Search Results (145)

Polyethylene is the most used plastic in the world, and over 90% of this plastic is ultimately disposed of in landfills or released into the environment, leading to severe ecological implications. In this research, the technoeconomic feasibility of upcycling low-density polyethylene (LDPE) to produce ethylene is studied. The catalytic conversion of LDPE to ethylene is considered in microwave heating mode and Joule heating mode. Experimental data is obtained under conditions where most of the upcycled products are in the gas phase. A flowsheet is developed that produces industrial quantities of ethylene for both heating modes. A technoeconomic analysis and a life cycle analysis are conducted and compared with the traditional ethane cracking process for producing ethylene. Simulation results indicate that the upcycling system exhibits a lower capital expenditure and a comparable operating expenditure relative to conventional ethane steam cracking while generating additional valuable co-products, such as propylene and aromatic hydrocarbons, leading to a higher net present value potential. Sensitivity analyses reveal that the electricity price has the most significant impact on both the net present value and levelized cost of production, followed by the low-density polyethylene feedstock cost. Life-cycle assessment reveals a substantial reduction in greenhouse-gas emissions in the upcycled process compared to the fossil-based ethane steam-cracking route, primarily due to the use of renewable electricity, the lower reaction temperature that reduces utility demand, and the use of plastic waste as the feedstock. Overall, the proposed process demonstrates strong potential for the sustainable production of ethylene from waste LDPE. Full article

This study assesses four hydrogen production pathways (electrolysis, ammonia cracking, steam biomethane reforming, and methane pyrolysis) for an inland refinery under European Renewable Energy Directive III (RED III) goals. Using multicriteria decision analysis (MCDA), economic, environmental, technological, and implementation factors were evaluated. The results show that biomethane reforming offers the lowest cost, while electrolysis provides the best environmental and technological performance. Sensitivity analysis highlights electricity price as the key factor. The MCDA model proved to be effective for systematic comparison and informed strategic decision making. However, RED III regulatory requirements may favor ammonia or electrolysis for renewable fuel of non-biological origin production, emphasizing the need for long-term strategic planning to maintain competitiveness. Full article

ZSM-5 zeolites with varying aluminum content were subjected to steam treatments of different severities by adjusting the temperature, duration, and water vapor pressure. The steamed samples were characterized using a range of analytical techniques. A quantitative assessment of the aluminum species—namely, tetrahedrally coordinated framework Al, dislodged framework Al, non-framework pentacoordinated Al, and non-framework hexacoordinated Al—was achieved through a combination of EDX analysis on Cs-exchanged materials and quantitative ²⁷Al MAS NMR spectroscopy, including spectral simulation. Contrary to previous reports, the catalytic activity per framework Al site in unsteamed ZSM-5 increases with aluminum content at low Si/Al ratios, aligning with recently proposed medium effects. Notably, at the point of maximum activity enhancement due to steaming, equivalent amounts (1:1) of framework and dislodged framework Al—both in tetrahedral coordination—are observed. The maximum enhancement factor per framework Al site, for a given material and reaction, remains independent of the specific steaming conditions (temperature, time, and pressure). However, the degree of activity enhancement varies with the type of reaction: it is more pronounced for n-hexane cracking (α-test) than for m-xylene isomerization. This suggests that both catalyst modification and reaction characteristics contribute to the observed steam-induced activity enhancement. A synergistic interaction between Brønsted and Lewis acid sites appears to underpin these effects. One plausible mechanism involves the strengthening of Brønsted acidity in the presence of adjacent Lewis acid sites. This enhancement is expected to be more significant for n-hexane cracking, which demands higher acid strength compared to m-xylene isomerization. In cases of n-hexane cracking, the increased acid strength and the formation of olefins via reactions on Lewis acid sites may act cooperatively. Importantly, the dislodged framework Al species—tetrahedrally coordinated in the hydrated catalyst at ambient temperature and functioning as Lewis acid sites in the dehydrated zeolite under reaction conditions—are directly responsible for the observed enhancement in acid activity. The transformation of framework Al into dislodged framework Al species is reversible, as demonstrated by hydrothermal treatment of the steamed samples at 150–200 °C. Nonetheless, reinsertion of Al into the framework is not fully quantitative: a portion of the dislodged framework Al is irreversibly converted into non-framework penta- and hexacoordinated species during the hydrothermal process. Among these, non-framework pentacoordinate Al species may serve as counterions to balance the lattice charges associated with framework Al. Full article

The methanol-to-olefins (MTO) process offers a viable alternative to traditional naphtha cracking for producing light olefins, providing flexibility in feedstock sources and the potential for reduced energy consumption. This study presents a detailed plant-wide design of an MTO process, developed and optimized to increase ethylene and propylene yields while reducing energy consumption. The methodology includes comprehensive reactor modeling of a fast fluidized-bed reactor–regenerator system, accounting for coke formation kinetics, along with rigorous process simulation for the subsequent separation and purification of products. A six-column distillation train has been designed and optimized for the recovery of polymer-grade ethylene and propylene, while dual-stage CO₂ absorption units ensure complete removal of carbon dioxide. Pinch analysis is used to identify opportunities for heat integration, resulting in an optimized heat-exchanger network that significantly reduces the need for external heating and cooling utilities. The results show that the optimized MTO design achieves a methanol conversion rate of over 99.9% and produces a propylene-rich product stream with a propylene-to-ethylene ratio of approximately 1.8, while maintaining a high purity level exceeding 99.5%. By implementing heat integration and recycling by-products, including using off-gas methane as furnace fuel and repurposing waste heat for steam generation, the plant reduces utility requirements by more than 85%, significantly improving energy efficiency. An economic evaluation shows a favorable payback period of approximately 5.4 years and an internal rate of return of 15–16%, confirming the viability and industrial potential of the integrated MTO process for sustainable olefin production. Full article

The risk of explosive spalling in high-strength cement-based materials during fire exposure poses a significant threat to structural integrity. To help mitigate this issue, this study explores the use of expanded polystyrene (EPS) beads as both a lightweight filler and a potential spalling-reduction agent in lightweight geopolymer and conventional cementitious mortars. Two EPS-containing mortars were developed: a lightweight alkali-activated slag (LWAS) mortar and a conventional lightweight Portland cement (LWPC) mortar, both incorporating EPS beads as a 50% volumetric replacement for sand. Specimens from both mortars were subjected to elevated temperatures of 200 °C, 400 °C, and 600 °C at a heating rate of 10 °C/min to simulate a rapid-fire scenario. Following thermal exposure, two cooling regimes were employed: gradual cooling within the furnace and rapid cooling by water immersion. Mechanical performance was evaluated through compressive, splitting tensile, and impact tests at room and elevated temperatures. Microstructural analysis was also conducted to examine internal changes and heat-induced damage. The results indicated that LWAS showed remarkable resistance to spalling, remaining intact up to 600 °C due to its nanoporous geopolymer structure, which allowed controlled steam release, while LWPC failed explosively at 550 °C despite EPS pores. At 400 °C, EPS beads enhanced thermal insulation in LWAS, lowering internal temperature by over 100 °C, but increased porosity led to faster strength loss. Both mortars gained strength at 200 °C from continued curing, yet LWAS retained strength better at high temperatures than LWPC. Microscopy revealed that EPS created beneficial fine cracks in the slag matrix but harmful voids in cement. Overall, LWAS composites offer excellent spalling resistance for fire-prone environments, though reinforcement is recommended to mitigate strength loss. Full article

Solvent-assisted steam-assisted gravity drainage (SA-SAGD) is an advanced hybrid oil recovery technique designed to enhance the extraction of heavy oil and bitumen. Unlike the conventional SAGD process, which relies solely on thermal energy from injected steam, SA-SAGD incorporates a coinjected solvent phase to improve oil mobility through the combined action of heat and mass transfer. This synergistic mechanism significantly reduces the demand for water and natural gas used in steam generation, thereby improving the energy efficiency and environmental sustainability of the process. Importantly, SA-SAGD retains the same well pair configuration as SAGD, meaning that its implementation often requires minimal modifications to existing infrastructure. This study explores the residual oil saturation following multi-component solvent coinjection in SA-SAGD using a linear sand pack model designed to emulate the properties and operational parameters of the Long Lake reservoir. Experiments were conducted with varying constant concentrations of cracked naphtha and gas condensate to assess their effectiveness in enhancing bitumen recovery. The results reveal that the injection of 15 vol% cracked naphtha achieved the lowest residual oil saturation and the highest rate of oil recovery, indicating superior solvent performance. Notably, gas condensate at just 5 vol% concentration outperformed 10 vol% cracked naphtha, demonstrating its effectiveness even at lower concentrations. These findings provide valuable insight into the phase behaviour and recovery dynamics of solvent–steam coinjection systems. The results strongly support the strategic selection of solvent type and concentration to optimise recovery efficiency while minimising steam consumption. Furthermore, the outcomes offer a robust basis for calibrating reservoir simulation models to improve the design and field-scale application of SA-SAGD, particularly in pilot operations such as those conducted by Nexen Energy ULC in the Athabasca Oil Sands. Full article

The fracture behavior of a locking pin used in the penultimate-stage blades of a 600 MW steam turbine in a thermal power plant was investigated through microstructural and microhardness characterization, fracture surface and energy-dispersive spectroscopy (EDS) analysis, as well as finite element load simulation. The microhardness values measured on the cross-section of the service pins ranged from 528 to 541 HV0.1, showing little difference from the unused pins. Scanning electron microscopy analysis revealed that approximately 70% of the fracture surfaces exhibited an intergranular “rock candy” morphology. The results indicate that pin failure was primarily caused by the combined effects of fretting wear and stress corrosion cracking (SCC). Specifically, vibration at the blade root, impeller, and pins due to start–stop cycles and load variations led to fretting wear, forming pits approximately 75 μm in size. Under the combined effects of weakly corrosive wet steam environments and shear stresses, SCC initiated at the high stress concentration points of these pits. Early crack propagation primarily followed original austenite grain boundaries, while later stages mainly extended along martensite plate boundaries. As cracks advanced, the cross-sectional area gradually decreased, causing the effective shear stress to increase until it exceeded the shear strength, ultimately leading to fracture. These findings not only provide a scientific basis for enhancing the reliability of steam turbine locking pins and extending their service life, but also contribute to a broader understanding of the failure mechanisms of key components operating under corrosive and fluctuating load environments. Full article

P92 martensitic heat-resistant steel is widely used in ultra-supercritical (USC) thermal power units due to its excellent creep resistance and high-temperature strength. However, prolonged exposure to high temperatures induces significant microstructural degradation, compromising mechanical properties and operational safety. This study investigates the evolution of microstructure and mechanical properties in P92 steel extracted from main steam pipelines after service durations of 30,000 h, 47,000 h, 56,000 h, 70,000 h, and 93,000 h. Comparative analyses of impact toughness, tensile strength, and creep strength were conducted and advanced characterization of SEM and TEM was used to investigate the microstructural evolution. The results reveal a progressive decline in mechanical properties with increasing service time. Specifically, impact toughness decreased by approximately 66.8%, room-temperature tensile strength reduced by 9.62%, and high-temperature tensile strength at 610 °C declined by 31.6%. Notably, the 10⁵ hour creep rupture strength exhibited a 10.4% decrease compared to as-received material. This decline is attributed to microstructural changes including precipitate coarsening, martensite lath boundary degradation, dislocation reconfiguration, and severe grain coarsening. The coarsening of precipitates weakens their bonding with the matrix, while the widening of martensite laths reduces resistance to crack propagation and dislocation movement, jointly contributing to strength deterioration. Full article

Si powder was deposited onto the surface of Zr-4 alloy via laser cladding to enhance its high-temperature oxidation resistance. The high-power laser radiation and rapid solidification lead to a reaction between Si and Zr, resulting in the formation of a microstructure consisting of lath-like ZrSi₂ and Si-rich phases. The oxidation behavior of the laser-cladding ZrSi coating was evaluated at 1100–1300 °C in water steam. The weight gain follows a parabolic law, and the oxidation activation energy of the ZrSi coating is 182.7 kJ mol⁻¹. The oxides produced by ZrSi₂ oxidation are mainly ZrSiO₄, ZrO₂, and SiO₂, and, under high-temperature conditions, the relative content of ZrSiO₄ in the oxide decreases with increasing temperature. The oxidation of the ZrSi₂ phase induces significant growth stresses, which are susceptible to causing cracks in the oxide, facilitating accelerated oxygen diffusion into the coating. However, the amorphous SiO₂ formed at 1300 °C, which may be softened and fluidized to enable a self-healing effect, can heal the cracks to diminish oxygen permeation into the coating, improving its oxidation resistance. The oxidation resistance of the laser cladding ZrSi coating is better than that of the Zr-4 alloy. Full article

This study addresses recurring failures of a gas boiler with a steam capacity of 65,000 kg/h, which is operating in a Polish industrial plant. To determine the cause, material examinations were carried out, including chemical composition and microstructural analysis of SA178A steel, as well as strength tests. The results revealed no significant material degradation outside the cracking zones, suggesting that the failures were primarily caused by thermo-mechanical interactions. A finite element model in Ansys Workbench software was developed, incorporating thermal and mechanical boundary conditions, to reproduce the behavior of the critical section. The analysis demonstrated stress concentrations at the junction between the box and the membrane wall, resulting from large thermal displacement differences. The plastic strains under static loading do not exceed 5%, which implies that, without considering the cyclic nature of boiler operation, the wall should not experience failure. Analysis taking into account only 3 full operating cycles indicates a continuous increase in plastic deformation, which leads to the occurrence of ratcheting. To mitigate these effects, a modification of the sealing box design was proposed. Simulations indicated a reduction in plasticized zones by approximately 65%, and the effectiveness of the solution was confirmed by two years of failure-free operation. The findings highlight the importance of an integrated diagnostic, numerical, and design approach to improving boiler durability. Full article

In this study, non-isothermal pyrolysis of a mixture of disposable surgical face masks (FMs) and nitrile gloves (NGs) was conducted, using a heating rate of 100 °C/min, N₂ flowrate of 100 mL/min, and temperatures between 500 and 800 °C. Condensable product yield peaked at 600 °C (76.9 wt.%), with gas yields rising to 31.0 wt.%, at 800 °C. GC-MS of the condensable product confirmed the presence of aliphatic compounds (>90%), while hydrogen, methane, and ethylene dominated the gas composition. At 600 °C, gasoline (C₄ to C₁₂)-, diesel (C₁₃ to C₂₀)-, motor oil (C₂₁ to C₃₅)-, and heavy hydrocarbon (C₃₅₊)-range compounds accounted for 23.7, 46.7, 12.5, and 17.1%, of the condensable product, respectively. Using model-free methods, the average activation energy and pre-exponential factor were found to be 309.7 ± 2.4 kJ/mol and 2.5 ± 3.4 × 10²⁵ s⁻¹, respectively, while a 2-dimensional diffusion mechanism was determined. Scale-up runs confirmed high yields of condensable product (60–70%), with comparable composition to that obtained from lab-scale tests. The pyrolysis oil exceeds acceptable oxygen, nitrogen, chlorine, and fluorine levels for industrial steam crackers—needing pre-treatment—while other contaminants like sulphur and metals could be managed through mild blending. In summary, this work offers a sustainable approach to address the environmental concerns surrounding disposable FMs and NGs. Full article

This study employed a two-stage fixed-bed pyrolysis-reforming reactor to investigate H₂ production behaviors from municipal solid waste (MSW) and biomass with their self-derived catalysts under different operating parameters. The self-derived catalysts are prepared by mechanically mixing pyrolysis-derived chars with CaO and iron powders. The main results are as follows: (1) The higher oxygen content in biomass facilitates oxidative dehydrogenation reactions, enabling in situ generation of H₂O, which results in a higher H₂/CO ratio for biomass compared to MSW under steam-free conditions. (2) There are optimal values for the reforming temperature and steam-to-feedstock ratio (S/F) to achieve best performance. In the presence of steam, MSW generally exhibits superior H₂ and syngas production performance to biomass; (3) Both MSW char (MSWC)- and biomass char (BC)-based catalysts showed satisfied H₂ production and tar cracking performance at 850–900 °C, and the MSWC-based catalyst demonstrated better catalytic activity than the BC-based catalyst due to its higher contents of several active metals. In addition, the iron powder can be recycled easily, proving the effectiveness of the self-derived convenient and cheap catalysts. Full article

A thermodynamic integrated process assessment and experimental evaluation of the conversion of woody biomass to H₂ using chemical looping approaches were explored in this work. Both a two- and three-reactor approach were evaluated for effectiveness with a CaFe₂O₄ oxygen carrier (OC). Experimental test campaigns consisted of semi-batch operations where a single reactor was loaded with a batch charge of the OC and fuel. Multi-reactor approaches were experimentally simulated by switching the gas atmosphere around the batch charge of the OC. The experiments showed that woody biomass was capable of reducing CaFe₂O₄, enabling the production of H₂ from steam oxidation. High steam conversion rates to H₂ of >75% were demonstrated. Reduced CaFe₂O₄ catalyzed tar cracking, multi-cycle tests showed stable reactivity, and sub-pilot-scale tests showed improved reactivity and H₂ yield, accompanied by improved attrition resistance after over 30 cycles. The three-reactor configuration showed the highest potential for H₂ yield between the case studies, while the two-reactor configuration had the lowest auxiliary feed requirement. Both approaches showed increased yields and lower utilities than the baseline steam gasification technology. Full article

This study investigates the role of Al alloying in tailoring the oxidation resistance of AlTiCrZrNbTa refractory high-entropy alloy (RHEA) coatings on Zry-4 substrates under high-temperature steam environments. Coatings with varying Al contents (0–25 at.%) were deposited via magnetron sputtering and subjected to oxidation tests at 1000–1100 °C. The results demonstrate that Al content critically governs oxidation kinetics and coating integrity. The optimal performance was achieved at 10 at.% Al, above which a dense, continuous composite oxide layer (Al₂O₃, TiO₂, Cr₂O₃) formed, effectively suppressing oxygen penetration and maintaining strong interfacial adhesion. Indentation tests confirmed enhanced mechanical integrity in Al-10 coatings, with minimal cracking post-oxidation. Excessive Al alloying (≥17 at.%) led to accelerated coating oxidation. This work establishes a critical Al threshold for balancing oxidation and interfacial bonding, providing a design strategy for developing accident-tolerant fuel cladding coatings. Full article

Zirconium alloys are essential materials for nuclear fuel cladding. During a loss-of-coolant accident (LOCA), zirconium alloy cladding can oxidize in high-temperature steam (>1000 °C), generating hydrogen and releasing significant heat. Without timely emergency actions, this can result in hydrogen explosions or nuclear leakage. In this study, titanium nitride (TiN), chromium (Cr), and TiN–Cr composite coatings were deposited on the surface of Zr-4 alloy using the magnetron sputtering method. The coatings’ surface and cross-sectional morphologies were examined using scanning electron microscopy (SEM), and their phase structures were analyzed with X-ray diffraction (XRD). The mechanical properties were evaluated using scratch tests, and their resistance to high-temperature steam oxidation was tested in a tube furnace connected to a steam generator. The results showed that the TiN, Cr, and TiN–Cr coatings exhibited strong adhesion to the Zr-4 substrates, with distinct interfaces and pure phase structures. After high-temperature steam oxidation, cracks appeared on the surfaces of the TiN, Cr, and TiN–Cr coatings, likely due to differences in the thermal expansion coefficients of TiO₂, Cr₂O₃, and residual Cr layers. These cracks created pathways for the oxidizing medium, potentially leading to the oxidation of the substrate or inner layers of the composite coatings. For the Cr and TiN–Cr coatings, despite cracking of the Cr layer and melting of the TiN layer at high temperatures, the residual Cr layer effectively restricted oxygen diffusion into the Zr-4 substrate. This study suggests that layers with low melting points, such as TiN, are unsuitable for composite coatings in high-temperature applications. However, adding a Cr layer on top of the TiN layer to form a TiN–Cr composite coating improves adhesion between the coating and the substrate. The TiN–Cr composite coating functions as an effective diffusion barrier at temperatures up to 1200 °C, comparable to a pure Cr coating. Full article