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This study introduces a distributed electrified heating approach that is able to innovate chemical engineering involving endothermic reactions. It enables rapid and uniform heating of gaseous reactants, facilitating efficient conversion and high product selectivity at specific equilibrium. Demonstrated in catalyst-free CH 4 pyrolysis, this approach achieves stable production of H 2 (530 g h -1 L reactor -1 ) and carbon nanotube/fibers through 100% conversion of high-throughput CH 4 at 1150 °C, surpassing the results obtained from many complex metal catalysts and high-temperature technologies. Additionally, in catalytic CH 4 dry reforming, the distributed electrified heating using metallic monolith with unmodified Ni/MgO catalyst washcoat showcased excellent CH 4 and CO 2 conversion rates, and syngas production capacity. This innovative heating approach eliminates the need for elongated reactor tubes and external furnaces, promising an energy-concentrated and ultra-compact reactor design significantly smaller than traditional industrial systems, marking a significant advance towards more sustainable and efficient chemical engineering society., (© 2024. The Author(s).)

Producing sustainable anode materials for lithium-ion batteries (LIBs) through catalytic graphitization of renewable biomass has gained significant attention. However, the technology is in its early stages due to the bio-graphite's comparatively low electrochemical performance in LIBs. This study aims to develop a process for producing LIB anode materials using a hybrid catalyst to enhance battery performance, along with readily available market biochar as the raw material. Results indicate that a trimetallic hybrid catalyst (Ni, Fe, and Mn in a 1:1:1 ratio) is superior to single or bimetallic catalysts in converting biochar to bio-graphite. The bio-graphite produced under this catalyst exhibits an 89.28% degree of graphitization and a 73.95% conversion rate. High-resolution transmission electron microscopy (HRTEM) reveals the dissolution-precipitation mechanism involved in catalytic graphitization. Electrochemical performance evaluation showed that the trimetallic hybrid catalyst yielded bio-graphite with better electrochemical performances than those obtained through single or bimetallic hybrid catalysts, including a good reversible capacity of about 293 mAh g -1 at a current density of 20 mA/g and a stable cycle performance with a capacity retention of over 98% after 100 cycles. This study proves the synergistic efficacy of different metals in catalytic graphitization, impacting both graphite crystalline structure and electrochemical performance., (© 2024. The Author(s).)

Typical non-metallic inclusions in two industrial low-carbon steels for oil pipelines were investigated as three-dimensional objects on film filters after electrolytic extraction and filtration of metal samples. A method of soft chemical extraction using a 10%AA electrolyte was used to study the initial corrosion process in the steel matrix surrounding various non-metallic inclusions. To determine and compare "corrosive" inclusions and their influence on the initial stages of corrosion of the adjacent layer of the steel matrix, quantitative parameters (such as the diameter of the corrosion crater ( D cr ) and pit ( D pit ), and the relative dissolution coefficient of the metal matrix ( KD ) around various inclusions) were determined after chemical extraction. It was found that CaO-Al 2 O 3 -MgO oxides and TiN inclusions did not cause an initial corrosion of the steel matrix surrounding these inclusions. However, tensile stresses in the steel matrix occurred around CaS inclusions (or complex inclusions containing a CaS phase), which contributed to the initiation of corrosion around these inclusions.

Different stainless steel slags have been successfully employed in previous experiments, for the treatment of industrial acidic wastewaters. Although, before this technology can be implemented on an industrial scale, upscaled pilot experiments need to be performed. In this study, the parameters of the upscale trials, such as the volume and mixing speeds, are firstly tested by dispersing a NaCl tracer in a water bath. Mixing time trials are used to maintain constant mixing conditions when the volumes are increased to 70, 80 and 90 L, compared to the 1 L laboratory trials. Subsequently, the parameters obtained are used in pH buffering trials, where stainless steel slags are used as reactants, replicating the methodology of previous studies. Compared to laboratory trials, the study found only a minor loss of efficiency. Specifically, in previous studies, 39 g/L of slag was needed to buffer the pH of the acidic wastewaters. To reach similar pH values within the same time span, upscaled trials found a ratio of 43 g/L and 44 g/L when 70 and 90 L are used, respectively. Therefore, when the kinetic conditions are controlled, the technology appears to be scalable to higher volumes. This is an important finding that hopefully promotes further investments in this technology.

In this study, CaO-containing wastes from pulp and paper industries such as fly ash (FA) and calcined lime mud (LM) were utilized to neutralize and purify acidic wastewaters from the pickling processes in steel mills. The investigations were conducted by laboratory scale trials using four different batches of wastewaters and additions of two types of CaO-containing waste materials. Primary lime (PL), which is usually used for the neutralization, was also tested in the same experimental set up in the sake of comparison. The results show that these secondary lime sources can effectively increase the pH of the acidic wastewaters as good as the commonly used primary lime. Therefore, these secondary lime sources could be potential candidates for application in neutralization processes of industrial acidic wastewater treatment. Moreover, concentrations of metals (such as Cr, Fe, Ni, Mo and Zn) can decrease dramatically after neutralization by using secondary lime. The LM has a purification effect from the given metals, similar to the PL. Application of fly ash and calcined lime mud as neutralizing agents can reduce the amount of waste from pulp and paper mills sent to landfill and decrease the need for nature lime materials in the steel industry.

Natural convection of molten steel flow in a tundish occurs due to the temperature variation of the inlet stream and heat losses through top surface and refractory walls. A computational fluid dynamics (CFD) model was applied to study the effect of thermal buoyancy on fluid flow and residence-time distribution in a single-strand tundish. The CFD model was first validated with the experimental data from a non-isothermal water model and then applied to both scale-down model and prototype. The effects of flow control devices, including weir, dam and turbulence inhibitor, were compared and analyzed. Parameter studies of different heat losses through the top surface were performed. The results show that thermal buoyancy has a significant impact on the flow pattern and temperature distributions of molten steel in the tundish. The increase of heat loss through the top surface shortens the mean residence time of molten steel in the tundish, leading to an increase in dead volume fraction and a decrease in plug flow volume fraction.

The flow behavior of gas in compressible and incompressible systems was investigated at an ambient temperature in an air-water system and at an operating process temperature in the IronArc system, using computational fluid dynamics. The simulation results were verified by experiments in the air-water system and established empirical equations to enable reliable predictions of the penetration length. The simulations in the air-water system were found to replicate the experimental behavior using both the incompressible and compressible models, with only small deviations of 7-8%. A lower requirement for the modified Froude number of the gas blowing to produce a jetting behavior was also found. For gas blowing below the required modified Froude number, the results illustrate that the gas will form large pulsating bubbles instead of a steady jet, which causes the empirical equation calculations to severely underpredict the penetration length. The lower modified Froude number limit was also found to be system dependent and to have an approximate value of 300 for the studied IronArc system. For submerged blowing applications, it was found that it is important to ensure sufficiently high modified Froude numbers of the gas blowing. Then, the gas penetration length will remain stable as a jet and it will be possible to predict the values using empirical equations.

Catalyst regeneration is economically attractive, and it saves resources. Thus, it is important to determine the influence of catalyst regeneration on the chemical composition of upgraded oil. The catalyst was regenerated several times, and the regenerated catalyst was reloaded in the reactor to proceed with the next run. The composition of the derived upgraded pyrolysis oils in relation to catalyst regeneration was determined. The results revealed that the catalyst cracking abilities decreased with an increased number of reaction cycles. The opposite trends of the organic fraction and water yields indicated that the deoxygenation process occurred via H 2 O production. A decrease in the CO and CO 2 yields revealed that the deoxygenation in catalytic pyrolysis with a catalyst mixture occurred via decarbonylation, decarboxylation, and dehydration mechanisms. The chemical formula of bio-oil changed from CH 0.17 O 0.91 for a noncatalytic experiment to CH 0.14 O 0.66 for a catalytic pyrolysis experiment after five reaction cycles, which indicated that the oxygen in the bio-oil decreased at the expense of hydrogen. The high heating value (HHV) of bio-oils decreased as the number of reaction cycles increased, albeit the minimum value of 22.41 wt % in the 6th reaction cycle was still higher than the value for the noncatalytic experiment. Compared to the HHVs of diesel fuel and gasoline petrol, the values of the produced bio-oil with catalyst mixtures were still low. The catalyst regained 94% of the surface area for the fresh catalyst, which indicated that the regeneration procedure was effective., Competing Interests: The authors declare no competing financial interest., (© 2020 American Chemical Society.)

Lignin and ferrous salt were mechanically mixed, melted, carbonized and steam activated to produce magnetic bio-activated carbons (MBACs). Phosphate adsorption capacity measurement was conducted on representative MBAC, which has a high surface iron oxide proportion and mesoporous volume. The results indicate that iron species are embedded into the carbon matrix by lignin melting. Steam is not only an activation agent for pore generation and widening but is also effective for the oxidization of Hagg iron carbide produced via ferrous salt decomposition and subsequent reduction during the carbonization process to form magnetite. The porous and magnetic properties and surface iron oxide content of the produced MBACs can be modified by controlling the steam/magnetic biochar (MBC) ratio. The MBAC production process is streamlined and novel, compared with conventional coprecipitation or impregnation methods. The maximum phosphate adsorption onto the representative MBAC product using the best fitting model, i.e., the Langmuir-Freundlich model, is estimated to be 21.18 mg/g, suggesting that the representative MBAC product has a comparable phosphate adsorption capacity to most of the reported MBCs and MBACs., (Copyright © 2019 Elsevier B.V. All rights reserved.)

A number of carbon-rich (containing up to 47 wt% C) and lime-rich (containing up to 96 wt% of CaO-compounds) waste products from the pulp and paper industries can be used in iron and steel industry as fuels and slag formers for various metallurgical processes such as blast furnaces (BF), cupola furnaces (CF), argon oxygen decarburization (AOD) converters and electric arc furnaces (EAF). In most cases, these wastes consist of different size powders. In order to facilitate loading, transportation and charging of these powder wastes, briquetting is required. In this study, a pulverized AOD slag was tested as a binder component for briquetting of CaO-containing wastes (such as mesa, lime mud and fly ash) from pulp and paper industries. Moreover, mechanical testing of the possibilities for loading, transportation and unloading operations were done, specifically drop test trials were done for briquettes with different chemical compositions and treatments such as heating and storage. The results showed that an addition of 10-20% of AOD slag as a binder component followed by heat-treatment at 850 °C significantly improved the mechanical properties of the CaO-containing briquettes. An application of these briquettes will significantly reduce the consumption of natural resources (such as nature lime) in the metallurgical processes. Moreover, it can reduce the landfill area of wastes from pulp and paper industries, which is important from an environmental point-of-view.