Search Results (226)

This study numerically investigates the critical fuel concentration and flammable regions of methane–air and methane oxy-fuel counterflow diffusion flames. The goal is to determine the effects of strain rate, oxidizer composition, and radiative heat transfer models on flame extinction. Calculations were performed using the counterflow diffusion flame with the adiabatic (ADI), optically thin (OTM), and statistical narrow-band (SNB) radiation models at strain rates of 10 s⁻¹, 80 s⁻¹, and 200 s⁻¹. The key findings are as follows: For methane–air flames, radiation reabsorption has a negligible impact. The flammable region decreases with increasing strain rate (S_Low > S_Mid > S_High) across all models. In O₂/CO₂ flames, radiation plays a significant role. While the ADI and SNB models maintain the same trend as in air flames, the OTM yields a different order (S_Mid > S_High > S_Low). Reducing oxygen concentration increases the critical fuel concentration and shrinks the flammable region. When the oxygen concentration is between 0.35 and 0.40, the combustion characteristics of O₂/CO₂ flames resemble those of conventional air flames. In conclusion, this work highlights the critical influence of radiation modeling and oxidizer composition on oxy-fuel flame extinction limits, providing insights for combustion system design under CO₂ dilution. Full article

Achieving efficient and clean use of low-volatile coal is of vital importance to China’s energy system. This study aims to elucidate how the high-concentration-CO₂ atmosphere influences the migration pathways of fuel-bound nitrogen during the pyrolysis of low-volatile coal, thereby providing critical insights for the prediction and control of NO_x emissions under oxy-fuel conditions. A high-temperature drop-tube furnace system capable of high heating rates (up to 10⁴–10⁵ °C/s) was employed to comparatively investigate the pyrolysis behavior of a typical low-volatile coal (volatile matter content of 7.44%) under Ar and pure CO₂ atmospheres at 1000–1400 °C. The outcomes show that the CO₂ atmosphere significantly promoted the release of volatiles, with the volatile release rate at 1400 °C reaching 2.1 times that under the Ar atmosphere. While volatile nitrogen primarily consists of HCN and NH₃ with HCN dominance at lower temperatures, NH₃ release exceeds HCN by more than tenfold at 1400 °C. CO₂ promotes nitrogen release through enhanced gasification reactions, reducing char nitrogen proportion while increasing volatile nitrogen yield approximately fourfold at elevated temperatures. The X-ray photoelectron spectroscopy analysis reveals the transformation pathway of nitrogen functionalities from quaternary nitrogen to pyridine nitrogen and subsequently to pyridine under oxy-fuel conditions. These findings provide fundamental insights into fuel nitrogen evolution mechanisms and offer theoretical support for optimizing oxy-fuel combustion processes toward efficient NO_x control. Full article

This work examines the behaviour of a spark-ignition engine using oxy-fuel combustion, coupled with an oxygen production cycle based on a mixed ionic-electronic ceramic membrane. Through 1D-0D simulations, two compression ratios are studied: the original ratio of 9.6 and the optimised CR of 20, under various load levels and altitude conditions. The results show that operational limits exist at part-load conditions, where reducing the load without implementing additional control strategies may compromise system performance. It is observed that at low loads, the intake pressure can fall below atmospheric pressure, encouraging the presence of N₂ in the combustion process. Additionally, the engine can operate efficiently up to an altitude of 4000 m, although increasing boosting is required to maintain proper membrane conditions. These findings emphasise the importance of load control and the potential need for energy assistance under certain circumstances. Full article

Oxy-fuel combustion technology is a critical pathway for carbon capture in the cement industry. However, the high-concentration CO₂ atmosphere significantly alters multiphysics coupling in the calciner and systematic studies on its comprehensive effects remain limited. To address this, a Computational Particle Fluid Dynamics (CPFD) model using the MP-PIC method was implemented using the commercial software Barracuda Virtual Reactor 22.1.2 to simulate an industrial-scale oxy-fuel cement calciner and validated against industrial data. Under oxy-fuel combustion with 50% oxygen concentration in the tertiary air, simulations showed a 38.4% increase in the solid–gas mass ratio compared to conventional air combustion, resulting in a corresponding 37.7% increase in total pressure drop. Flow resistance was concentrated primarily in the constriction structures. Local temperatures exceeded 1200 °C in high-oxygen regions. The study reveals a competition between the inhibitory effect of high CO₂ partial pressure on limestone decomposition and the promoting effect of elevated overall temperature. Although the CO₂-rich atmosphere thermodynamically suppresses calcination, the higher operating temperature under oxy-fuel combustion effectively compensates, achieving a raw meal decomposition rate of 92.7%, which meets kiln feed requirements. This research elucidates the complex coupling mechanisms among flow, temperature, and reactions in a full-scale oxy-fuel calciner, providing valuable insights for technology design and optimization. Full article

Carbon dioxide (CO₂) is the most significant anthropogenic greenhouse gas (GHG), accounting for approximately 81% of total emissions, with methane (CH₄), nitrous oxide (N₂O), and fluorinated gases contributing the remainder. Rising atmospheric CO₂ concentrations, driven primarily by fossil fuel combustion, industrial processes, and transportation, have surpassed the Earth’s natural sequestration capacity, intensifying climate change impacts. Carbon Capture, Utilization, and Storage (CCUS) offers a portfolio of solutions to mitigate these emissions, encompassing pre-combustion, post-combustion, oxy-fuel combustion, and direct air capture (DAC) technologies. This review synthesizes advancements in CO₂ capture materials including liquid absorbents (amines, amino acids, ionic liquids, hydroxides/carbonates), solid adsorbents (metal–organic frameworks, zeolites, carbon-based materials, metal oxides), hybrid sorbents, and emerging hydrogel-based systems and their integration with utilization and storage routes. Special emphasis is given to CO₂ mineralization using mine tailings, steel slag, fly ash, and bauxite residue, as well as biological mineralization employing carbonic anhydrase (CA) immobilized in hydrogels. The techno-economic performance of these pathways is compared, highlighting that while high-capacity sorbents offer scalability, hydrogels and biomineralization excel in low-temperature regeneration and integration with waste valorization. Challenges remain in cost reduction, material stability under industrial flue gas conditions, and integration with renewable energy systems. The review concludes that hybrid, cross-technology CCUS configurations combining complementary capture, utilization, and storage strategies will be essential to meeting 2030 and 2050 climate targets. Full article

Additive and coating technologies, such as high-velocity oxy-fuel (HVOF) thermal spraying and direct metal laser sintering (DMLS), often require extensive post-processing to meet dimensional and surface quality requirements, which remains challenging for nickel-based superalloys such as Inconel 718. This study presents the design and topology optimisation of a cutting tool with a linear cutting edge, capable of operating in turn-milling or turning modes, offering a viable alternative to conventional grinding. A non-optimised tool served as a baseline for comparison with a topology-optimised variant improving cutting-force distribution and stiffness-to-mass ratio. Finite element analyses and experimental turn-milling trials were performed on DMLS and HVOF Inconel 718 using carbide and CBN inserts. The optimised tool achieved significantly reduced roughness values: for DMLS, Ra decreased from 0.514 ± 0.069 µm to 0.351 ± 0.047 µm, and for HVOF from 0.606 ± 0.069 µm to 0.407 ± 0.069 µm. Rz was similarly improved, decreasing from 4.234 ± 0.343 µm to 3.340 ± 0.439 µm (DMLS) and from 5.349 ± 0.552 µm to 4.521 ± 0.650 µm (HVOF). The lowest measured Ra, 0.146 ± 0.030 µm, was obtained using CBN inserts at the highest tested cutting speed. All improvements were statistically significant (p < 0.005). No measurable tool wear was observed due to the small engagement and the use of a fresh cutting edge for each pass. The resulting surface quality was comparable to grinding and clearly superior to conventional turning. These findings demonstrate that combining topology optimisation with a linear-edge tool provides a practical and efficient finishing approach for additively manufactured and thermally sprayed Inconel 718 components. Full article

Legal requirements are increasingly promoting the thermal treatment of sewage sludge in Germany, and alternative disposal methods are being investigated. Oxyfuel combustion is one promising thermal process for treating sewage sludge. However, the flue gas produced during the combustion process contains high levels of CO₂, a greenhouse gas that poses environmental harm. To address this issue, this study analyzed oxyfuel combustion and various CO₂ capture methods, aiming to utilize CO₂ as a feedstock for methanol production. Energy and material balance simulations were carried out using Aspen Plus. Four distinct carbon capture methods: membrane carbon capture, cryogenic carbon capture, monoethanolamine carbon capture, and ionic liquid carbon capture were modeled. Three different oxygen configurations were tested: pure air, pure oxygen, and a 50/50 air–oxygen mixture. The oxygen separation systems, including air separation units and alkaline electrolyzers, were also studied and modeled. As a result, 14 different scenarios were created. The performances, energy efficiency, and economic results of each scenario were compared to one another and to existing literature, allowing for the identification of the most effective approaches. The oxyfuel combustion scenarios achieved the highest methanol output. MEA and ionic liquid capture combined with air combustion proved to be the most cost-effective options, while cryogenic capture incurred the highest costs due to its helium-based cooling requirements. Although ASU-based oxyfuel combustion achieved the lowest specific energy requirement for methanol production, electrolysis-integrated configurations remained economically disadvantageous, underscoring the critical influence of electricity prices on the overall feasibility of the system. Full article

The low hardness of copper alloys, which are the substrate material used for continuous casting molds, makes them prone to plastic deformation, wear, and high-temperature oxidation, leading to premature failure and the formation of surface defects on billets. In this work, the microstructure, phase composition, mechanical, and tribological properties of Cr₃C₂–NiCr coatings deposited by high-velocity oxy-fuel (HVOF) spraying onto copper substrates used in molds were investigated. This research was driven by the need to extend the service life of copper molds in continuous steel casting processes. It was established that spraying parameters have a decisive influence on porosity, coating thickness, microhardness, and friction behavior under conditions simulating billet contact with the working surface of the mold. Among the investigated regimes, the coating deposited at a powder feed rate of 11.39 m/s exhibited a dense lamellar structure and the highest level of microhardness. Tribological tests confirmed that this coating exhibited the lowest coefficient of friction, whereas the other coatings were characterized by higher porosity and poorer wear resistance. Thus, the results emphasize the necessity of optimizing spraying parameters to develop highly effective HVOF protective coatings for copper molds operating under extreme thermomechanical loads during steel casting. Full article

Marine engineering equipment operates under extreme conditions such as high salinity, humidity, and flow velocity during marine resource exploration. These harsh environments impose strict requirements on surface performance, especially in terms of wear and corrosion resistance. Wear-resistant coatings are increasingly regarded as a crucial surface engineering approach to mitigate multi-mechanism degradation and improve the long-term reliability of marine equipment. In this review, the typical wear mechanisms in marine environments are systematically analyzed. Corresponding to different service scenarios, the main categories of coating materials, such as metal matrix composite coatings, cermet coatings, functionally graded coatings, and nanolayered coatings are summarized in terms of their structure and performance characteristics. Furthermore, mainstream fabrication techniques, including high-velocity oxy-fuel (HVOF), high-velocity air-fuel (HVAF), laser cladding, cold spray, and physical/chemical vapor deposition (PVD/CVD), are reviewed with respect to their influence on coating micro-structure and properties. Standardized evaluation methods for coating performance are also discussed. Finally, the current research challenges are identified, and future development trends are outlined, with an emphasis on multifunctional, intelligent, and environmentally friendly coating systems. This work aims to provide a systematic reference and theoretical basis for the design and application of wear-resistant coatings in marine environments. Full article

Carbon dioxide (CO₂), the primary anthropogenic greenhouse gas, drives significant and potentially irreversible impacts on ecosystems, biodiversity, and human health. Achieving the Paris Agreement target of limiting global warming to well below 2 °C, ideally 1.5 °C, requires rapid and substantial global emission reductions. While recent decades have seen advances in clean energy technologies, carbon capture, utilization, and storage (CCUS) remain essential for deep decarbonization. Despite proven technical readiness, large-scale carbon capture and storage (CCS) deployment has lagged initial targets. This review evaluates CCS technologies and their contributions to net-zero objectives, with emphasis on sector-specific applications. We found that, in the iron and steel industry, post-combustion CCS and oxy-combustion demonstrate potential to achieve the highest CO₂ capture efficiencies, whereas cement decarbonization is best supported by oxy-fuel combustion, calcium looping, and emerging direct capture methods. For petrochemical and refining operations, oxy-combustion, post-combustion, and chemical looping offer effective process integration and energy efficiency gains. Direct air capture (DAC) stands out for its siting flexibility, low land-use conflict, and ability to remove atmospheric CO₂, but it’s hindered by high costs (~$100–1000/t CO₂). Conversely, post-combustion capture is more cost-effective (~$47–76/t CO₂) and compatible with existing infrastructure. CCUS could deliver ~8% of required emission reductions for net-zero by 2050, equivalent to ~6 Gt CO₂ annually. Scaling deployment will require overcoming challenges through material innovations aided by artificial intelligence (AI) and machine learning, improving capture efficiency, integrating CCS with renewable hybrid systems, and establishing strong, coordinated policy frameworks. Full article

The decarbonization of hard-to-defossilize sectors, such as international maritime transport, requires innovative, and at times disruptive, energy solutions that combine efficiency, scalability, and climate benefits. Therefore, power-to-liquid (PtL) routes have stood out for their potential to use low-emission electricity for the production of synthetic fuels, via electrolytic hydrogen and CO₂ capture. However, the high energy demand inherent to these routes poses significant challenges to large-scale implementation. Moreover, PtL routes are usually at most neutral in terms of CO₂ emissions. This study evaluates, from a thermo-energetic perspective, the optimization potential of an e-methanol synthesis route through integration with a biomass oxy-fuel combustion process, making use of electrolytic oxygen as the oxidizing agent and the captured CO₂ as the carbon source. From the standpoint of a first-law thermodynamic analysis, mass and energy balances were developed considering the full oxygen supply for oxy-fuel combustion to be met through alkaline electrolysis, thus eliminating the energy penalty associated with conventional oxygen production via air separation units. The balance closure was based on a small-scale plant with a capacity of around 100 kta of methanol. In this integrated configuration, additional CO₂ surpluses beyond methanol synthesis demand can be directed to geological storage, which, when combined with bioenergy with carbon capture and storage (BECCS) strategies, may lead to net negative CO₂ emissions. The results demonstrate that electrolytic oxygen valorization is a promising pathway to enhance the efficiency and climate performance of PtL processes. Full article

Water walls in power plant boilers are prone to failure under extreme conditions involving high temperature, corrosion, and wear, which severely threaten unit reliability and operational economy. In this work, a NiCr-Cr₃C₂ protective coating was deposited on SA213-T12 steel substrates using high-velocity oxy-fuel (HVOF) spraying, with arc-sprayed PS45 coating as a reference. The NiCr-Cr₃C₂ coating exhibited a dense, low-porosity structure with homogeneous dispersion of Cr₃C₂ hard phases in the NiCr matrix, forming a typical cauliflower-like composite morphology. During high-temperature sulfate corrosion tests at 750 °C, the NiCr-Cr₃C₂ coating demonstrated superior corrosion resistance, with a weight gain of only 2.7 mg/cm², significantly lower than that of the PS45 coating and the SA213-T12 substrate. The higher microhardness and lower friction coefficient also indicate excellent high-temperature wear resistance. The enhanced performance of the NiCr-Cr₃C₂ coating is attributed to the high Cr content, which promotes the formation of a continuous and protective scale composed of Cr₂O₃ and NiCr₂O₄, effectively inhibiting corrosive diffusion and penetration. This work demonstrates the application prospects of NiCr-Cr₃C₂ coatings on water walls of power plant boilers and guides the development of advanced HVOF coatings. Full article

This study presents a comprehensive performance assessment of combustion-based options for Bioenergy with Carbon Capture and Storage (BECCS), widely regarded as key enablers of future climate neutrality. From 972 publications (2000–2025), 16 sources are identified as providing complete data. Seven technologies are considered: Calcium Looping (CaL), Chemical Looping Combustion (CLC), Hot Potassium Carbonate (HPC), low-temperature solvents (mainly amine-based), molten sorbents, Molten Carbonate Fuel Cells (MCFCs), and oxyfuel. First- and second-law efficiencies are reported for 53 bioenergy configurations (19 reference plants without carbon capture and 34 BECCS systems). Performance is primarily evaluated via the reduction in second-law (exergy) efficiency and the Specific Primary Energy Consumption per CO₂ Avoided (SPECCA), both relative to each configuration’s reference plant. MCFC-based systems perform best, followed by CLC; molten sorbents and oxyfuel also show very good performance, although each is documented by a single source. Low-temperature solvents span a wide performance range—from poor to competitive—highlighting the heterogeneity of this category; HPC performs in line with the average of low-temperature solvents. CaL exhibits modest efficiency penalties alongside appreciable energy costs of CO₂ capture, a counterintuitive outcome driven by the high performance of the benchmark plants considered in the definition of SPECCA. To account for BECCS-specific features (multiple outputs and peculiar fuels), a dedicated evaluation framework with a revised SPECCA formulation is introduced. Full article

This study examines advanced electrospark alloying (ESA) as a pulse-driven surface hardening technique for marine engineering components operating in corrosive and abrasive environments. Coatings were deposited using cobalt-based (Stellite 6), nickel-based (NiCrBSi), titanium-based (VT1-0), and boron-based (B₄C) electrodes, with pulse energies of 0.2–0.5 J, discharge frequencies of 100–200 Hz, electrode feed rates of 5–8 mm/min, applied loads of 15–20 N, and treatment durations of 40–60 s. The effects of processing parameters on coating microstructure, adhesion strength, microhardness, corrosion resistance, and wear behaviour were systematically evaluated. ESA treatments increased microhardness by 35–48% and adhesion strength by 22–30%, while reducing the corrosion rate from 0.043 mm/year to 0.025–0.027 mm/year and lowering wear volume loss by 40–47%. Compared with high-velocity oxy-fuel (HVOF) spraying and laser hardening, ESA achieved 37–58% lower energy consumption and 40–70% lower CO₂ emissions. These findings highlight ESA as an energy-efficient and environmentally sustainable option for on-site maintenance and modernisation of maritime equipment. Full article

Biocompatible coatings are widely employed in dental applications to enhance the biofunctionality of metallic implants exposed to the aggressive oral environment. Among them, hydroxyapatite (HAp)-based and carbide-reinforced coatings have been explored due to their favorable mechanical and biological performance. In this study, Cr₃C_-20(Ni20Cr)-20HAp-XSi coatings were deposited using the high-velocity oxy-fuel (HVOF) technique. The coatings were applied onto commercially pure titanium substrates, with the silicon content varied between X = 0, 5, 10, and 20 wt%. To evaluate the coatings’ corrosion resistance, electrochemical techniques such as potentiodynamic polarization curves, linear polarization resistance (LPR), electrochemical impedance spectroscopy (EIS), and open circuit potential (OCP) were employed. Artificial saliva was used as the corrosive medium at 37 °C for 168 h. The feasibility of producing carbide-HAp-Si coatings with excellent corrosion resistance and cytocompatibility via HVOF was demonstrated here, although some of the tested coatings (20 wt% Si) showed reduced electrochemical stability, attributed to faster dissolution processes and associated with a thinner coating layer, as confirmed by SEM analyses. X-ray diffraction (XRD) analyses revealed the formation of new phases in the coatings during thermal spraying, including Cr₂O₃ and Cr₇C₃. Additionally, MTT assays using 3T3-L1 fibroblasts showed no significant cytotoxic effects after 24 and 72 h of exposure to some of the coatings, confirming their biocompatibility for potential dental applications. Full article