Search Results (67)

Diverging from conventional dephosphorization approaches, this study employs a novel pre-reduction and smelting separation (PR-SS) to efficiently co-recover iron and phosphorus from high-phosphorus oolitic iron ore, directly yielding Fe–P alloy, and the Fe–P alloy shows potential as feedstock for high-phosphorus weathering steel or wear-resistant cast iron, indicating promising application prospects. Using oolitic magnetite concentrate (52.06% Fe, 0.37% P) as feedstock, optimized conditions including pre-reduction at 1050 °C for 2 h with C/Fe mass ratio of 2, followed by smelting separation at 1550 °C for 20 min with 5% coke, produced a metallic phase containing 99.24% Fe and 0.73% P. Iron and phosphorus recoveries reached 99.73% and 99.15%, respectively. EPMA microanalysis confirmed spatial correlation between iron and phosphorus in the metallic phase, with undetectable phosphorus signals in vitreous slag. This evidence suggests preferential phosphorus enrichment through interfacial mass transfer along the pathway of the slag phase to the metal interface and finally the iron matrix, forming homogeneous Fe–P solid solutions. The phosphorus migration mechanism involves sequential stages: apatite lattice decomposition liberates reactive P₂O₅ under SiO₂/Al₂O₃ influence; slag–iron interfacial co-reduction generates Fe₃P intermediates; Fe₃P incorporation into the iron matrix establishes stable solid solutions. Full article

Solid oxide fuel cells (SOFCs) represent a pivotal technology in renewable energy due to their clean and efficient power generation capabilities. Their role in potential carbon mitigation enhances their viability. SOFCs can operate via a variety of alternative fuels, including hydrocarbons, alcohols, solid carbon, and ammonia. However, several solutions have been proposed to overcome various technical issues and to allow for stable operation in dry methane, without coking in the anode layer. To avoid coke formation thermodynamically, methane is typically reformed, contributing to an increased degradation rate through the addition of oxygen-containing gases into the fuel gas to increase the O/C ratio. The performance achieved by reforming catalytic materials, comprising active sites, supports, and electrochemical testing, significantly influences catalyst performance, showing relatively high open-circuit voltages and coking-resistance of the CH₄ reforming catalysts. In the next step, the operating principles and thermodynamics of methane reforming are explored, including their traditional catalyst materials and their accompanying challenges. This work explores the components and functions of SOFCs, particularly focusing on anode materials such as perovskites, Ruddlesden–Popper oxides, and spinels, along with their structure–property relationships, including their ionic and electronic conductivity, thermal expansion coefficients, and acidity/basicity. Mechanistic and kinetic studies of common reforming processes, including steam reforming, partial oxidation, CO₂ reforming, and the mixed steam and dry reforming of methane, are analyzed. Furthermore, this review examines catalyst deactivation mechanisms, specifically carbon and metal sulfide formation, and the performance of methane reforming and partial oxidation catalysts in SOFCs. Single-cell performance, including that of various perovskite and related oxides, activity/stability enhancement by infiltration, and the simulation and modeling of electrochemical performance, is discussed. This review also addresses research challenges in regards to methane reforming and partial oxidation within SOFCs, such as gas composition changes and large thermal gradients in stack systems. Finally, this review investigates the modeling of catalytic and non-catalytic processes using different dimension and segment simulations of steam methane reforming, presenting new engineering designs, material developments, and the latest knowledge to guide the development of and the driving force behind an oxygen concentration gradient through the external circuit to the cathode. Full article

This research work seeks to introduce eco-friendly, low-carbon, and high-octane biofuel gasoline production using a synergistic approach. Four types of high-octane gasoline, including SynergyFuel-92, SynergyFuel-95, SynergyFuel-98, and SynergyFuel-100, were generated, emphasizing the deliberate combination of petroleum-derived gasoline fractions using reformate, isomerate, and delayed coking (DC) naphtha with octane-boosting compounds—bio-methanol and bio-ethanol. A set of tests have been performed to examine the effects of antiknock properties, density, oxidation stability, distillation range characteristics, hydrocarbon composition, vapor pressure, and the volatility index on gasoline blends. The experimental results indicated that the gasoline blends made from biofuel (SynergyFuel-92, -95, -98, and 100) showed adherence to important fuel quality criteria in the USA, Europe, and China. These blends had good characteristics, such as low quantities of benzene and sulfur, regulated levels of olefins and aromatics, and good distillation qualities. By fulfilling these strict regulations, Synergy Fuel is positioned as a competitive and eco-friendly substitute for traditional gasoline. The results reported that SynergyFuel-100 demonstrated the strongest hot-fuel-handling qualities and resistance to vapor lock among all the mentioned Synergy Fuels. Finally, the emergence of eco-friendly, low-carbon, and high-octane biofuel gasoline production with synergistic benefits is a big step in the direction of sustainable transportation. Full article

Carbon-based nanomaterials have emerged as a promising strategy for bitumen modification to enhance the mechanical and thermal performance of pavements. This review evaluates the present advancements in the inclusion of coke and carbon nanomaterials (CNMs) such as carbon nanotubes (CNTs) and graphene into bituminous systems. The findings and limitations of recent experiments in synthesis procedures along with dispersion methods are deeply explored to determine their impact on the rheological properties of bitumen as well as aging resistance and durability characteristics. Petroleum coke enhances bitumen softening points by 10–15 °C and causes up to 30% improvement in rutting resistance while simultaneously prolonging material fatigue life and aging resistance. Bitumen modification through petroleum coke faces challenges in addition to mixing difficulties due to its high viscosity. Moreover, the incorporation of CNTs and graphene as CNMs shows significant enhancements in rutting resistance with improved tensile strength, lower additive requirements, and enhanced dispersion. Both the superior mechanical properties of carbon nanomaterials and processing advancements in nano-enhanced bitumen have the capability to solve technical issues including material costs and specialized mixing processes. Combining coke with CNMs to enhance performance is a future research direction, which could result in economic and scalability considerations. This review comprehensively explores insights into physicochemical interactions, performance outcomes, and processing techniques, crucial for the development of sustainable, high-performance bitumen composites tailored for next-generation infrastructure applications. Full article

Previous studies have shown that fats, oils, and greases (FOG) can be deoxygenated to fuel-like hydrocarbons over inexpensive alumina-supported Ni catalysts promoted with Cu or Fe to afford excellent yields of renewable diesel (RD). In this study, supports other than alumina—namely, SiO₂-Al₂O₃, Ce_0.8Pr_0.2O₂, and ZrO₂—were investigated to develop catalysts showing improved RD yields and resistance to coke-induced deactivation relative to Al₂O₃-supported catalysts. Results showed that catalysts supported on Ce_0.8Pr_0.2O₂ and ZrO₂ outperformed SiO₂-Al₂O₃-supported formulations, with 20%Ni-5%Fe/ZrO₂ affording a quantitative yield of diesel-like hydrocarbons. Notably, the abundance of weak acid sites varied considerably across the different supports, and a moderate concentration of these sites corresponded with the best results. Additionally, temperature-programmed reduction measurements revealed that Ni reduction is greatly dependent on both the identity of the promoter and catalyst support, which can also be invoked to explain catalyst performance since metallic Ni is identified as the likely active site for the deoxygenation reaction. It was also observed that Ce_0.8Pr_0.2O₂ provides high oxygen storage capacity and oxygen mobility/accessibility, which also improves catalyst activity. Full article

The production of hydrocarbon-based biofuels has been the target of intense research worldwide. In this context, the core goal of the present work was to investigate the use of mesopore-rich activated carbons (ACs) as support for sulfided Mo-based catalysts intended for the hydroprocessing of lipidic feedstocks. The key motivations for the work were that, in comparison to traditional inorganic supports such as Al₂O₃, ACs are less propense to form coke, due to their lower acidity, and are highly resistant to hydrolysis, which is a very important aspect in the hydroprocessing of lipidic feedstocks because water is abundantly produced during the process. Furthermore, the porosity of ACs can be tailored to give rise to a high mesopore content, which is important for improving the access of bulky triglyceride molecules to metallic active sites located inside the pores network. A systematic study on the effects of the preparation conditions on the properties and performance of the obtained catalysts was carried out for the first time. The highest hydrodeoxygenation (HDO) activity was verified for the catalyst prepared through sequential deposition of Mo and Ni by wet impregnation. The prepared catalyst presented better performance for coconut oil HDO than an industrial sulfided NiMo/Al₂O₃ catalyst. Furthermore, it presented good stability, provided that the sulfidation degree was kept high. The obtained results evidenced that ACs have great potential to replace inorganic support in sulfided Mo-based catalysts. 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

Biomass tar, an inevitable byproduct of biomass pyrolysis and gasification, poses a significant challenge due to its tendency to condense in pipelines, causing clogging and operational issues. Catalytic steam reforming can convert tar into syngas, addressing the tar issue while simultaneously producing hydrogen. However, the reforming catalyst is highly susceptible to deactivation by coking, especially when dealing with highly concentrated polymeric hydrocarbons such as tar. This study focused on enhancing the durability of tar-reforming catalysts. Nickel-based catalysts were prepared using carbon supports known for their high coking resistance, such as carbon black (CB), activated carbon (AC), and low-rank coal (LRC). Their performance was then tested for the steam reforming of high-concentration toluene, a representative tar. All three carbon supports (CB, AC, LRC) showed high catalytic performance with NiMg catalysts at 500 °C. Among them, the mesoporous CB support exhibited the highest stability when exposed to steam, with NiMg on CB (NiMg/CB) remaining stable for long-term continuous operation without any deactivation due to coking or thermal degradation. 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

Catalyst deactivation, mainly due to coke deposition, presents a significant challenge in the process of dry reforming of methane (DRM). This study focused on coke-resistant catalysts for DRM, particularly nickel-based catalysts supported on hydroxyapatite (HAP). A novel HAP formulation (HAP_S) with a Ca/P ratio of 1.54, below the stochiometric ratio studied in previous studies, was compared with commercial HAP (HAP_C), and both were impregnated with 10 wt% nickel. The synthesis of HAP_S involved low temperature (60 °C), moderate stirring, and a pH of 11, using a custom setup. Dry-reforming reactions were conducted under severe conditions (T = 800 °C) to assess the resistivity of both supports over 120 h. Our findings indicated sustained high conversion rates, reaching 93% for CH₄ and 98% for CO₂ with HAP_S, despite an increase in gas hourly space velocity. Characterisation, including X-ray diffraction, thermogravimetric analysis, and transmission electron microscopy, revealed coke formation using HAP_C, leading to initial deactivation, in contrast with the custom support. This discrepancy may be attributed to the distinct physical and chemical properties of the catalysts, their reaction mechanisms, and the deactivation precursors. Overall, the performance of nickel-based catalysts significantly hinges on support–catalyst interactions, in addition to thermal stability. Full article

This study investigates the impact of kaolin and boehmite alumina binders on the synthesis, catalytic properties, and attrition resistance of a La_0.7Sr_0.3FeO₃ (LSF) perovskite catalyst designed for the chemical looping partial oxidation (CLPO) of methane to produce synthesis gas sustainably. The as-synthesized and used catalysts with varying kaolin and boehmite alumina contents (KB_(x,y)/LSF) were scrutinized by a variety of characterization methods, including XRD, FE-SEM/EDS, BET, TPD-NH₃, and TPD-O₂ techniques. The catalytic activity of the synthesized samples was tested at 800 to 900 °C in a fixed-bed reactor producing syngas through the CLPO process over the consecutive redox cycles. Additionally, the attrition resistance of the fresh and used catalyst samples was examined in a jet cup apparatus to assess their durability against the stresses induced by thermal shocks or changes in the crystal lattice caused by chemical reactions. The characterization results showed the pure perovskite crystal structure of KB_(x,y)/LSF catalysts demonstrating adequate oxygen adsorption capacity, effective coke mitigation capability, robust thermal stability, and resilience to agglomeration during repetitive redox cycles. Among the tested catalysts, KB_(25,15)/LSF was identified as the superior sample, as it could consistently produce syngas with a suitable H₂:CO molar ratio varying from 2 to 3 within ten redox cycles at 900 °C, with CH₄ conversion and CO selectivity values up to 64% and 87%, respectively. The synthesized catalysts demonstrated a logarithmic attrition pattern in the jet cup tests at room temperature, featuring high attrition resistance after the erosion of particle shape irregularities or weakly bound particles. Moreover, the KB_(25,15)/LSF catalyst used at 900 °C showed great resistance in the attrition test, warranting its endurance in the face of extraordinarily harsh conditions in fluidized bed reactors employed for the CLPO process. Full article

Converting CO₂ into methane is considered a promising and economically viable technology for global transportation and utilization of this greenhouse gas. This study involves the preparation of a Ni-CZ (CeO₂-ZrO₂)/ATP (attapulgite) catalyst through the co-precipitation and impregnation methods. XRD, SEM, TEM, N₂ absorption-desorption isotherms, XPS, H₂-TPR, CO₂-TPD, TG/DSC, and Raman were adapted to characterize the obtained samples. Real-time GC was used to measure the catalytic performances and to intensively study the impact of Ni loading content and ATP to CZ ratio on the catalytic performance of the products. DRIFTs was used to monitor the interstitial radicals in the catalytic reactions and to deduce the catalytic mechanisms. The results indicate that the composite catalytic matrix composed of CZ assembled on ATP demonstrated higher CO₂ methanation stability and better carbon deposition resistance ability than the single CZ or ATP as the carrier, which should be attributed to the improved specific surface area and pore volume of the ATP assembled matrix and the enhanced dispersibility of the CZ and Ni species. The adoption of CZ solid solutions improves the oxygen storage capability of the catalyst, thereby providing continued mobile O²⁻ in the matrix and accelerating the molecular exchange rate in the catalytic reactions. The ideal loading quantity of nickel contents on the CZA matrix is 15%, as the CO₂ conversion decreases at elevated temperatures when the Ni loading content reaches 20%. Among the tested samples, the 15Ni-0.8CZA sample showed the best catalytic performance of 75% CO₂ conversion and 100% CH₄ selectivity at 400 °C. After 50 h of stability tests, the CO₂ conversion rate still remained 70.84%, and the CH₄ selectivity obtained 97.46%. No obvious coke was detected according to the Raman spectra of the used catalyst. The in situ DRIFTS experiment showed that formate is the main intermediate of the CO₂ hydrogenation reaction on the 15Ni-0.8CZA catalyst. Full article

Among the countless routes for renewable hydrogen (H₂) production, Biogas Dry Reforming (DR) has been highlighted as one of the most promising for the circular bio-economy sector. However, DR requires high operating temperatures (700 °C–900 °C), and, for greater efficiency, a thermally stable catalyst is necessary, being, above all, resistant to coke formation, sintering, and sulfur poisoning. Mesoporous metallic catalysts, such as nickel (Ni) supported on silica, stand out due to their high catalytic activity concerning such characteristics. In this regard, the presented work evaluated the influences of the nickel addition stage during the synthesis of mesoporous catalyst type Si-MCM-41. Two different catalysts were prepared: catalyst A (Ni/Si-MCM-41_A), synthesized through the in situ addition of the precursor salt of nickel (Ni(Ni(NO₃)₂·6H₂O) before the addition of TEOS (Tetraethyl orthosilicate) and after the addition of the directing agent; and catalyst B (Ni/Si-MCM-41_B), resulting from the addition of the precursor salt after the TEOS, following the conventional methodology, by wet impregnation in situ. The results evidenced that the metal addition stage has a direct influence on the mesoporous structure. However, no significant influence was observed on the efficiency concerning BDR, and the conversions into H₂ were 97% and 96% for the Ni/SiMCM-41_A and Ni/Si-MCM-41_B catalysts, respectively. Full article

CH₄ has become the most attractive fuel for solid oxide fuel cells due to its wide availability, narrow explosion limit range, low price, and easy storage. Thus, we present the concept of on-cell reforming via SOFC power generation, in which CH₄ and CO₂ can be converted into H₂ and the formed H₂ is electrochemically oxidized on a Ni-BZCYYb anode. We modified the porosity and specific surface area of a perovskite reforming catalyst via an optimized electrostatic spinning method, and the prepared LCMN nanofibers, which displayed an ideal LaMnO₃-type perovskite structure with a high specific surface area, were imposed on a conventional Ni-BZCYYb anode for on-cell CH₄ reforming. Compared to LCMN nanoparticles used as on-cell reforming catalysts, the NF-SOFC showed lower ohmic and polarization resistances, indicating that the porous nanofibers could reduce the resistances of fuel gas transport and charge transport in the anode. Accordingly, the NF-SOFC displayed a maximum power density (MPD) of 781 mW cm⁻² and a stable discharge voltage of around 0.62 V for 72 h without coking in the Ni-BZCYYb anode. The present LCMN NF materials and on-cell reforming system demonstrated stability and potential for highly efficient power generation with hydrocarbon fuels. Full article