Search Results (196)

Leaching carbon residue (LCR) is a carbonaceous solid waste generated during the hydrometallurgical recycling of spent lithium-ion batteries. Although its high graphite content offers substantial potential for resource recovery, the residual heavy metals and fluorides present in LCR pose considerable environmental risks. Currently, LCR has not garnered sufficient attention within the industry, and the lack of recycling technologies suitable for large-scale disposal results in resource wastage and environmental pollution. To address these challenges, this study proposes an innovative strategy based on the concept of multi-field synergistic enhancement. The proposed approach involves recovering and regenerating graphite (RG) from LCR via low-temperature molten salt roasting assisted by high-pressure and mechanical activation. A combination of advanced characterization techniques was employed to compare the physicochemical properties of RG and commercial graphite (CG) and to systematically evaluate the technical feasibility of using regenerated graphite as an anode material for lithium-ion batteries. The results demonstrate that, under optimized molten salt roasting and aqueous leaching conditions, the carbon content of RG reaches 99.94 wt%, indicating the efficient removal of non-carbon impurities from the graphite matrix. Compared to CG, RG retains a typical layered structure; however, a lower carbon content (99.94 wt%) and poorer structural order (I_D/I_G = 0.30) are observed. In terms of electrochemical performance, RG delivers a discharge specific capacity of 394.64 mAh/g during the first cycle and exhibits excellent cycling stability, with a capacity retention of 86.50% after 100 cycles. This electrochemical performance is comparable to that of commercial graphite. The proposed multi-field-assisted low-temperature molten salt roasting technique enables the efficient recovery of high-value graphite resources from LCR, establishing a full-lifecycle recycling strategy tailored for lithium-ion battery applications. Full article

Electronic waste (e-waste) offers a sustainable pathway for recovering critical metals, yet its heterogeneous composition complicates the design of advanced alloys. This work applies a computational approach to design multicomponent superalloys from e-waste, using Thermo-Calc to predict phase stability and microstructural evolution. Nickel-based alloys alloyed with Cu–Sn–Pb fractions were modeled, revealing improved ductility through phase refinement and suppression of graphite formation. Experimental validation with SEM and XRD confirmed the computational predictions. This study demonstrates the potential of integrating computational thermodynamics with e-waste recycling to develop high-performance superalloys, advancing both sustainability and material innovation. Full article

Accelerated industrial development demands the search for efficient remediation technologies. Microbial fuel cells (MFCs) have the capacity to remediate organic matter-rich effluent by utilizing bacteria as biocatalysts capable of oxidizing organic material while simultaneously producing electricity. In this paper, a novel electrode is prepared through the carbonization of a tailored photopolymer with iron nanoparticles and carbon black (C-iNPCB) and its performance tested as an anode using dual chamber MFCs for the remediation of paper recycling plant effluent. Its efficiency is compared to a graphite rod (GR) and a carbon black-coated 3D-printed structure (3D-CB). The paper effluent containing chemical oxygen demand 5.0 g/L was used as feedstock in the MFCs. The GR anode (0.91 A/m²; 0.32 W/m²) and 3D-CB anode (0.88 A/m²; 0.30 W/m²) both achieved 56% COD removal, while the C-iNPCB-anode (5.71 A/m²; 3.75 W/m²) was the best performing, with over 80% COD removal. The photopolymerized doped anode exhibited superior performance in terms of both organic matter oxidation and conductivity, indicating higher effectiveness of this type of electrode in MFC technology. Full article

The hematite phase decorated with iron-doped cerium oxide nanoparticles (F@FC) was precipitated from cerium and iron oxalate intermediate products. The photocatalytic composite of graphitic carbon nitride (gCN) and F@FC was prepared by a simple method involving mixing the two components, followed by thermal treatment at 400 °C. According to electron microscopy, F@FC is composed of a submicron iron oxide (hematite) phase decorated with iron-doped cerium oxide nanoparticles deposited on gCN substrate. A hierarchically structured composite was observed instead of a simple mechanical mixture of α-Fe₂O₃, Fe-CeO₂, and gCN. To observe two types of degradation activity, photocatalytic and Photo-Fenton degradation activity, Rhodamine B (RhB) was applied as the model water pollutant. The influence of the amount of photocatalyst, the RhB concentration, the presence of cations and anions, the pH, and the effect of e⁻, h⁺, •OH, and •O₂⁻ scavenging reactants were studied. The Photo-Fenton degradation exhibited high efficiency across the entire tested pH range, whereas photocatalytic degradation showed comparable activity only at acidic pH. The F@FC-gCN composite catalyst exhibited a high degree of recyclability. The degradation pathways of photocatalytic and Photo-Fenton reactions were suggested by HPLC-MS analysis of the reaction products. A notable finding of this study was the observation that the green-yellow, fluorescent intermediate Rhodamine 110 was formed during the photocatalytic degradation of RhB. However, the high reactivity of the generated •OH radicals during Photo-Fenton degradation has been demonstrated to inhibit the formation of intermediate Rhodamine 110. Full article

The growing volume of fiber-reinforced polymer composite waste creates an urgent need for efficient recycling technologies. While solvolysis effectively breaks down thermoset matrices for fiber reinforcement recovery, the process generates hydrocarbon-rich liquid by-products that require further management. This study validates the use of these liquid recycling streams—derived from the solvolysis of unsaturated polyester and epoxy resins—as sustainable carbon precursors for the growth of carbon nanomaterials. Synthesis was performed via catalytic chemical vapor deposition (CVD) at 850 °C using iron nanoparticles impregnated on a zeolite substrate. Morphological analysis confirmed the production of one-dimensional nanostructures (carbon nanotubes/nanofibers), with average diameters below 100 nm. Raman spectroscopy revealed a high degree of graphitization, with I_D/I_G ratios ranging from 0.25 to 0.58, which is comparable to structures synthesized from conventional precursors. Thermogravimetric analysis (TGA) demonstrated high thermal stability and carbon purity reaching up to 90.3%. These findings demonstrate a viable upcycling pathway that enhances the economic attractiveness of composite recycling by transforming waste into advanced nanomaterials. Full article

Spent carbon cathode (SCC), a hazardous solid waste discharged from aluminum electrolysis, exhibits significant fluoride and cyanide leaching toxicities. Existing high-temperature disposal strategies are constrained by high investment costs for specialized equipment, low product added value, and unclear application scenarios, hindering their large-scale implementation. Consequently, substantial quantities of SCC remain underutilized, resulting in the waste of valuable carbon and fluoride components. This study focuses on the targeted conversion of valuable components in SCC through the innovative integration of simple processes, including atmospheric high-temperature roasting, deep purification, Al-based inducer addition, and pH regulation. Volatilization kinetics and solution equilibrium chemistry were used to investigate impurity removal mechanisms and to guide cryolite synthesis, respectively. The results demonstrate the successful recovery of high-purity regenerated graphite with a high carbon content, low sulfur content, and a high degree of graphitization. Simultaneously, cryolite with a high NaF/AlF₃ molecular ratio was synthesized from the roasting flue gas absorption liquor by controlling ionic composition and pH. Guided by the principles of cleaner production and resource recycling, the entire recovery process generates negligible waste gas, wastewater, or solid residue emissions. In conclusion, the proposed disposal strategy achieved the targeted conversion of SCC into high-value products while mitigating environmental pollution risks, offering both environmental and economic benefits. This innovative design provides a feasible pathway for the large-scale disposal and utilization of SCC. Full article

The rapid expansion of lithium-ion battery (LIB) applications and the imminent surge in end-of-life batteries have intensified the demand for efficient, scalable recycling technologies. Physical separation of cathode and anode materials is a crucial pretreatment step that enables high-value metal recovery and direct material regeneration. This review critically examines recent advances in three major physical separation technologies—magnetic separation, gravity separation, and flotation—for processing spent LIB electrodes. Rather than offering a descriptive summary, the review systematically analyzes separation mechanisms, key controlling parameters, and pretreatment strategies across representative cathode chemistries, including LiFePO₄ (LFP), LiCoO₂ (LCO), and Ni–Co–Mn (NCM) systems. Particular emphasis is placed on emerging flotation-enhancement strategies, such as nanobubble-assisted and ultrasonic-enhanced flotation, and their underlying mechanistic roles in improving selectivity and recovery. Comparative evaluation indicates that magnetic separation has reached industrial maturity for LFP–graphite systems but remains chemistry-specific. Gravity separation is effective for coarse particles and centrifugal-assisted graphite recovery yet shows limited selectivity for fine particles. Flotation has become the dominant research focus for complex, fine-particle separations due to its tunable surface chemistry. Despite significant laboratory progress, challenges remain, including incomplete binder removal, limited understanding of electrode surface reconstruction during pretreatment, fine-particle entrainment, and the gap between bench-scale research and industrial implementation. Future research priorities include green reagent development, intelligent separation control, and integration with direct regeneration routes to advance closed-loop LIB recycling towards sustainable development. Full article

Injection-molding purges are heterogeneous, bulky residues whose uncertain composition and irregular geometry hinder direct reinsertion, making cold shredding costly and maintenance-intensive. This work develops a low-infrastructure solar-assisted pre-processing route using a PMMA Fresnel lens to induce controlled sub-onset softening and enable clean shear cutting without destructive thermal histories. The sub-onset softening is here defined into a viscoelastically active range (at or above T_g for the amorphous phase) while remaining below the melting onset (T_m, onset) and below the onset of thermal degradation (T_d, onset). The station was engineered via QFD and risk-oriented design tools, while a weighted Pugh matrix selected shear cutting over saw-based alternatives. A screening factorial DOE showed that lens height, angle, and their interaction significantly govern focal-spot diameter and receiver temperature, yielding linear relations for conservative set-point selection. Receiver benchmarking further indicated that copper reaches substantially higher temperatures than graphite under identical exposure conditions, supporting copper as the simplest, rapid-heating receiver. Under DOE-calibrated operation, tear-free shear cutting was achieved across representative purge families (PP–ABS, PC–ABS–PP, PA66, PA66-filler, and POM) without forced convection. From a recycling and waste-management perspective, the approach converts bulky purge scrap into mill-compatible feedstock with reduced mechanical resistance, lowering tool wear and fines generation, accelerating downsizing, and limiting stockpiling that elevates combustible-inventory fire risk. Overall, the proposed DOE-calibrated, operator-friendly framework improves recycling feasibility by enabling safer handling, more stable preprocessing throughput, and reduced reliance on disposal or long-term storage for heterogeneous industrial purges. Full article

The electrochemical reuse of spent graphite from the negative electrodes of lithium-ion batteries is influenced by regeneration-induced changes in near-surface chemical and defect states. These states govern solid electrolyte interphase (SEI) re-formation, particularly when bulk contaminants are suppressed. Acidic malic-acid leaching and ethylenediaminetetraacetic acid chelation under alkaline conditions (pH 8.7) were compared under similar operating parameters to isolate the role of the leaching environment. This was followed by heat treatment at 1200 °C to decouple chemical cleaning from structural restoration. Both methods reduced the total impurities from 217.85 ppm to ~1.8 ppm, approaching that of commercial graphite. Despite the comparable bulk purity, depth-resolved X-ray photoelectron spectroscopy after formation cycling revealed distinct outermost surface states relevant to SEI re-formation: acidic processing yielded a more oxygenated carbon signature and higher LiOH fraction at the outermost surface (~16%), whereas alkaline chelation produced a more graphitic, carbonate-dominated surface with lower LiOH (~7%). Electrochemical and impedance measurements were consistent with these differences, suggesting that after the bulk impurities were minimized, resistance development was largely governed by the leaching-conditioned near-surface state, which biased the SEI composition. The comparison under matched conditions linked the regeneration environment to SEI-relevant surface speciation and provided a mechanistic basis for selecting regeneration routes to reuse spent graphite as a negative-electrode active material. Full article

The photovoltaic industry generates a substantial amount of high-purity waste silicon powder during the diamond-wire saw cutting process, which can serve as an environmentally friendly and cost-effective resource for lithium-ion battery recycling. However, its commercial application is hindered by the surface attachment of silicon dioxide, organic substances, metal impurities, as well as its intrinsic drawbacks such as significant volume expansion (>300%) during lithium (de)intercalation and low electronic conductivity. To address these issues, this study first purifies the waste silicon powder and then designs the structure of the composites. Using a simple ball-milling combined with sol-gel method, a core-shell composite material with a carbon-coated two-dimensional conductive network (FVW-Si/G₅₀₀@C) was synthesized. The two-dimensional conductive network provides sufficient space to accommodate the volume expansion of silicon, while the mesoporous structure on the carbon shell offers a fast transport pathway for Li⁺, thereby enhancing the electrode kinetics. The prepared FVW-Si/G₅₀₀@C electrode maintained a high reversible capacity of 951.8 mAh g⁻¹ after 100 cycles at a current density of 0.2 A g⁻¹. Even at a high current density of 1 A g⁻¹, it retained a reversible capacity of 230.4 mAh g⁻¹. The results indicated that the synergistic effect between graphite sheets and the mesoporous carbon shell significantly improved the rate performance and cycling stability of the FVW-Si/G₅₀₀@C electrode. This study provided a theoretical foundation for the scalable, green, and high-value utilization of waste silicon powder in the photovoltaic industry and offered technical support for sustainable energy development. Full article

Carbon Fiber-Reinforced Polymer (CFRP) composites represent a transformative class of structural materials, combining low density, high specific strength, and excellent fatigue resistance. This review provides a comprehensive overview of CFRPs, addressing their structure, manufacturing routes, mechanical performance, and functional behavior, with particular emphasis on damage tolerance, tribological properties, and environmental durability. The discussion begins with the classification and morphology of carbon fibers, highlighting their influence on composite anisotropy and interlaminar behavior. The effects of impact loading, delamination, and environmental conditioning on residual strength and fatigue life are then examined, with reference to established evaluation methods such as ASTM D7136 and compression-after-impact (CAI) testing. From a tribological perspective, the incorporation of nanoscale additives, such as graphite nanoplatelets and TiO₂ nanoparticles, and their contribution to enhancing wear resistance by promoting the formation of stable tribofilms, is explored. Advances in processing techniques, including low-pressure curing and improved resin systems, are also discussed for their roles in enhancing manufacturability and energy efficiency. Overall, the review underscores that optimal CFRP performance is achieved through the synergistic integration of fiber architecture, matrix design, and precise processing control, while future progress in nanomodification, recycling, and sustainable curing technologies is expected to further expand CFRP applications in the aerospace, automotive, and high-performance engineering sectors. Full article

Zinc(II) bis(8-hydroxyquinolinate) (Zn(HQ)₂) and 1,10-phenanthroline (phen) were combined to fabricate an organic semiconductor in a bulk heterojunction architecture and subsequently embedded in a poly 3,4-ethylene dioxythiophene–polystyrene sulfonate (PEDOT–PSS) matrix. The resulting Zn(HQ)₂-phen/PEDOT–PSS was deposited as a film upon tin-oxide-coated glass and graphite-covered Tetra Pak (TP)-recycled substrates for the manufacture of organic photoconductive devices. The topographical and micromechanical characteristics of the hybrid films were assessed by atomic force microscopy, with an average roughness of 5.6 nm, maximum tensile strength of 7.95 MPa, and Knoop microhardness of 14.7. The fundamental energy gap (E_g) was determined employing the Kubelka–Munk function, with E_g of 3.5–3.8 eV. These results were complemented with a computational DFT molecular orbital analysis of the species involved in the hybrid semiconductor. The devices were electrically characterized under UV irradiation conditions, obtaining the current–voltage and power–voltage relationships. The maximum current in the TP–graphite device is 1.8 × 10⁻² A and 1.1 × 10⁻² A in the device on glass–ITO. Zn(HQ)₂-phen/PEDOT–PSS film presents its own operating regimes relating to a photoconductor or flexible photoresistor. The power in the device on glass–ITO is 120 mW and 113 mW for shortwave and longwave, respectively, and in the device on TP–graphite, it is 198 mW and 139 mW. 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

Aluminothermic reduction is gaining renewed interest as an alternative processing route for the circular economy. A unique Na₂O-fluxed MnO₂ ore formulation with a small quantity of carbon reductant was applied to ensure rapid pre-reduction to MnO. This approach negates the pre-roasting step. The Na₂O flux enables the formation of the water-soluble compound, NaAlO₂, which enables recycling of Al₂O₃ for aluminium production. The addition of copper as a collector metal improved the overall alloy yield from 43% to 57%, which includes a 6% increase in Mn recovery to the alloy. The product alloy is a medium-carbon Fe–Mn–Si–Al–Cu complex ferroalloy that can be used as a steelmaking ferroalloy additive. The ferroalloy consists of 54% Mn, 19% Fe, 2.1% Si, 2.6% Al, 21% Cu, and 1.2% C. This carbon content is modulated by low-carbon solubility copper, despite the use of a graphite crucible. The formulated slag exhibits high Al₂O₃ solubility, enabling effective alloy–slag separation from the high Al₂O₃ content slag of 52% Al₂O₃. Gas–slag–metal equilibrium calculations for 1650 °C–1950 °C overlap with the experimentally produced alloy chemistry in %C and %Si, but not the %Al, as the uptake of aluminium exceeds the equilibrium calculation at 0.03–0.17%. Full article

The oxidation of chlorophenolic compounds is essential for converting these persistent and toxic pollutants into less harmful products, thereby reducing their environmental and health impacts. In this study, a p-coumaric acid ester derivative was employed as the starting material to synthesize the corresponding phthalonitrile precursor (EnCA-CN), followed by the preparation of non-peripherally substituted Co(II) and Cu(II) phthalocyanine complexes (EnCA-Copc and EnCA-CuPc). These complexes were subsequently characterized using a range of spectroscopic techniques and designed to engage in π–π interactions with graphitic carbon nitride to form efficient photocatalytic materials. The structures of the two effective catalysts were characterized by FT-IR, SEM, and XRD analyses, after which their photocatalytic performance and recyclability in the degradation of 2-chlorophenol, 2,3-dichlorophenol, and 2,3,6-trimethylphenol were evaluated. The optimum catalyst loading for the MPc/g-C₃N₄ composites was determined to be 0.5 g/L, yielding the highest photocatalytic efficiency. The EnCA-CoPc/g-C₃N₄ catalyst achieved 90.8% product selectivity and 82.6% conversion in the oxidation of 2-chlorophenol, whereas the EnCA-CuPc/g-C₃N₄ catalyst exhibited approximately 80.0% pollutant removal. The degradation efficiencies followed the order 2-CP > 2,3-DCP > 2,3,6-TCP, with benzoquinone derivatives identified as the major oxidation products. In recyclability tests, both catalysts retained more than 50% of their activity after five cycles; EnCA-CoPc/g-C₃N₄ maintained 68% conversion in the 5th cycle, while EnCA-CuPc/g-C₃N₄ retained 60% conversion in the 4th cycle. Full article