Powder TechnologyPub Date : 2025-10-06DOI: 10.1016/j.powtec.2025.121730
Xiaopeng Yan , Maojiang Li , Song Deng , Chengyuan Xu , Mingguo Peng , Haoran Jing , Xinran Lian , Wujun Li , Zhenjiang You
{"title":"Fracture plugging failure under oil-based drilling fluids condition in deep geoenergy formations: A mesoscopic mechanical structure evolution perspective","authors":"Xiaopeng Yan , Maojiang Li , Song Deng , Chengyuan Xu , Mingguo Peng , Haoran Jing , Xinran Lian , Wujun Li , Zhenjiang You","doi":"10.1016/j.powtec.2025.121730","DOIUrl":"10.1016/j.powtec.2025.121730","url":null,"abstract":"<div><div>The structural integrity of the particle plugging zone directly affects the success of drilling operations in oil, gas, and geothermal reservoirs through its ability to withstand tectonic pressures. The impact of oil - based drilling fluids on the structural stability of the fracture plugging zone is crucial for preventing leakage during the drilling process. This study employs photoelastic experiments to investigate force chain evolution in rigid particle plugging zones under dry, water-based, and oil-based conditions. Results show distinct behaviors: dry conditions exhibit linear pressure increases followed by decline, water-based conditions show fluctuating trends, and oil-based conditions stabilize after multiple fluctuations with the lowest pressure-bearing capacity. Weak force chains dominate numerically. Under load, strong and medium force chains increase. The key point is that under oil-based conditions, the strong force chain network is relatively sparse, with the dominant orientation being 60°; orientations along 0° and 240° are less prevalent. This makes it difficult to form a fishbone-like high-pressure-bearing structure, and the reduced topological complexity results in poor stability. The evolution of force chain energy is influenced by fluid properties: the decrease in friction leads to particle displacement and structural damage, which compromise the integrity of the force chain structure, induce local fracture failure, and consequently trigger macroscopic failure. Modifying particle properties and integrating tackifiers can enhance force chain networks, improving plugging zone stability and shear strength. These findings offer practical strategies for optimizing drilling fluid systems in deep fractured reservoirs.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"469 ","pages":"Article 121730"},"PeriodicalIF":4.6,"publicationDate":"2025-10-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145264704","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Powder TechnologyPub Date : 2025-10-04DOI: 10.1016/j.powtec.2025.121709
Deji Jing , Qisheng Kan , Yabin Li , Shuaishuai Ren , Mingxing Ma , Jichuang Ma , Ping Chang
{"title":"Simulation and experimental study of radial jet blowing–suction air curtain dust control technology in auxiliary haulage roadways of coal mines","authors":"Deji Jing , Qisheng Kan , Yabin Li , Shuaishuai Ren , Mingxing Ma , Jichuang Ma , Ping Chang","doi":"10.1016/j.powtec.2025.121709","DOIUrl":"10.1016/j.powtec.2025.121709","url":null,"abstract":"<div><div>The widespread adoption of trackless rubber-tyred vehicles in coal mines enhances production efficiency but exacerbates dust pollution in auxiliary haulage roadways, endangering workers' health. To effectively solve this problem, we developed a radial jet blowing–suction air curtain dust control technology. Through numerical simulations, the effects of the jet velocity and blowing duct arrangement on dust control performance were analyzed, identifying optimal dust control parameters: a 25 m/s jet velocity with a blowing duct at position B (0.8 m behind the side directly facing the suction duct). An experimental platform was established on the basis of similarity theory. Through smoke tracing and dust control experiments, single air curtain and blowing–suction air curtain were compared, further validating their effectiveness. Finally, by applying radial jet blowing–suction air curtain dust control technology to the auxiliary haulage north roadway of the Qipanjing Coal Mine, air curtain performance tests were conducted. The dust removal efficiency behind the air curtain exceeded 85 %, whereas the dust removal efficiency ahead of the air curtain exceeded 90 %, which was significantly higher than that behind it. Additionally, for the same test cross-section, the dust removal efficiency increases closer to the blowing outlet. The newly developed air curtain dust control technology provides an effective method for controlling dust in coal mine auxiliary haulage roadways.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"469 ","pages":"Article 121709"},"PeriodicalIF":4.6,"publicationDate":"2025-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145264601","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Powder TechnologyPub Date : 2025-10-04DOI: 10.1016/j.powtec.2025.121711
Fuqiang Gou , Youliang Ni , Zhenjie Qian , Tengxiang Yang , Chengqian Jin , Jin Wang , Mingbo Li
{"title":"A study on the calibration method of bonding parameters for soybean threshing materials based on GA-BP model and whale optimization algorithm","authors":"Fuqiang Gou , Youliang Ni , Zhenjie Qian , Tengxiang Yang , Chengqian Jin , Jin Wang , Mingbo Li","doi":"10.1016/j.powtec.2025.121711","DOIUrl":"10.1016/j.powtec.2025.121711","url":null,"abstract":"<div><div>The simulation of grain and stem breakage mechanisms during the soybean threshing process can effectively reveal the interaction mechanisms between threshing materials and operating components; however, its accuracy is highly dependent on the precision of the bonding parameters. To address the lack of accurate bonding parameters for soybean threshing materials, this study proposes a calibration method that integrates a GA-BP neural network with the whale optimization algorithm. First, shear tests of stems and compression tests of grains were conducted to obtain the ultimate load, which served as the reference index for parameter calibration. Subsequently, a predictive model for soybean threshing materials was constructed, and parameter optimization was achieved in combination with the whale optimization algorithm. Finally, the effectiveness of the calibrated parameters was verified by comparing simulation results with experimental data. The results demonstrated that the relative errors between the simulated and measured failure loads of stems and grains under the calibrated parameters were 0.38 % and 1.41 %, respectively, confirming the accuracy and reliability of the proposed method. This study not only provides precise bonding parameters for soybean threshing materials but also offers important references for discrete element method-based threshing mechanism studies and parameter calibration of other materials.</div></div><div><h3>Science4Impact statement</h3><div>This study addresses the lack of accurate bonding parameters for soybean threshing materials by proposing a calibration method that integrates a genetic algorithm-optimized BP neural network with the Whale Optimization Algorithm for bonding parameter optimization. Compared with RF, SVR, and RBF models, the BP neural network demonstrated superior prediction accuracy and generalization ability. Additionally, the Whale Optimization Algorithm outperformed the genetic algorithm in terms of convergence speed and optimization efficiency. Validation tests of the optimal bonding parameters showed that the mechanical response of the calibrated soybean threshing materials exhibited minimal error compared to the actual load, indicating high accuracy and reliability.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"469 ","pages":"Article 121711"},"PeriodicalIF":4.6,"publicationDate":"2025-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145322015","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Powder TechnologyPub Date : 2025-10-04DOI: 10.1016/j.powtec.2025.121716
Xiaokun Zhang , Sanpeng Gong , Xinwen Wang , Runhui Geng , Ruile Li , Yixin Wang , Ningning Xu , Dongdong Lin
{"title":"Dynamics of a banana flip-flow screen considering arc-shaped arrangement and translational-rotational coupling effects","authors":"Xiaokun Zhang , Sanpeng Gong , Xinwen Wang , Runhui Geng , Ruile Li , Yixin Wang , Ningning Xu , Dongdong Lin","doi":"10.1016/j.powtec.2025.121716","DOIUrl":"10.1016/j.powtec.2025.121716","url":null,"abstract":"<div><div>Vibrating flip-flow screens (VFFSs) are essential equipment for the deep screening of moist fine particles. The arc-shaped arrangement characteristics of the banana flip-flow screen (BFFS) help regulate the material flow velocity, thereby controlling the material layer thickness and improving screen surface utilization. However, existing dynamic models of BFFSs often neglect the effects of the relative motion caused by the arc-shaped arrangement characteristics and the double-body system's translational-rotational coupling characteristics. To reflect the actual motion characteristics, a dynamic model is developed using the Lagrangian method, taking into account both the arc-shaped arrangement characteristics and the double-body system's translational-rotational coupling characteristics. The model is validated through multi-body dynamics simulation and experimental testing. The arc-shaped arrangement characteristics significantly influence the second-order resonance peak and the anti-resonance position of the angular amplitude <span><math><msub><mi>A</mi><mi>θ</mi></msub></math></span> of the main screen frame. For the amplitudes <span><math><msub><mi>A</mi><mi>x</mi></msub></math></span> and <span><math><msub><mi>A</mi><mi>y</mi></msub></math></span> of the main screen frame in the <em>x</em> and <em>y</em> directions, and the relative amplitude <span><math><msub><mi>A</mi><msub><mi>x</mi><mn>2</mn></msub></msub></math></span> of the floating screen frame, the arc-shaped arrangement characteristics only slightly affect the second-order resonance frequency. The double-body system's translational-rotational coupling characteristics mainly affect the number of resonance regions of <span><math><msub><mi>A</mi><mi>θ</mi></msub></math></span>, while having only a slight effect on the second-order resonance frequencies of <span><math><msub><mi>A</mi><mi>x</mi></msub></math></span>, <span><math><msub><mi>A</mi><mi>y</mi></msub></math></span>, and <span><math><msub><mi>A</mi><msub><mi>x</mi><mn>2</mn></msub></msub></math></span>. The nonlinear terms introduced by these two structural characteristics do not significantly affect the amplitude of each DOF in calculations but only shift the steady-state equilibrium positions.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"469 ","pages":"Article 121716"},"PeriodicalIF":4.6,"publicationDate":"2025-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145322382","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Powder TechnologyPub Date : 2025-10-04DOI: 10.1016/j.powtec.2025.121720
Juhui Chen , Shuxiang Pang , Dan Li , Ying Mao , Michael Zhurakov , Siarhei Lapatsin , Wenrui Jiang
{"title":"Numerical simulation of chemical looping combustion applying solar energy to a dual circulating fluidized bed reactor","authors":"Juhui Chen , Shuxiang Pang , Dan Li , Ying Mao , Michael Zhurakov , Siarhei Lapatsin , Wenrui Jiang","doi":"10.1016/j.powtec.2025.121720","DOIUrl":"10.1016/j.powtec.2025.121720","url":null,"abstract":"<div><div>This study presents a theoretical model for coupled flow and heat transfer processes in a dual circulating fluidized bed reactor for solar energy applications. A mathematical simulation of gas-solid two-phase flow is conducted using the Eulerian-Eulerian method, incorporating chemical reactions within the system. Computational fluid dynamics (CFD) is employed to simulate the integrated process of solar-assisted flow, heat transfer, and chemical reactions inside the reactor. The distribution patterns of particles and gas products, the heat transfer characteristics between the two reactors, and the transient behavior of particles in the solid recirculation loop are analyzed. The effects of varying solar radiation flux and air inlet velocity on the reactor's coupled flow and heat transfer characteristics are compared. Results indicate that particle volume fraction and particle velocity in the recirculation loop increase with higher radiation flux or air inlet velocity. Gas product concentrations also increase as the reaction proceeds, and higher solid particle temperatures are observed in regions with greater particle accumulation.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"469 ","pages":"Article 121720"},"PeriodicalIF":4.6,"publicationDate":"2025-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145264206","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Analytical study of the trend in the field of factors affecting the viscosity of nanofluids and evaluation of their rheological behavior under different conditions during the years (2013-2023): Scientometric analysis","authors":"Mohammad Hemmat Esfe , Seyed Naser Hosseini Tamrabad , Davood Toghraie","doi":"10.1016/j.powtec.2025.121673","DOIUrl":"10.1016/j.powtec.2025.121673","url":null,"abstract":"<div><div>This review examines nanofluid viscosity research (2013-2023) by analyzing 5261 articles to identify the best in the field and provide a path for the future of the field. The findings show that the publication of articles has been on an upward trend, indicating the importance of this field in the industry. Physics and astronomy, engineering, and chemical engineering were the most widely used subject areas. Prominent researchers such as Hemmat Esfe, Toghraei, and Sheikholesalami have played the most prominent roles in this research. India, Iran, and China are at the top of the field of carbon nanotube viscosity, respectively, with the highest number of published documents. Saudi Arabia and Egypt have led the way in intercontinental collaborations with 80 international collaborations. The Journal of Molecular Fluids (253 articles) and the Journal of Heat and Mass Transfer (13,153 citations) were identified as the top journals in this field. The most frequently used keywords included nanofluids, viscosity, and rheological behavior. This study provides guidance for researchers and policymakers for future research.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"469 ","pages":"Article 121673"},"PeriodicalIF":4.6,"publicationDate":"2025-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145264212","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Powder TechnologyPub Date : 2025-10-03DOI: 10.1016/j.powtec.2025.121699
Leqi Lin , Kaiyuan Yang , Xingyu Zhou , Mingzhe Yu , Li Liu , Xizhong Chen
{"title":"Unveiling particle mixing from non-destructive 3D XCT imaging with machine learning aided spatial distribution analysis","authors":"Leqi Lin , Kaiyuan Yang , Xingyu Zhou , Mingzhe Yu , Li Liu , Xizhong Chen","doi":"10.1016/j.powtec.2025.121699","DOIUrl":"10.1016/j.powtec.2025.121699","url":null,"abstract":"<div><div>Efficient mixing of binary particle systems is essential in process engineering, as it directly impacts product quality, stability, and cost. Traditional evaluation methods rely on empirical modeling from the theoretical assumptions or macroscale characterizations, both remaining time- and cost-intensive. In this study, X-ray computed tomography (XCT) is employed to perform non-destructive three-dimensional imaging of particulate systems. This advanced technique enables detailed characterization of microstructural features and spatial arrangements, yielding critical insights into mixing conditions at the microscale, and is quantified by tailored evaluation metrics. Machine learning-enhanced image segmentation enables efficient particle identification in 2D cross-sections from 3D XCT data. This framework enhances XCT-based feature extraction, enabling simultaneous qualitative observation and quantitative analysis to optimize and improve chemical engineering processes and product quality.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"469 ","pages":"Article 121699"},"PeriodicalIF":4.6,"publicationDate":"2025-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145264209","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Powder TechnologyPub Date : 2025-10-02DOI: 10.1016/j.powtec.2025.121704
Mengnan Li , Zhanwei Liu , Hengwei Yan , Wenhui Ma , Zhanliang Yu , Mingyi Hu , Jiaping Zhao
{"title":"Desulfurization of high‑sulfur bauxite through roasting with various additives: phase transformation and micromorphological evolution","authors":"Mengnan Li , Zhanwei Liu , Hengwei Yan , Wenhui Ma , Zhanliang Yu , Mingyi Hu , Jiaping Zhao","doi":"10.1016/j.powtec.2025.121704","DOIUrl":"10.1016/j.powtec.2025.121704","url":null,"abstract":"<div><div>The high‑sulfur content of bauxite presents a significant challenge in alumina production. This study explored oxidative roasting as a desulfurization strategy, examining the effects of roasting temperature, duration, and various additives on sulfur removal. The results indicated that under conditions of 600 °C for 120 min without additives, the sulfur mass fraction in the roasted bauxite decreased from 16.63 % to 0.27 %, achieving a sulfur removal rate of 98.75 %. The addition of O<sub>2</sub> enhanced desulfurization efficiency. At 500 °C for 120 min with an O<sub>2</sub> flow rate of 1.2 g/min, sulfur content decreased to 0.66 %, corresponding to a 96.83 % removal rate, which was 26.53 % higher compared with that achieved without O<sub>2</sub> assistance. However, when NaNO<sub>3</sub> and Na<sub>2</sub>O<sub>2</sub> were introduced, the formation of Na<sub>2</sub>SO<sub>3</sub>, NaFeS<sub>2</sub>, and Na<sub>2</sub>SO<sub>4</sub> significantly suppressed sulfur release. Furthermore, upon using various modern analytical techniques, the study investigated mineralogical characteristics, phase transformations, chemical composition, and microstructural evolution of bauxite before and after roasting. Results indicated that pyrite, the primary sulfur-bearing phase, decomposed to Fe<sub>2</sub>O<sub>3</sub> and SO<sub>2</sub>. Notably, both additive-free and O<sub>2</sub>-assisted roasting increased surface roughness, porosity, and crack formation of the bauxite, which enhanced its digestion performance.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"469 ","pages":"Article 121704"},"PeriodicalIF":4.6,"publicationDate":"2025-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145264705","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Powder TechnologyPub Date : 2025-10-02DOI: 10.1016/j.powtec.2025.121698
Xiaowei Gu , Zhenguo Zhu , Jianping Liu , Fan Yang , Xiaochuan Xu , Shenyu Wang , Kai Zhan
{"title":"Particle breakage behavior of recycled construction and demolition waste mixed aggregates during compaction and biaxial compression","authors":"Xiaowei Gu , Zhenguo Zhu , Jianping Liu , Fan Yang , Xiaochuan Xu , Shenyu Wang , Kai Zhan","doi":"10.1016/j.powtec.2025.121698","DOIUrl":"10.1016/j.powtec.2025.121698","url":null,"abstract":"<div><div>The breakage behavior of construction and demolition waste (CDW) materials significantly impacts the mechanical performance of pavement base courses. In this study, a DEM model was employed to simulate the compaction and biaxial compression of recycled CDW base-course filler. The model was parameterized using compaction and sieving tests and morphology analysis, explicitly accounting for particle shape, gradation, and mix proportion. By integrating laboratory and numerical results, the mesoscopic breakage mechanisms and their evolution during compaction and post-compaction biaxial compression were systematically revealed. Results show that the mixing ratios of recycled concrete aggregate (RCA), recycled brick aggregate (RBA), and recycled mortar aggregate (RMA), as well as the particle size distributions of RCA and RBA, primarily determine the crushing behavior of the mixture. RBA and RMA are the main sources of breakage. Smaller RBA particles are more susceptible to pulverization, which increases the bond breakage ratio but reduces the volumetric breakage ratio. Higher RBA content and smaller RBA size further accelerate bond breakage during post-compaction biaxial compression. RCA serves as the skeleton, forming main force chains, while RBA and RMA form secondary chains that help redistribute and alleviate breakage of RCA. Optimizing RCA proportion and RBA size improves compactness and stability. When the mix ratio of RCA: RBA: RMA is 6:3:1 and RBA particle size is less than 9.5 mm, maximum dry density and optimal mechanical performance are achieved. These findings provide theoretical and practical support for mix ratio optimization and engineering application of recycled CDW pavement base fillers.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"469 ","pages":"Article 121698"},"PeriodicalIF":4.6,"publicationDate":"2025-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145264203","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Powder TechnologyPub Date : 2025-10-02DOI: 10.1016/j.powtec.2025.121719
Mengjie Hu , Deqing Zhu , Jian Pan , Siwei Li
{"title":"Near-zero carbon iron powder from high‑phosphorus oolitic pellets via hydrogen reduction-electromagnetic iron phase reconstruction - magnetic separation","authors":"Mengjie Hu , Deqing Zhu , Jian Pan , Siwei Li","doi":"10.1016/j.powtec.2025.121719","DOIUrl":"10.1016/j.powtec.2025.121719","url":null,"abstract":"<div><div>To overcome the limitations of conventional carbothermic reduction—specifically its high carbon footprint and the inefficient treatment of finely disseminated iron minerals in high‑phosphorus oolitic iron ore (HPOIO)—this study introduces an innovative process combining hydrogen reduction, electromagnetic induction heating, and magnetic separation. Under optimized reduction conditions (950 °C, 90 min, 10 L/min H₂ flow), the oxidized pellets attained a metallization degree of 85.56 %. A profound microstructural transformation was achieved via electromagnetic induction heating at 1350 °C for 30 min, which resulted in an approximately 16-fold increase in the average equivalent circular diameter of the metallic iron grains, from an initial 1.19 μm to a final 19.03 μm. This microstructural evolution, driven by recrystallization and phase rearrangement, converted finely dispersed iron phases into coarse vermicular and massive aggregates, markedly improving slag–metal separation. The efficacy of the induction treatment was demonstrated by a substantial upgrade in the magnetic concentrate. This was evidenced by an elevation of the iron grade to 91.18 % from an initial 59.57 %, a concomitant drop in phosphorus content to 0.09 % from 0.26 %, and a resultant surge in dephosphorization efficiency to 79.77 % from 12.14 %. The integrated approach demonstrates a viable near-zero-carbon route for converting HPOIO into high-grade, low-phosphorus iron powder via hydrogen-based direct reduction and precisely controlled iron phase reconstruction.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"469 ","pages":"Article 121719"},"PeriodicalIF":4.6,"publicationDate":"2025-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145264213","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}