Search Results (25)

The increasing reliance on conventional coatings such as WC-Co raises serious environmental and health concerns due to the toxicity of cobalt and the ecological footprint of these materials. To address this challenge, the present study explores the development of eco-friendly multifunctional coatings via the Plasma Spray (PS) process, using titanium (Ti), silicon carbide (SiC), and tungsten carbide-cobalt (WC-Co) mixtures as alternative feedstocks. Steel substrates were coated under different deposition strategies (powder mixing, layer-by-layer) and current settings (800-900 A). The coatings were characterized by scanning electron microscopy (SEM/EDX), 3D profilometry, sliding wear testing, and potentiodynamic corrosion measurements. Results showed that Ti-WC (mix, 900 A) and Ti-SiC (layer, 900 A) coatings achieved the most favorable performance, combining excellent adhesion, uniform coverage, reduced porosity, and improved resistance to wear and corrosion compared to conventional Cr₂O₃ coatings. Notably, Ti-WC coatings provided surface roughness values comparable to Cr₂O₃, while significantly lowering the environmental impact. These findings demonstrate that PS-based Ti-WC and Ti-SiC systems can serve as sustainable and high-performance alternatives for protective applications in harsh environments, particularly in marine industries, supporting the transition toward coatings with reduced ecological footprint. Full article

Plastic waste is currently a major concern in Romania due to the annual increase in quantities generated from anthropogenic and industrial activities, especially from end-of-life vehicles (ELVs), and the need to reduce environmental impact. This study investigates an alternative valorization route for polypropylene (PP) and polyethylene (PE) plastic waste through microwave-assisted pyrolysis, aiming to maximize conversion into gaseous products, particularly hydrogen-rich gas. A monomode microwave reactor was employed, using layered configurations of plastic feedstock, silicon carbide as a microwave susceptor, and activated carbon as a catalyst. The influence of catalyst loading, reactor configuration, and plastic type was assessed through systematic experiments. Results showed that technical-grade PP, under optimal conditions, yielded up to 81.4 wt.% gas with a hydrogen concentration of 45.2 vol.% and a hydrogen efficiency of 44.8 g/g. In contrast, PE and mixed PP + PE waste displayed lower hydrogen performance, particularly when containing inorganic fillers. For all types of plastics studied, the gaseous fractions obtained have a high calorific value (46,941–55,087 kJ/kg) and at the same time low specific CO₂ emissions (4.4–6.1 × 10⁻⁵ kg CO₂/kJ), which makes these fuels very efficient and have a low carbon footprint. Comparative tests using conventional heating revealed significantly lower hydrogen yields (4.77 vs. 19.7 mmol/g plastic). These findings highlight the potential of microwave-assisted pyrolysis as an efficient method for transforming ELV-derived plastic waste into energy carriers, offering a pathway toward low-carbon, resource-efficient waste management. Full article

This study investigates the fabrication of a ZrSiO₄-based coating (ZSO coating) on substrate surfaces using atmospheric plasma spraying (APS) technology, with ZrSiO₄ as the feedstock material. A comprehensive characterization of the coating systems was conducted, including an in-depth analysis of phase composition and a systematic evaluation of the effects of spray thickness and heat treatment temperature on phase evolution, microstructural development, and the resulting properties. The coatings’ resistance to silicon corrosion and the associated failure mechanisms were thoroughly examined. The key findings reveal that the plasma-sprayed coatings form a multiphase system composed of ZrSiO₄, along with the decomposition products of ZrO₂ and SiO₂. Optimal performance was observed within a critical thickness range of 154–240 μm. Post-deposition heat treatment at 1500 °C significantly improved the integrity of the coatings, as evidenced by a marked reduction in crack density and porosity, leading to substantial enhancement in densification. The coatings demonstrated outstanding performance in the high-temperature silicon corrosion tests, maintaining structural integrity after 4 h of exposure to molten silicon and its oxides at 1500 °C. Notably, the coatings effectively prevented the penetration of silicon into the C/C substrate, preserving strong interfacial adhesion without the formation of permeable cracks. Furthermore, post-corrosion analysis showed that the surface reaction products could be easily removed, underscoring the coatings’ exceptional protective capability for the underlying C/C substrate. Full article

The shift toward sustainable energy sources is essential to curb greenhouse gas emissions and satisfy energy demands. Among renewable options, carbon-based materials—such as agricultural residues and municipal solid waste—provide a dual advantage by generating energy and fuels while also reducing landfill waste. A notable innovation is transforming plastic waste into methane-rich streams via catalytic hydrogasification, a process in which carbon-based feedstocks interact with hydrogen using a selective catalyst. In this study, a structured catalyst was developed, characterized, and tested for converting plastic waste samples. The thermal degradation properties of plastic waste were first studied using thermogravimetric analysis. The catalyst was prepared using an Oxygen Bonded Silicon Carbide (OBSiC) open-cell foam as the carrier, coated with γ-Al₂O₃-based washcoat, CeO₂, and Ni layers. It was characterized in terms of specific surface area, coating adhesion, pore distribution, acidity, and the strength of its active sites. Experimental tests revealed that a hydrogen-enriched atmosphere significantly enhances CH₄ formation. Specifically, during catalytic hydrogasification, methane selectivity reached approximately 59%, compared to 6.7%, 13.7%, and 7.8% observed during pyrolysis, catalyzed pyrolysis, and non-catalyzed hydrogasification tests, respectively. This study presents a novel and effective approach for converting plastic waste using a structured catalyst, a method rarely explored in literature. Full article

The purification and removal of polar impurities in olefin feedstocks is crucial for downstream deep processing, and adsorption is the main method for deep purification of such impurities. This article takes dimethyl ether, a typical oxygen-containing compound impurity in MTOs, as a polar impurity molecule, and LTA and FAU topological zeolites as research objects. The influence of zeolite topology, morphology, skeleton silicon–aluminum (Si/Al) ratio, and ion type on the adsorption and removal of trace dimethyl ether was investigated by XRD, SEM, XRF, and nitrogen adsorption–desorption methods. The FAU topological zeolites show a better adsorption performance for dimethyl ether owing to their larger specific surface area and unobstructed pores compared with LTA zeolites. Among FAU topological zeolites, the NaX zeolite a with lower framework silica–alumina ratio has the highest adsorption capacity for dimethyl ether. Magnesium ion exchange on NaX zeolites (MgNaX) reduce the specific surface area and adsorption capacity of the NaX zeolite. However, after forming with alumina as a binder, the adsorption capacity of the MgNaX–Al₂O₃ adsorbent is about 13% higher than that of the NaX–Al₂O₃ adsorbent without Mg ion exchange. This may be due to the decomposition of residual organic Mg salts in the Mg ion exchange samples during high-temperature calcination, resulting in a larger specific surface area for the formed adsorbent. Further characterization of NH₃–TPD and CO₂–TPD shows that Mg ion exchange weakens the acid–base active sites on the adsorbent surface. The reduction in acid–base sites reduces the occurrence of side reactions such as polymerization and isomerization caused by the exothermic adsorption of olefins on adsorbents. Repeated adsorption data show that the formed adsorbent has excellent regeneration–adsorption performance. Full article

Photovoltaic (PV) installations have experienced significant growth in the past 20 years. During this period, the solar industry has witnessed technological advances, cost reductions, and increased awareness of renewable energy’s benefits. As more than 90% of the commercial solar cells in the market are made from silicon, in this work we will focus on silicon-based solar cells. As PV research is a very dynamic field, we believe that there is a need to present an overview of the status of silicon solar cell manufacturing (from feedstock production to ingot processing to solar cell fabrication), including recycling and the use of artificial intelligence. Therefore, this work introduces the silicon solar cell value chain with cost and sustainability aspects. It provides an overview of the main manufacturing techniques for silicon ingots, specifically Czochralski and directional solidification, with a focus on highlighting their key characteristics. We discuss the major challenges in silicon ingot production for solar applications, particularly optimizing production yield, reducing costs, and improving efficiency to meet the continued high demand for solar cells. We review solar cell technology developments in recent years and the new trends. We briefly discuss the recycling aspects, and finally, we present how digitalization and artificial intelligence can aid in solving some of the current PV industry challenges. Full article

Oil spills and chemical leakages are a serious source of pollution in oceans and rivers, and have attracted worldwide attention. Many scientists are currently engaged in the development of oil–water separation technology. In this study, the umbrella skirt of a discarded silicone rubber insulator was utilized as feedstock, and polydimethylsiloxane (PDMS) was employed to immobilize the prepared powder (FXBW) onto a polyurethane (PU) sponge skeleton. Without any modifications using chemical reagents, a novel oil–water separation material, FXBW-PU, was developed, with a water contact angle of 155.3°. The FXBW-PU sponge exhibited an absorption capacity ranging from 11.79 to 26.59 g/g for various oils and organic solvents, while maintaining an excellent selective adsorption performance, even after undergoing ten compression cycles, due to its exceptional chemical and mechanical stability. With the assistance of a vacuum pump, the FXBW-PU sponge was utilized in a continuous separation apparatus, resulting in a separation efficiency exceeding 98.6% for various oils and organic solvents. The separation efficiency of n-hexane remains as high as 99.2% even after 10 consecutive separation cycles. Notably, the FXBW-PU sponge also separated the dichloromethane-in-water emulsions, which achieved the effect of purifying water. In summary, FXBW-PU sponge has great potential in the field of cleaning up oil/organic solvent contamination due to its low preparation cost, environmental friendliness and excellent performance. Full article

Solar photovoltaics (PV) has emerged as one of the world’s most promising power-generation technologies, and it is essential to assess its applications from the perspective of a material-energy-water (MEW) nexus. We performed a life cycle assessment of the cradle-to-grave MEW for single-crystalline silicon (s-Si) and CdTe PV technologies by assuming both PV systems are recycled at end of life. We found that the MEW network was dominated by energy flows (>95%), while only minor impacts of materials and water flows were observed. Also, these MEW flows have pyramid-like distributions between the three tiers (i.e., primary, secondary/sub-secondary, and tertiary levels), with greater flows at the primary and lower flows at the tertiary levels. A more detailed analysis of materials’ circularity showed that glass layers are the most impactful component of recycling due to their considerable weight in both technologies. Our analysis also emphasized the positive impacts that increased power-conversion efficiency and the use of recycled feedstock have on the PV industry’s circularity rates. We found that a 25% increase in power-conversion efficiency and the use of fully recycled materials in PV panel feedstocks resulted in 91% and 86% material circularity for CdTe and s-Si PV systems, respectively. Full article

The Silicon on Dust Substrate (SDS) is a gas-to-wafer process that produces multicrystalline silicon ribbons directly from gaseous feedstock (silane), avoiding the standard industry steps of polysilicon deposition, crystal growth, and wafering. The SDS technique consists of three main steps: (i) micrometric-sized silicon powder production by grinding silicon chunks; (ii) chemical vapor deposition (CVD) of silicon over this silicon powder substrate; and (iii) zone-melting recrystallization (ZMR) of the nanocrystalline pre-ribbon obtained in the CVD step. Several samples were produced by this technique. During CVD, mechanically self-sustained nanocrystalline pre-ribbons were grown over silicon powder substrates, with growth rates in the order of 50 µm/min. The ZMR process performance is substantially impacted by the pre-ribbon physical characteristics. The best and largest recrystallizations were achieved on pre-ribbons grown over powder substrates with smaller particle sizes, which also have lower substrate powder incorporation ratios. Multicrystalline silicon ribbons with crystalline areas as large as 2 × 4 cm² were successfully produced. These areas have visible columnar crystal growth with crystal lengths up to 1 cm. The SDS ribbons’ measured resistivity confirmed the high powder content of the resulting material. The ability to produce solar cells on SDS multicrystalline silicon ribbons was demonstrated. Full article

Lignocellulosic biomass from rice husk (RH) is a renewable resource for fuel production, but it could pose ash-related challenges. This work focused on investigating the effects of pretreatment at different sodium hydroxide (NaOH) concentrations (i.e., 0.0, 0.25, 0.50, 0.75 and 1.00 M) on the calorific values and ash contents of treated RH products, and also finding the optimal torrefaction conditions. The results showed that alkaline pretreatment by sodium hydroxide (NaOH) reduced the ash content in the RH samples by over 85 wt%. Due to its relatively excellent calorific values and low ash content, the RH sample with 0.25 M NaOH pretreatment (i.e., RH-25) was chosen as a starting feedstock in the subsequent torrefaction experiments as a function of 240–360 °C for holding time of 0–90 min. In addition, the surface properties by scanning electron microscopy—energy dispersive X-ray spectroscopy (SEM-EDS) and Fourier-transform infrared spectroscopy (FTIR) were also used to observe the elemental compositions preliminarily. Based on the fuel properties of the torrefied RH products, the optimal torrefaction conditions can be found at around 280 °C for holding 30 min. As compared to the calorific value of the RH-25 (i.e., 18.74 MJ/kg) and its mass yield (i.e., 0.588), the calorific value, enhancement factor and energy yield of the optimal product were 28.97 MJ/kg, 1.55 and 0.91, respectively. Although the resulting product has a high calorific value like coal, it could have slight potential for slagging and fouling tendency and particulate matter emissions due to the relatively high contents of silicon (Si) and sodium (Na), based on the results of EDS and FTIR. Full article

Spray drying is a widely used method of converting liquid material (aqueous or organic solutions, emulsions and suspensions) into a dry powder. Good flowability, narrow size distribution, and controllable morphology are inherent in powders produced by spray drying. This review considers the granulation factors that influence the final properties of the silicon nitride dried powders. The first group includes the types of atomizers, manifolds, and drying chamber configurations. The process parameters fall into the second group and include the following: inlet temperature, atomizing air flow, feed flow rate, drying gas flow rate, outlet temperature, and drying time. Finally, the last group, feedstock parameters, includes many factors such as feed surface tension, feed viscosity, solvent type, solid particle concentration, and additives. Given the large number of factors affecting morphology, particle size and moisture, optimizing the spray drying process is usually achieved by the “trial and error” approach. Nevertheless, some factors such as the effect of a solvent, dispersant, binder, and sintering additives considered in the literature that affect the Si₃N₄ granulation process were reviewed in the work. By summarizing the data available on silicon nitride powder production, the authors attempt to tackle the problem of its emerging demand in science and industry. Full article

An increase in the number of independent breweries and distilleries has led to an increase in the amount of spent grains with inadequate means of disposal. One option for disposal is as feedstock for anaerobic digestion if digester stability is ensured. In this study, brewers’ spent grain and distillers’ spent grain were used as substrate for anaerobic digestion for 32 weeks. The digestate was treated by recirculation through a silicone hose located in an external tank filled with saline solution. The hose served as a permeable membrane allowing for the passage of gases. The recirculation tanks were fitted with check valves to maintain three pressure/gas regimes: 26 mm Hg N₂, 26 mm Hg aeration or 100 mm Hg aeration. A fourth digester was operated with no recirculation as the control. These treatments were chosen to determine if differences in digester stability, wastewater treatment efficiency, and biogas production could be detected. A combination of dairy and swine manure was used as seeding to provide a methanogenic consortium and bicarbonate buffering. However, despite trying to provide for adequate initial bicarbonate buffering, all four digesters had low initial buffering and consequently low pH as short-chain fatty acids accumulated. After six weeks, bicarbonate buffering and pH increased as methane production increased, and short-chain fatty acids decreased. Later, despite the fluxes of O₂ and N₂ across the silicone membrane being very low, differences between the various treatments were noted. The pH of the digestate treated by N₂ recirculation was lower than the other digesters and decreased further after distillers’ spent grain was substituted for brewers’ spent grain. Aeration at a pressure of 26 mm Hg and 100 mg Hg increased biogas production compared to other treatments but only significantly so at 100 mm Hg. These results suggest that partial purging of dissolved gases in anaerobic digestate by the small fluxes of N₂ or O₂ across a permeable membrane may affect digester performance. Full article

Cost and performance-effective materials used in advanced oxidation processes such as photocatalysis have obtained widespread attention in recent years. In this study, thermal spraying was used as a one-step method to obtain thick visible-light-active photocatalyst coatings on two types of substrates, namely, plain carbon steel and copper. A mixed metallic titanium–silicon powder bearing 10% wt. Si was used as feedstock. The optical bandgaps of the coatings were close to 1.000 eV, allowing good photodecoloration efficiencies (>89%) and mineralization efficiencies (>67%) for methylene blue dye from aqueous solutions under visible light irradiation. The photodegradation process could be successfully modelled by the Langmuir–Hinshelwood pseudo-first-order kinetic model, with reaction rate constants k between 0.16 and 1.06 h⁻¹. Full article

Research and development in the field of metal-based additive manufacturing are advancing steadily every year. In order to increase the efficiency of powder bed fusion of metals using a laser beam system (PBF LB/M), machine manufacturers have implemented extensive optimizations with regard to the laser systems and build volumes. However, the optimization of metallic powder materials using nanoparticle additives enables an additional improvement of the laser–material interaction. In this work, tool steel 1.2709 powder was coated with silicon carbide (SiC), few-layer graphene (FLG), and iron oxide black (IOB) on a nanometer scale. Subsequently, the feedstock material and the modified powder materials were analyzed concerning the reflectance of the laser radiation and processed by PBF-LB/M in a systematic and consistent procedure to evaluate the impact of the nano-additivation on the process efficiency and mechanical properties. As a result, an increased build rate is achieved, exhibiting a relative density of 99.9% for FLG/1.2709 due to a decreased reflectance of this modified powder material. Furthermore, FLG/1.2709 provides hardness values after precipitation hardening with only aging comparable to the original 1.2709 material and is higher than the SiC- and IOB-coated material. Additionally, the IOB coating tends to promote oxide-formation and lack-of-fusion defects. Full article

In contrast to other additive manufacturing methods such as Wire Arc Additive Manufacturing or Laser Metal Deposition, the cold spray system designed by SPEE3D allows for structures to be printed at much lower temperatures. As a result, structures printed via cold spray often undergo post processing heat treatments that potentially alter the distribution of trace elements throughout the sample. The distribution of elements within these structures may then have a direct impact on the corrosion properties of these materials. The impact of post processing heat treatment parameters on the microstructure and distribution of Mg and Si trace elements within an Al alloy was investigated using cross section analysis of samples by SEM-EDS. From an Al-powered feedstock, alloys were printed using SPEED3D’s LightSPEE3D printer utilising air as the carrier gas, at 30 Bar and 500 °C; various post processing heat and water quench treatments were then applied. The results revealed a reorganisation of Mg (which subsequently becomes oxidised) toward the edges of pores, regions that typically have a higher surface energy. This is in direct contrast to the largely homogenous distribution of Mg in the samples that did not undergo post printing heat treatments. The addition of charcoal during the heat treatment process also resulted in the redistribution of Si within the sample, and the creation of silicon carbide structures. The impact of the reorganisation of Mg within the sample as well as the creation of silicon carbide structures on the selective corrosion of these materials was then investigated using potentiodynamic corrosion testing and electrochemical impedance spectroscopy. Full article