Process Safety and Environmental Protection最新文献

{"title":"Explosion suppression characteristics and molecular dynamics of NH4H2PO4 in explosions of CH4–coal dust mixtures","authors":"Qiuhong Wang , Yifei Liu , Jun Deng , Zhenmin Luo , Weiguo Cao , Fuxin Chen , Yiyu Mo","doi":"10.1016/j.psep.2025.107878","DOIUrl":"10.1016/j.psep.2025.107878","url":null,"abstract":"<div><div>Explosions of CH<sub>4</sub>–coal dust mixtures are associated with severe casualties and economic losses. Therefore, controlling and preventing such explosions are essential. Based on the complexity of gas-solid two-phase explosions, three conditions involving CH<sub>4</sub>–coal dust (condition A: 8 vol% CH<sub>4</sub> + 500 g/m<sup>3</sup> coal dust; condition B: 10 vol% CH<sub>4</sub> + 130 g/m<sup>3</sup> coal dust; and condition C: 12 vol% CH<sub>4</sub> + 130 g/m<sup>3</sup> coal dust) were examined to determine the effect of NH<sub>4</sub>H<sub>2</sub>PO<sub>4</sub> on their explosive behavior and to identify their explosion suppression mechanism through molecular dynamics simulations. Comparison of flame transmission and gas product release patterns revealed that NH<sub>4</sub>H<sub>2</sub>PO<sub>4</sub> effectively inhibited explosions of CH<sub>4</sub>–coal dust mixtures. When the concentration of NH<sub>4</sub>H<sub>2</sub>PO<sub>4</sub> was increased from 200 to 1000 g/m<sup>3</sup>, the explosion flame propagation velocity, explosion pressure, and explosion flame temperature exhibited a linear decreasing trend. The inhibitory effect of NH<sub>4</sub>H<sub>2</sub>PO<sub>4</sub> powder on explosions of CH<sub>4</sub>–coal dust mixtures reached its strongest level at a NH<sub>4</sub>H<sub>2</sub>PO<sub>4</sub> concentration of 1000 g/m<sup>3</sup>. Specifically, under conditions A, B, and C, the maximum reduction observed in flame propagation speed was 31.49 %, 21.62 %, and 31.65 %, respectively; the maximum reduction observed in explosion pressure was 20.21 %, 14.52 %, and 12.50 %, respectively; the maximum reduction observed in the temperature of the upper thermocouple was 38.02 %, 26.68 %, and 21.73 %, respectively; and the maximum reduction observed in the temperature of the lower thermocouple was 25.90 %, 17.16 %, and 22.90 %, respectively. Under condition B, the addition of a small quantity of inhibitory dust increased the pressure generated by explosions of CH<sub>4</sub>–coal dust mixtures. Molecular dynamics simulations revealed that CH<sub>3</sub>•, CH<sub>2</sub>O, H•, and OH• were the main intermediate substances in the combustion process. NH<sub>4</sub><sup>+</sup> inhibited the chain reaction of CH<sub>4</sub>–coal dust by inhibiting the formation of CH<sub>3</sub>• and accelerating the consumption of free radicals through OH• and O• free radical trapping in the detached H• system. H• was easily captured by H<sub>3</sub>PO<sub>4</sub> and its decomposition products H<sub>2</sub>PO<sub>4</sub>•, HPO<sub>3</sub>, PO<sub>2</sub>•, HOPO, and PO•, which in turn inhibited the combustion of CH<sub>4</sub>, CH<sub>3</sub>•, and CH<sub>2</sub>• by reacting with H• instead of O<sub>2</sub>. The characteristics of explosion suppression in complex working conditions were explored, and the mechanism of explosion suppression was described from the atomic point of view. It provided a theoretical basis for further exploration o","PeriodicalId":20743,"journal":{"name":"Process Safety and Environmental Protection","volume":"203 ","pages":"Article 107878"},"PeriodicalIF":7.8,"publicationDate":"2025-09-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145159731","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"环境科学与生态学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A novel numerical model for simulating dynamic pipeline fracture propagation in CO2 considering complex decompression behavior","authors":"Yifei Wang ,&nbsp;Yaqi Guo ,&nbsp;Qihui Hu ,&nbsp;Xuefeng Zhao ,&nbsp;Lan Meng ,&nbsp;Buze Yin ,&nbsp;Lijun Zhang ,&nbsp;Yuxing Li","doi":"10.1016/j.psep.2025.107864","DOIUrl":"10.1016/j.psep.2025.107864","url":null,"abstract":"<div><div>The pressure wave inside a supercritical/dense CO₂ pipeline that fractures displays typical staged decompression characteristics due to the CO₂ leaking inside the pipeline. It is necessary to consider the effects of CO₂ decompression behavior. Given the high computational cost of fluid-structure interaction (FSI) methods, this paper proposes an efficient and robust decoupled approach for solving CO₂ fracture propagation. This method uses shock tube models, decompression wave models, and empirical formulas for pipe flap decompression to describe the complete decompression behavior of CO₂ in the pipe during the pipe fracture process. Different forms of decompression pressure loads are applied to the crack tip and the areas in front of and behind it to simulate the CO₂ decompression response during the fracture process. Based on the Cohesive Zone Model (CZM), a full-length model and a short pipe section rupture model were built, taking into account the interaction between the pipe and the soil during the rupture process using the SPH method. According to the study, the model's predicted maximum speed and average speed had relative errors of 8.6 % and 12.6 %, respectively. Among them, the full-length model can predict the fracture speed of each pipe section more conservatively, and when the crack propagates to the production pipe, it shows a clear tendency to arrest. The initiation and transition pipes' fracture velocities can be described by the short pipe section model, but it has limited predictive power for fracture arrest.</div></div>","PeriodicalId":20743,"journal":{"name":"Process Safety and Environmental Protection","volume":"203 ","pages":"Article 107864"},"PeriodicalIF":7.8,"publicationDate":"2025-09-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145097743","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"环境科学与生态学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Indoor air treatment of formaldehyde by N-enriched activated carbon beads with or without CuO/Cu supported nanoparticles","authors":"Laurence Reinert ,&nbsp;Michel Ondarts ,&nbsp;Laurent Duclaux ,&nbsp;Fabrice Guy ,&nbsp;Peter Moonen ,&nbsp;Emilie Planes ,&nbsp;Jonathan Outin ,&nbsp;Benjamin Golly ,&nbsp;Evelyne Gonze ,&nbsp;Yasushi Soneda","doi":"10.1016/j.psep.2025.107870","DOIUrl":"10.1016/j.psep.2025.107870","url":null,"abstract":"<div><div>Activated carbon beads, either with or without copper-based nanoparticles, were prepared using an original method involving the impregnation of a chitosan hydrogel with KOH or NH₃, followed by thermochemical activation at temperatures between 500°C and 900°C. Elemental analysis and X-ray photoelectron spectroscopy indicate successful surface N-enrichment. The specific surface areas of the microporous beads ranged from 370 to 1330 m².g⁻¹. NH₃-activated carbons were shown to have a lower affinity for water vapor than KOH-activated carbons. Breakthrough curves for formaldehyde removal were investigated at an indoor air concentration of 850 ppbv and various humidities (0–50 % RH). High formaldehyde removal was found at RH = 50 % (43 mg.g⁻¹) for the NH₃-activated carbon, which is attributed to the presence of ultramicropores and nitrogen functional groups on its surface, such as pyrrolic groups. Well-dispersed aggregates of Cu and CuO nanoparticles were evidenced in the decorated beads using SEM and micro-tomography. In these novel materials, the nanoparticles can catalyse the degradation of formaldehyde into CO₂ and H₂O regardless of the relative humidity tested. Maximum degradation was reached at RH = 20 %. These innovative adsorbents and catalytic materials can degrade formaldehyde under indoor air conditions (25°C and humid air), suggesting promising applications in indoor air purification.</div></div>","PeriodicalId":20743,"journal":{"name":"Process Safety and Environmental Protection","volume":"203 ","pages":"Article 107870"},"PeriodicalIF":7.8,"publicationDate":"2025-09-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145159077","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"环境科学与生态学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Carbonated steel slag as a dual-function additive for strength and sustainability enhancement of alkali-activated slag","authors":"SU Bo ,&nbsp;Yong SUN ,&nbsp;Chao ZHANG ,&nbsp;Xingtong YUE ,&nbsp;Liancheng WANG ,&nbsp;Jingping QIU ,&nbsp;Yingliang ZHAO","doi":"10.1016/j.psep.2025.107868","DOIUrl":"10.1016/j.psep.2025.107868","url":null,"abstract":"<div><div>This study investigates carbonated steel slag (CS) as a dual-function additive in NaOH-activated blast furnace slag (AAS) binders, aiming to enhance both mechanical performance and sustainability. Incorporating CS significantly improved compressive strength at all curing ages, with a ∼70 % increase at 28 days for 30 wt% substitution. Microstructural analyses revealed reduced capillary porosity and improved micromechanical properties of C–(A)–S–H. Environmental assessment further showed that CS reduced total CO₂ emissions and improved the environmental index by more than 35 %. Mechanistically, CS moderated early-age reaction kinetics through pH buffering, while supplying reactive CaCO₃ and silica gels that promoted sustained gel formation. These effects enhanced silicate polymerization and induced Na–Ca carbonate formation, yielding a denser and more stable hybrid gel network. Overall, CS not only improves strength and refines microstructure, but also acts as a CO₂ sink, offering a sustainable pathway for developing high-performance, low-carbon AAS binders.</div></div>","PeriodicalId":20743,"journal":{"name":"Process Safety and Environmental Protection","volume":"203 ","pages":"Article 107868"},"PeriodicalIF":7.8,"publicationDate":"2025-09-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145061461","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"环境科学与生态学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Numerical study on aerosol dispersion and infection risk controlling mechanism in an isolation ward with various ventilation strategies","authors":"Yikang Wang ,&nbsp;Feifei Wang ,&nbsp;Chang Huang ,&nbsp;Yuan Zhang ,&nbsp;Xinhua Xu","doi":"10.1016/j.psep.2025.107871","DOIUrl":"10.1016/j.psep.2025.107871","url":null,"abstract":"<div><div>This article numerically studied the aerosol transport and infection risk controlling mechanism in an isolation ward with various ventilation strategies, including up-supplying and down-exhaust (UD), up-supplying and up-exhaust (UU), under floor air distribution (UFAD) and perforated ceiling air supplying (PCAS). The numerical models were first validated by the measurements from the present experiments and the literature. On the basis of a dose-response model, an infection risk evaluation model coupled with CFD was developed. Then, effects of ventilation strategy, air change rate and virus type on the flow structure, aerosol dispersion and infection risk within the wards were then analyzed. Results indicate that streamlines from the two patients’ mouths are flowed directly to outlets in the wards with UU and UFAD, whose heights are relatively higher. Consequently, the isolation ward with UU has the lowest quantity of suspended aerosols and overall infection risk, followed by UFAD, PCAS, and UD. In special, the average and maximal infection risk within the isolation ward is respectively determined by the total quantity and the relative standard deviation of aerosol concentrations. In other words, when optimizing airflow organization within an isolation ward by mechanical ventilating, not only a high removal efficiency but also a high dispersion ability of contaminant or airborne bio-aerosols should be reached simultaneously, so that both of the average and maximal infection risks can be properly controlled.</div></div>","PeriodicalId":20743,"journal":{"name":"Process Safety and Environmental Protection","volume":"203 ","pages":"Article 107871"},"PeriodicalIF":7.8,"publicationDate":"2025-09-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145119729","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"环境科学与生态学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Sustainable poultry house emissions control: A novel electrostatic-biotrickling filter powered by PV","authors":"Emad A. Almuhanna ,&nbsp;Mohamed A. Eltawil ,&nbsp;Saeed Y. Al-Ramadan","doi":"10.1016/j.psep.2025.107869","DOIUrl":"10.1016/j.psep.2025.107869","url":null,"abstract":"<div><div>This study presents the development and experimental evaluation of a novel electrostatic-biotrickling filter system powered by photovoltaic (PV) energy for sustainable control of poultry house emissions. The system combines an electrostatically charged water spray with a vertical biotrickling filter bed composed of locally sourced materials-pittmoss, palm sheath fiber, and crushed tempered glass-to enhance the removal of particulate matter and ammonia. Under charged spray conditions, removal efficiencies of 79.5 %, 71.5 %, and 50 % were achieved for total suspended particles (TSP), PM₁₀, and PM₂.₅, respectively, with ammonia removal reaching 92.3 % at an empty bed residence time of 1.5 s. The PV array, rated at 1338 W peak power, supplies surplus energy exceeding 35 %, enabling off-grid operation. PV panel efficiency varied inversely with temperature, ranging from 16.1 % at cooler times to 11.3 % during peak heat. This integration of renewable energy with innovative filtration demonstrates a promising, energy-efficient, and environmentally responsible approach for mitigating air pollution in poultry farming. The study lays foundational work for advancing sustainable agricultural emissions control using cost-effective materials and clean power.</div></div>","PeriodicalId":20743,"journal":{"name":"Process Safety and Environmental Protection","volume":"203 ","pages":"Article 107869"},"PeriodicalIF":7.8,"publicationDate":"2025-09-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145110041","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"环境科学与生态学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation of the performance of superfine tailings wet shotcrete doped with nano-TiO2: From macro performance to hydration mechanism","authors":"Yafei Hu ,&nbsp;Bo Zhang ,&nbsp;Zhuping Jia ,&nbsp;Lujing Zheng ,&nbsp;Zhen Wang ,&nbsp;Bin Han","doi":"10.1016/j.psep.2025.107872","DOIUrl":"10.1016/j.psep.2025.107872","url":null,"abstract":"<div><div>The recycling of superfine tailings has become an important research direction in the mining field toward low-carbon and clean production. In this study, superfine tailings were used as aggregate, and nano-TiO₂ (NT) was introduced as a reinforcing material to prepare NT-doped superfine tailings wet shotcrete (TWSC). Macro-scale experiments showed that as the NT dosage increased, the strength of TWSC exhibited a trend of first increasing and then decreasing, with the optimal dosage being 2 %. Microscopic characterization reveals that at an NT dosage of 2 % and different curing ages, TWSC exhibits abundant and stable hydration products, the lowest porosity, and a relatively complete three-dimensional bonding structure at the microscopic level. The polymerization degree of the gel phase, a key hydration product, is highest, consistent with the strength changes. Density functional theory (DFT) calculations indicate that during the early hydration stage, the presence of NT forms Si-O-Ti, providing heterogeneous nucleation sites for the formation of the calcium silicate hydrate(C-S-H) gel phase. This synergizes with Si-O-Si and Si-O-Al to serve as the key steps in the dimerization reaction prior to gel phase nucleation, thereby promoting the early hydration reaction of TWSC. This study provides new insights into the potential utilization and improved utilization rate of superfine tailings in wet shotcrete.</div></div>","PeriodicalId":20743,"journal":{"name":"Process Safety and Environmental Protection","volume":"203 ","pages":"Article 107872"},"PeriodicalIF":7.8,"publicationDate":"2025-09-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145097744","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"环境科学与生态学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Research on the accelerated thermal runaway mechanism and fire-explosion risk mode of NCM523 lithium-ion batteries induced by rapid penetration under separator melting condition","authors":"Qi Zhang ,&nbsp;Jianbing Wang ,&nbsp;Gang Zhou ,&nbsp;Huaheng Lu ,&nbsp;Wenchao Song ,&nbsp;Tianyu Liang ,&nbsp;Jiajing Zhao ,&nbsp;Bingyu Guo ,&nbsp;Mingqi Zhang ,&nbsp;Shengzhu Zhang","doi":"10.1016/j.psep.2025.107863","DOIUrl":"10.1016/j.psep.2025.107863","url":null,"abstract":"<div><div>The separator melting (or critical thermal load) is a key point in the thermal runaway (TR) process of lithium-ion battery (LIB). In this state, rapid penetration tends to accelerate the TR process, making the TR mechanism and evolution dynamics more complex, and significantly increasing the difficulty of early warning, prevention and control. In order to reveal the accelerated thermal runaway mechanism and fire-explosion risk of LIB induced by rapid penetration under separator melting condition (set as the initial thermal load of 100℃), an 18650 LIB coupling stimulation TR experimental platform was independently built. Taking NCM523 batteries with different state of charge (SOC) as the research object, the TR behavior: smoke diffusion, spark injection and flame propagation characteristics induced by rapid penetration under critical thermal load were experimentally studied. The results show that the temperature change of the batteries surface during the TR process can be divided into three typical stages: slow temperature rise, rapid temperature rise, and slow temperature drop. The maximum temperature of the batteries surface increase with the increase of SOC, from 122.4℃ at 0 % SOC to 691.2℃ at 100 % SOC. The temperature rise rate of the batteries also increases with the increase of SOC, with the maximum increase of 91.2℃/s. This phenomenon is attributed to the increase of power and the feedback heating behavior of the emitted flue gas/flame. According to the temperature rise rate of the batteries, the TR state induced by rapid penetration NCM523 batteries at 100℃ were divided into mild, moderate and severe TR. With the increase of SOC, the mass loss of the batteries after TR increased by 10.775 g, and the mass loss rate increased by 24.17 %. NCM523 batteries showed complex eruption behavior, with the increase of SOC, the eruption behavior of severe TR batteries experienced smoke diffusion mode, transverse spark jet mode, longitudinal spark jet mode and flame jet mode, and the spark jet area also increased significantly, with the maximum area increased by 41.44 %. The complex and changeable eruption dynamics make the TR of NCM523 battery presents the dual risks of smoke explosion of lithium iron phosphate battery and jet fire of high nickel LIBs. The research results provide important theoretical guidance and practical value for enriching the TR failure mechanism of NCM523 lithium-ion battery under extreme condition, carrying out fire and explosion risk assessment, and proposing fire and explosion risk prevention and control measures.</div></div>","PeriodicalId":20743,"journal":{"name":"Process Safety and Environmental Protection","volume":"203 ","pages":"Article 107863"},"PeriodicalIF":7.8,"publicationDate":"2025-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145097186","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"环境科学与生态学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"New findings on the occurrence, removal, and ecological risk assessment of micropollutants in publicly owned industrial wastewater treatment plants","authors":"Hong-Duck Ryu,&nbsp;Jae-Hoon Kim,&nbsp;Su-Kyung Lee,&nbsp;Jeong Ki Yoon,&nbsp;Kyunghyun Kim","doi":"10.1016/j.psep.2025.107853","DOIUrl":"10.1016/j.psep.2025.107853","url":null,"abstract":"<div><div>Previous research on micropollutants (MPs) in wastewater treatment facilities has mainly focused on pharmaceuticals and personal care products in sewage treatment plants. This study presents the first comprehensive investigation into the occurrence, removal efficiency, and potential ecological risks of 34 unregulated inorganic and organic MPs in 12 publicly owned industrial wastewater treatment plants (POIWTPs) in South Korea. These facilities, located in areas with high densities of industrial complexes, have treatment capacities ranging from 5,000 to 185,000 m³ /day. All MPs were analyzed using internationally accredited methods. Among the target compounds, 24 were detected in effluents, with inorganic MPs occurring more frequently than organic ones. Ecological risk assessment using hazard quotient (HQ) values identified selenium (Se) and nickel (Ni) as priority pollutants, with HQ values of 125.1 and 1.5, respectively, posing a “high hazard” for aquatic life. These substances showed low removal efficiencies through conventional coagulation–flocculation (CF) treatment, with average rates of only 7.9 % and 28.3 %. The findings underscore the need for regulatory attention and improved treatment strategies. This study contributes meaningful insights toward the effective management of policy-relevant MPs in POIWTPs and highlights the importance of optimizing treatment processes to reduce ecological risks posed by industrial effluents.</div></div>","PeriodicalId":20743,"journal":{"name":"Process Safety and Environmental Protection","volume":"203 ","pages":"Article 107853"},"PeriodicalIF":7.8,"publicationDate":"2025-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145048202","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"环境科学与生态学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Study on the rapid titanium–iron separation mechanism in titanomagnetite driven by flash Joule heating","authors":"Sheng Dou ,&nbsp;Shiteng Qin ,&nbsp;Shijie Ma ,&nbsp;Jun Chen ,&nbsp;Budeebazar Avid ,&nbsp;Hongyu Zhao","doi":"10.1016/j.psep.2025.107865","DOIUrl":"10.1016/j.psep.2025.107865","url":null,"abstract":"<div><div>To address the complex properties of this titanomagnetite sample and the high energy consumption and pollution associated with conventional reduction roasting, this study developed a rapid and eco-friendly process for reducing ilmenite using Joule heating. Results show that as the current intensity increased from 60 A to 150 A during reduction roasting, the reduction rate of magnetite significantly improved within a short period. Metallic iron formation progressively increased, while impurity content in ilmenite and titanium-bearing phases decreased. Consequently, optimal separation and recovery of titanium and iron from the raw ore were achieved at 150 A current intensity, 30 % graphite dosage, and 15-second reduction time, effectively lowering the titanium grade in the sample. Kinetic studies revealed that the three-dimensional diffusion model accurately describes titanomagnetite decomposition under Joule heating, with a calculated activation energy of 30 kJ/mol—far lower than that of conventional roasting methods. Furthermore, energy consumption and carbon emission comparisons demonstrated that Joule heating roasting consumes only 1/54 of the energy required by traditional methods, with significantly reduced carbon emissions. Thus, Joule heating reduction roasting not only enhances reaction efficiency and product quality but also demonstrates clear advantages in energy savings and environmental impact. And finite element simulations and first-principles DFT calculations further indicate that under an applied electric field, the energy band structures of graphite and ilmenite undergo significant changes: narrowed bandgaps facilitate electron transitions and free charge carrier formation, thereby accelerating the reduction reaction. These findings provide a novel technological pathway for the efficient utilization of titanomagnetite resources.</div></div>","PeriodicalId":20743,"journal":{"name":"Process Safety and Environmental Protection","volume":"203 ","pages":"Article 107865"},"PeriodicalIF":7.8,"publicationDate":"2025-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145048203","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"环境科学与生态学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}