₂–PDS system. Full article

This study proposed an innovative assembled blast-resistant composite structure integrating ultra-high performance concrete plates and ceramic foam layers, designed to enhance blast protection for a power valve hall hole blocking system. Based on the full-scale blast test and numerical simulation, the dynamic response of the structure under blast load was revealed. The parametric studies showed that when the thickness of the UHPC ribbed plate was increased from 30 mm to 40 mm, the maximum displacement at the edge of the hole was reduced by 60.9%. However, a further increase in thickness to 50 mm led to an increase in the inertia effect due to the high stiffness, resulting in a reduction in the maximum displacement value by only 8.61%. In addition, a machine learning framework combining generative adversarial networks (GANs) and Extremely Randomized Trees (ERT) model was constructed to predict the maximum displacement of the structure under blast loading. Furthermore, interpretability analysis by the (SHapley Additive exPlanations) SHAP algorithm verified the consistency of the decision logic of the ERT model with the physical mechanism of the explosion. This study established a full-chain design framework of structural design, mechanism research and intelligent prediction, which provided theoretical support and an intelligent tool system for protection engineering. Full article

Explosion venting is an important measure for mitigating gas explosion hazards in confined spaces; however, conventional venting processes often generate high speed, high temperature jet flames, leading to severe secondary hazards. To achieve flameless venting, an experimental study on methane explosions under the coupled effects of dual explosion vents and porous materials was conducted in a confined pipe. Porous silicon carbide foam ceramics with different pore densities (10, 20, and 25 PPI) were installed at the vent openings under various vent layout conditions. Combined with high-speed imaging and dynamic pressure measurements, the flame evolution, jet flame suppression, and explosion overpressure characteristics were systematically analyzed. The results indicate that porous materials effectively attenuate jet flame intensity without compromising venting efficiency and increasing pore density significantly enhances flame-quenching performance. In addition, explosion vents located closer to the ignition source facilitate earlier energy release, thereby improving the reliability of flameless venting. Full article

N₂O emissions exacerbate the greenhouse effect, urgently demanding advances in abatement technologies. Catalytic decomposition of N₂O over cobalt-based oxides with alkali metal promoters remains challenging because these catalysts are used in pelletized form, limiting their activity to a narrow outer-shell region due to internal diffusion limitations. However, research efforts continue to focus on enhancing Co–alkali metal contact on unsupported powder samples under inert conditions, even though, under industrial conditions, catalysts are exposed to inhibitory components of waste gases and N₂O, and the powder form is unsuitable for practical application. This study aims at testing N₂O decomposition over catalysts with a Co₃O₄-Cs active phase supported on a ceramic foam. For this purpose, we characterized these catalysts by H₂ temperature-programmed reduction, H₂O and NO temperature-programmed desorption, atomic absorption spectroscopy, and X-ray diffraction and assessed their catalytic performance under an inert-gas atmosphere and with O₂, water vapor, and NO to simulate industrial conditions. Using a pseudo-homogeneous, one-dimensional model of an ideal plug flow reactor in an isothermal regime, the simulation calculations for a full-scale catalytic reactor for N₂O abatement in waste gas from HNO₃ production were performed. The Cs₂CO₃ precursor significantly enhanced catalyst reducibility and electron transferability, increasing N₂O decomposition efficiency in inert gas, but its high hygroscopicity decreased resistance to water vapor and NO, overriding its advantages under industrial conditions. Conversely, glycerol-assisted impregnation enhanced catalyst performance regardless of Cs precursor. These foam-supported catalysts offered several other advantages, including lower pressure drop and lower active phase loading with matching catalytic activity. Based on our findings, depositing Cs₂CO₃ on ceramic foam through glycerol-assisted impregnation may facilitate catalytic N₂O decomposition at the industrial level and, therefore, promote environmental sustainability by reducing N₂O emissions. Full article

In the present study, glass/ceramic hybrid fibers were chosen as a paper matrix, which effectively balance toughness and high-temperature resistance for soot combustion applications. In order to address the issue of unevenness in the performance of paper-type catalysts caused by the differences in the dispersion behavior of glass fibers and ceramic fibers in water, a facile foam-forming technology was proposed. The obtained glass fiber/mullite composite paper with various mass ratios (1:1, 2:1, 3:1, 4:1, and 5:1) exhibit high evenness, and better high-temperature resistance than the pure glass fibers. After impregnating K-Mn active ingredients, 15K5Mn-GFF-3G1C (GF/CF = 3:1) demonstrates high tensile strength, excellent catalytic activity (T50 = 388 °C), reusability (five cycles), and high-temperature stability (800 °C, 12 h). Full article

The possibility of transforming debris from a ceramic clinker into high quality foam granulate is discussed. The foaming process, which was carried out at temperatures 150–200 °C higher than the production process, was studied by HSM and DTA-TG coupled with MS. Phase and structural transformations were investigated by XRD and SEM, respectively. The results highlight that the foaming mechanism is related to the release of oxygen due to a reduction in Fe³⁺ to Fe²⁺ after the melting of hematite and the dissolution of pseudobrookite present in clinker waste. Granules obtained after 30 min of holding at 1280 °C are impermeable to water and, depending on the cooling applied, have a density between 0.4 and 0.7 g/cm³, porosity between 70 and 85 vol %, and compressive strength between 0.7 and 1.1 MPa. These results meet the requirements for high-quality fire-resistance lightweight aggregates. Full article

The growing energy demand in the residential sector, driven by the extensive use of air conditioning systems, poses serious environmental and economic challenges. A sustainable alternative is the use of efficient insulating materials derived from waste resources. This study presents the synthesis of glass–ceramic foams produced from recycled glass (90 wt%), pumice (5 wt%), and limestone (5 wt%), sintered at 800 °C for 10 min. The resulting foams exhibited a low apparent density of 684 kg/${\mathrm{m}}^3$ and thermal conductivity of 0.09 W/m·K. These were incorporated into composite insulating panels composed of 70 wt% ceramic pellets and 30 wt% Portland cement, achieving a thermal conductivity of 0.18 W/m·K. The panels were evaluated in a 64.8 ${\mathrm{m}}^2$ social housing model located in Chihuahua, Mexico, using TRNSYS v.17 to simulate annual energy performance. Results showed that applying a 1.5-inch ceramic foam panel reduced the annual energy demand by 16.9% and the total energy cost by 14.7%, while increasing the panel thickness to 2 in improved savings to 18.4%. Compared with expanded polystyrene (EPS), which achieved 24.9% savings, the proposed ceramic panels offer advantages in fire resistance, durability, local availability, and environmental sustainability. This work demonstrates an effective, low-cost, and circular-economy-based solution for improving thermal comfort and energy efficiency in social housing. Full article

With the advancement of aerospace equipment toward high-speed and heavy-duty applications, conventional forced lubrication systems are facing significant challenges in terms of reliability and adaptability to complex operating conditions. Porous medium materials, owing to their unique self-lubricating and oil-retention capabilities, are regarded as an ideal lubrication solution. However, their seepage behavior is governed by the strong coupling effects of microscopic pore structures and fluid physicochemical properties, the mechanisms of which remain inadequately understood, thereby severely constraining the design and application of high-performance lubricating materials. To address this, this paper systematically reviews recent research progress on seepage behavior in porous media, with the aim of establishing a correlation between microstructural characteristics and macroscopic performance. Starting from the characterization of porous media, this work comprehensively analyzes the structure–seepage relationships in porous polymers, metal foams, and porous ceramics, and constructs a multi-scale theoretical framework encompassing macroscopic continuum theories, mesoscopic lattice Boltzmann methods (LBM), pore network models, and microscopic molecular dynamics. The advantages and limitations of experimental measurements and numerical simulation approaches are also compared. In particular, this study critically highlights the current neglect of key interfacial parameters such as surface wettability and pore roughness, and proposes an in-depth investigation into the seepage mechanisms of polyimide porous cage materials based on LBM. Furthermore, the potential application of emerging research paradigms such as data-driven approaches and intelligent computing in seepage studies is discussed. Finally, it is emphasized that future efforts should focus on developing deeply integrated cross-scale simulation methodologies, strengthening multi-physics coupling and artificial intelligence-assisted research, and advancing the development of intelligent porous lubricating materials with gradient structures or stimulus-responsive characteristics. This is expected to provide a solid theoretical foundation and technical pathway for the rational design and optimization of high-performance lubrication systems. Full article

Lithium-containing zeolites are receiving significant attention due to their intriguing properties in various industrial applications, mainly related to gas separation and catalyzed processes. This paper presents an in-depth exploration of a nucleation strategy aimed at producing porous ceramic monoliths enriched with lithium zeolites. The synthesis was obtained by means of a geopolymer gel conversion, carried out by submerging either sodium- or lithium-rich geopolymers in lithium hydroxide solutions and performing a hydrothermal treatment. A full factorial design of experiments (DoE) was adopted to investigate the effect of LiOH molarity, treatment temperature, and time on the zeolite content in the samples. The most abundant and recurring zeolites obtained were Li-ABW (ABW) and lithium edingtonite (EDI). Concerning the lithium/sodium-containing systems, the competing presence of sodium directed the nucleation towards faujasite as well, together with minor amounts of other zeolites. In contrast, in pure lithium treatment media, the samples showed just ABW and EDI as the only crystalline phases. Full article

This study investigates the ballistic performance and energy-absorption behavior of advanced multilayer ceramic composite armor systems composed of silicon carbide (SiC) ceramics, composite metal foam (CMF), rolled homogeneous armor (RHA), ultra-high-molecular-weight polyethylene (UHMWPE), aluminum, and rubber interlayers. The objective is to enhance impact resistance and optimize energy dissipation efficiency against armor-piercing (AP) projectiles. Ballistic tests were performed following the NIJ Standard 0101.06 Level IV specifications using .30” caliber AP M2 rounds with an impact velocity of 784–844 m/s. Experimental results revealed that the SiC front layer effectively fragmented the projectile and dispersed its kinetic energy, while the CMF and UHMWPE layers were the primary energy absorbers, dissipating approximately 70% of the total impact energy (≈3660 J). The aluminum and RHA layers provided additional reinforcement, and the rubber interlayer significantly reduced stress-wave propagation and suppressed crack growth in the ceramic. The most efficient configuration 0.5 mm RHA + 7 mm SiC + 7 mm EPDM + 7 mm CMF + 5 mm UHMWPE achieved an areal density absorption of 77.2 J·m²/kg and a unit thickness absorption of 190.6 J/mm. These findings establish a quantitative layer-wise energy dissipation framework, highlighting the synergistic interaction between brittle, porous, and ductile layers. This work provides practical design principles for developing lightweight, high-efficiency composite armor systems applicable to defense, aerospace, and personal protection fields. Moreover, this study not only validates the NIJ Standard 0101.06 ballistic performance experimentally but also establishes a reproducible methodology for quantitative, layer-wise energy analysis of hybrid ceramic-CMF-fiber armor systems, offering a scientific framework for future model calibration and optimization. Full article

This study demonstrates a high-value pathway for fabricating porous ceramics by utilizing gold tailings (GT) as the principal raw material, with silicon carbide (SiC) as a high-temperature foaming agent. The microstructure, mechanical strength, and thermal conductivity were tailored by adjusting GT content, sintering temperature, raw material particle size, and foaming agent dosage. The optimized ceramics exhibit a total porosity of 60.1–83.7%, a compressive strength of 3.25–7.18 MPa, and a thermal conductivity of 0.15–0.32 W·m⁻¹·K⁻¹. These properties not only meet, but in fact exceed the key requirements specified in the Chinese National Standard GB/T 16533-1996 for porous thermal insulation ceramics. Notably, the materials achieve an optimal balance between high porosity and adequate mechanical strength. The findings confirm that gold tailings can be effectively valorized to produce standardized, porous ceramics suitable for industrial thermal insulation applications. Full article

Waste glass recycling generates waste streams such as fine glass fraction, waste ceramics containing fine glass, and waste polyethylene plastics. All of the aforementioned streams contain contaminants of organic and inorganic origin that are difficult to remove. This research was conducted to determine technological processes aimed at achieving a circular economy (CE) in the recycling of waste glass. Foam glass was made from the fine-grained, multicolored fraction of contaminated glass, an effective method for recycling glass waste at a low cost. A frothing system based on manganese oxide (MnO₂) and silicon carbide (SiC) was proposed, and an optimum weight ratio of MnO₂/SiC equal to 1.0 was determined. The possibility of controlling the process to achieve the desired foam glass densities was demonstrated. Statistical analysis was used to determine the effect of the MnO₂/SiC ratio and MnO₂ content on the density of the resulting foam glass products. Waste ceramics contaminated with different-colored glass were transformed into ceramic–glass granules. The characteristic temperature curve of the technological process was determined. The metal content in water extracts from ceramic–glass granules and pH value indicate their potential use for alkalizing areas degraded by industry and agriculture. Waste polyethylene-based plastics were converted into polyethylene waxes by thermal treatment carried out in two temperature ranges: low temperature (155–175 °C) and high temperature (optimum in 395 °C). The melting temperature range of the obtained waxes (95–105 °C) and their FTIR spectral characteristics indicate the potential application of these materials in the plastics and rubber industries. The integrated management of all material streams generated in the glass recycling process allowed for the development of a CE model for the glass recycling plant. Full article