Waste Disposal & Sustainable Energy最新文献

{"title":"Municipal solid waste open burning: an overview of inventory and dispersion modelling of emerging pollutant emissions","authors":"Oyetola Ogunkunle,&nbsp;Adewemimo Oluwakunmi Popoola,&nbsp;Lukuman Adekilekun Jimoda,&nbsp;Michael Olusoji Olusanya","doi":"10.1007/s42768-026-00280-7","DOIUrl":"10.1007/s42768-026-00280-7","url":null,"abstract":"<div><p>The open burning of municipal solid waste (MSW) remains a significant environmental and public health challenge, particularly in developing regions where waste management systems are insufficiently regulated. This study investigates the integration of emission inventories with advanced dispersion modelling to characterize the atmospheric dynamics of pollutants released during MSW open burning. Detailed emission inventories, including particulate matters (PM_2.5 and PM₁₀), volatile organic compounds (VOCs), heavy metals, and persistent organic pollutants (POPs) such as dioxins, were utilized to inform models like the American Environmental Protection Agency’s regulatory air-dispersion model (AERMOD) and the weather research and forecasting model with chemistry (WRF-Chem). These models simulated the spatial and temporal distributions of contaminants, enabling the quantification of exposure risks and the identification of emission hotspots. The results revealed that pollutant concentrations, particularly in communities near waste dump sites, frequently exceed national air quality standards, with PM_2.5 and VOCs posing the greatest health risks. The findings emphasize the necessity for high-resolution emission inventories to enhance the predictive accuracy of dispersion models and provide actionable insights into mitigating pollutant impacts. This study presents a comprehensive framework for integrating emission and dispersion analyses, providing policymakers and stakeholders with a critical tool for developing evidence-based waste management strategies, regulatory interventions, and air quality control measures to mitigate the environmental and health impacts of MSW burning.</p><h3>Graphical abstract</h3>\u0000<div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":807,"journal":{"name":"Waste Disposal & Sustainable Energy","volume":"8 1","pages":"179 - 208"},"PeriodicalIF":0.0,"publicationDate":"2026-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147558765","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Fabrication and characterization of corn-silk biochar@Fe3O4 composite for the adsorption of malachite green dye","authors":"Akshay Verma,&nbsp;Pooja Dhiman,&nbsp;Chin Wei Lai,&nbsp;Alberto García-Peñas,&nbsp;Gaurav Sharma","doi":"10.1007/s42768-025-00274-x","DOIUrl":"10.1007/s42768-025-00274-x","url":null,"abstract":"<div><p>The unregulated discharge of toxic dyes and agrochemicals resulting from industrial processes poses serious risks to aquatic and terrestrial ecosystems, highlighting the need for efficient remediation processes. In this work, a new corn silk-derived biochar/iron oxide (Fe₃O₄) composite (BCCS@Fe₃O₄) was synthesised via an in situ co-precipitation technique to effectively remove malachite green (MG) dye from aqueous solutions. The uniqueness of this study stems from the innovative use of corn silk, an agricultural waste, as a sustainable biochar precursor combined with Fe₃O₄ nanoparticles to achieve both high adsorption capacity and magnetic recoverability. The prepared composite exhibited a high surface area, well-developed porosity, and strong magnetic properties that enabled efficient separation and reuse. Remarkably, the BCCS@Fe₃O₄ composite exhibited superior adsorption uptake of 1000 mg/g, substantially surpassing conventional biochar and many previously reported adsorbents. The improved performance was due to electrostatic attraction, hydrogen bonding, and π–π interaction between dye molecules and the composite surface. The adsorption behaviour was well described by the Langmuir isotherm model, suggesting a monolayer adsorption pattern. Furthermore, the kinetic studies align with the pseudo-second-order model, indicating that chemisorption was the dominant mechanism governing the adsorption process. In addition, the material exhibited high recyclability, retaining 88.39% adsorption over four cycles. These findings highlight the promise of BCCS@Fe₃O₄ composite as a low-cost, eco-friendly, and recyclable adsorbent for wastewater treatment processes.</p><h3>Graphical abstract</h3>\u0000<div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":807,"journal":{"name":"Waste Disposal & Sustainable Energy","volume":"8 1","pages":"159 - 178"},"PeriodicalIF":0.0,"publicationDate":"2026-01-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s42768-025-00274-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147561548","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A novel eco-friendly composite panel based on pistachio shells and sunflower capitulum: acoustic, thermal, and combustibility characterizations","authors":"Mohammadreza Jamshidijam,&nbsp;Mohamed Ackmez Mohit","doi":"10.1007/s42768-025-00275-w","DOIUrl":"10.1007/s42768-025-00275-w","url":null,"abstract":"<div><p>Environmental issues such as climate change and resource depletion highlight the need for sustainable solutions in construction. This study explores the feasibility of making wood-based panels from agricultural wastes, namely, pistachio shells (PS) and sunflower capitulum (SC), to address the rising demand for eco-friendly materials. Using sun-dried raw materials, composite panels with SC:PS ratios of 0:100, 25:75, 50:50, 75:25, and 100:0 were produced with polyurethane adhesive and tested for density, thermal conductivity, sound absorption, and combustion behavior. Increasing SC content lowered the density (365 to 205 kg/m³) and thermal conductivity (0.89 to 0.54 W/m·K) while enhancing sound absorption (0.537 to 0.813). In contrast, a higher PS content yielded a higher density, contributed to a reduced rate of CO emission (0.0019 to 0.0016 g/s) and increased the ignition time from 20 to 30 s. These findings highlight a sustainable approach to utilizing agricultural waste as construction materials with potential applications in lightweight partition walls, interior acoustic panels and thermal insulation boards.</p><h3>Graphical abstract</h3>\u0000<div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":807,"journal":{"name":"Waste Disposal & Sustainable Energy","volume":"8 1","pages":"61 - 70"},"PeriodicalIF":0.0,"publicationDate":"2026-01-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147561706","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Syngas and carbon nanostructures from pyrolysis-catalysis of nitrogen-containing plastics","authors":"Yukun Li,&nbsp;Mohammed A. Farji,&nbsp;Shogo Kumagai,&nbsp;Shao Zhuze,&nbsp;Toshiaki Yoshioka,&nbsp;Paul T. Williams","doi":"10.1007/s42768-025-00269-8","DOIUrl":"10.1007/s42768-025-00269-8","url":null,"abstract":"<div><p>This study investigated the pyrolysis-catalysis behavior of three representative nitrogen-containing plastics (polyamide 6 (PA6), polyurethane (PU), and polyacrylonitrile (PAN)) in the presence of a Ni/Fe bimetallic catalyst. The aim was to produce both product syngas (H₂/CO) and multi-walled carbon nanotubes (CNTs). Several comprehensive analytical techniques, including thermogravimetric analysis, differential thermogravimetric analysis, gas chromatography/mass spectrometry, gas product analysis, scanning electron microscopy, high-resolution transmission electron microscopy, and temperature-programmed oxidation (TPO), have been used to examine their pyrolysis characteristics, volatile component compositions, syngas and hydrogen yields, and catalyst carbon deposition structures. The results showed that PA6 and PU produced high syngas yields (75.44%–77.97%, mass fracction), whereas PAN presented a higher H₂/CO molar ratio and higher solid residue yield, indicating a greater tendency toward the formation of stable solid products during pyrolysis. In terms of the catalyst carbon deposition morphology, the pyrolysis volatiles from PA6 promoted the growth of well-structured multi-walled CNTs. PU mainly produced agglomerated graphitic carbon, and PAN formed a mixed structure containing bamboo-like CNTs and graphite layers. These morphological differences were further supported by TPO analysis, which revealed clear distinctions in the thermal stability of the resulting carbon structure. Overall, this work demonstrates the controlling role of the plastic molecular structure in influencing the distribution of pyrolysis products and the growth pathways of carbon materials. These findings provide theoretical support and an experimental basis for the resource utilization of nitrogen-containing polymers and the targeted synthesis of functional carbon nanomaterials.</p><h3>Graphical abstract</h3>\u0000<div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":807,"journal":{"name":"Waste Disposal & Sustainable Energy","volume":"8 1","pages":"23 - 39"},"PeriodicalIF":0.0,"publicationDate":"2026-01-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s42768-025-00269-8.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147560528","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Low-carbon cementitious materials from industrial wastes: synergistic sulfate-alkali activation of granulated blast furnace slag and lithium slag","authors":"Yannian Zhang,&nbsp;Lin Zhang,&nbsp;Qingjie Wang,&nbsp;Tao Gao,&nbsp;Weifeng Zhang,&nbsp;Yunzhi Shang,&nbsp;Zhijun Li","doi":"10.1007/s42768-025-00273-y","DOIUrl":"10.1007/s42768-025-00273-y","url":null,"abstract":"<div><p>The cement industry faces mounting pressure to reduce carbon emissions and transition toward more sustainable practices. This study introduces a novel all-solid-waste cementitious material (ASWCM) through the synergistic activation of granulated blast furnace slag (GBFS) and lithium slag (LS) using petroleum coke desulfurization ash (PCDA) and calcium carbide slag (CCS). The effects of the PCDA:CCS ratio and GBFS:LS ratio on the properties of ASWCM were systematically evaluated through flowability, compressive strength, hydration analysis, and microscopic morphology. The optimal formulation (PCDA:CCS=1:1, GBFS:LS=3:2) achieved a 28 d compressive strength of 56.7 MPa, meeting the strength requirement of 52.5R-grade cement. CCS established an alkaline environment, enhancing precursor dissolution, while PCDA provided SO₄²⁻ for ettringite crystallization. Excessive PCDA reduced system alkalinity, hindering C–(A)–S–H gels formation and inducing microstructural degradation. The balance between ettringite (AFt) and C–(A)–S–H gels formation was crucial for strength enhancement. Environmental and economic assessments revealed that, compared with ordinary Portland cement, the ASWCM reduced the global warming potential by 94.39%, while the total cost decreased by 48.19%, demonstrating its potential as a cost-effective, environmentally friendly alternative. This work demonstrates a scalable pathway to valorize multiple industrial wastes into high-performance, low-carbon cementitious material, advancing circular economy principles in construction.</p><h3>Graphical abstract</h3>\u0000<div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":807,"journal":{"name":"Waste Disposal & Sustainable Energy","volume":"8 1","pages":"139 - 158"},"PeriodicalIF":0.0,"publicationDate":"2026-01-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147559741","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Techno-economic analysis and life cycle assessment of integrated carbon capture and methanation using Ni/MgO/Al2O3 dual functional material","authors":"Muhammad Saddam Hussain,&nbsp;Yaozu Wang,&nbsp;Bocheng Yu,&nbsp;Yongqing Xu,&nbsp;Haiyang Liu,&nbsp;Muhammad Junaid Aslam,&nbsp;Qinghai Li,&nbsp;Yanguo Zhang,&nbsp;Shaoguang Feng,&nbsp;Xuan Bie,&nbsp;Hui Zhou","doi":"10.1007/s42768-025-00272-z","DOIUrl":"10.1007/s42768-025-00272-z","url":null,"abstract":"<div><p>Carbon capture and utilization (CCU) plays a pivotal role in mitigating carbon dioxide emissions by converting captured CO₂ into valuable products. However, conventional CCU technologies face significant challenges, including high energy consumption and substantial financial costs. In contrast, integrated carbon capture and utilization (ICCU) can reduce the large energy consumption associated with the CCU process. Although several CCU methods have been explored in existing literatures, a comprehensive techno-economic analysis and life cycle assessment (LCA) are still needed to fully evaluate the economic and environmental feasibility of integrated processes. This study performs a detailed economic and environmental assessment of three distinct scenarios for methane production. The results demonstrate that the ICCU scenario utilizing a single reactor offers the most cost-effective option for methane production, with a production cost of 892.9 USD/t. Furthermore, the economic benefits of the steam and carbon taxes can further reduce the methane production cost to 717 USD/t, which is close to the market price. Economic viability is highly sensitive to the hydrogen price: parity with market methane is contingent on very low-cost, low-carbon H₂. Additionally, the ICCU scenario with a single reactor exhibits the lowest environmental impact, with a net global warming potential (GWP) of − 4370 kg CO₂-eq per 1 t CO₂ in flue gas, underscoring its potential as a sustainable and economically viable solution for methane production.</p><h3>Graphical abstract</h3>\u0000<div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":807,"journal":{"name":"Waste Disposal & Sustainable Energy","volume":"8 1","pages":"41 - 60"},"PeriodicalIF":0.0,"publicationDate":"2026-01-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147559179","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Dual valorization of phosphogypsum and fly ash in cement mortar: experimental performance and environmental assessment","authors":"Alain Tèebwaoga Sina,&nbsp;Jamal Ait Brahim,&nbsp;Bilal Ben Ali,&nbsp;Brahim Achiou,&nbsp;Redouane Beniazza","doi":"10.1007/s42768-025-00271-0","DOIUrl":"10.1007/s42768-025-00271-0","url":null,"abstract":"<div><p>Being a major contributor to the global greenhouse gas emissions, the cement industry targets net-zero emissions by 2050 through lowering clinker CO₂ emissions via low-carbon raw materials and partial substitution of clinker with supplementary cementitious materials (SCMs). This study explores a sustainable approach to low-carbon cement through the dual integration of phosphogypsum (PG) and fly ash (FA) by-products as SCMs for potential CO₂ reduction. The synergistic effect of PG and FA on cement properties was investigated at different substitution rates of clinker. The results showed that the optimized mortar containing 10% purified PG and 10% FA exhibited remarkable mechanical properties, with compressive and flexural strengths of 57.8 MPa and 9.5 MPa, respectively, at 28 d. Notably, the optimized mortar composition outperformed the CEM II/B-M 32.5 mortar, with compressive and flexural strengths that are 41% and 16% higher, respectively. These findings highlight that the dual valorization of PG and FA not only enhances engineering performance but also presents a viable strategy for reducing CO₂ emissions in the cement industry by nearly 16% annually. This approach contributes to circular economic initiatives and offers significant environmental benefits. Furthermore, large-scale feasibility, PG treatment costs, and long-term durability should be further investigated.</p><h3>Graphical abstract</h3>\u0000<div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":807,"journal":{"name":"Waste Disposal & Sustainable Energy","volume":"8 1","pages":"123 - 138"},"PeriodicalIF":0.0,"publicationDate":"2026-01-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147559468","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Mechanistic insights into the impact of high H2O and high-NOx exhaust from ammonia-fueled engines on Cu-SSZ-13 SCR catalyst activity","authors":"Dongwei Yao,&nbsp;Yi Fu,&nbsp;Jiangling Song,&nbsp;Yihe Zhang,&nbsp;Jinpeng Du,&nbsp;Haibin He,&nbsp;Feng Wu,&nbsp;Yinhuan Wang","doi":"10.1007/s42768-025-00260-3","DOIUrl":"10.1007/s42768-025-00260-3","url":null,"abstract":"<div><p>High NO_<i>x</i> emission concentrations and H₂O contents in ammonia engine exhaust pose significant challenges to the catalyst activity and hydrothermal stability of conventional selective catalytic reduction (SCR) catalysts. This study involved synthesizing the Cu-SSZ-13 catalyst via a one-spot hydrothermal method and evaluating its efficacy for SCR after-treatment in ammonia engines, focusing on the effects of the NO_<i>x</i> concentration and H₂O content on the SCR reaction. The catalyst exhibited excellent SCR activity between 300 and 400 °C, even under extreme conditions of 2000×10⁻⁶ NO_<i>x</i> and 20% H₂O content, achieving conversion efficiencies exceeding 95% for both NO_<i>x</i> and NH₃. At temperatures below 300 °C, H₂O significantly inhibits catalyst activity; however, while increased NO_<i>x</i> concentrations can mitigate this effect, excessively high NO_<i>x</i> levels also impair catalyst performance. Above 300 °C, the inhibitory effect of H₂O diminishes, and elevated NO_<i>x</i> concentrations enhance catalyst activity. Ammonia temperature programmed desorption (NH₃-TPD) and in-situ diffuse reflectance infrared Fourier transform spectroscopy tests showed that at low temperatures, H₂O competes with NH₃ for adsorption at Z₂Cu sites, inhibiting the catalyst activity. At high temperatures, while this competition persists, the H₂O-Z₂Cu interaction becomes unstable, weakening the inhibitory effect. This research confirms the adaptability of Cu-SSZ-13 catalysts for the ammonia engine after-treatment and provides insights for developing more applicable after-treatment catalysts for future ammonia engines.</p><h3>Graphical abstract</h3>\u0000<div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":807,"journal":{"name":"Waste Disposal & Sustainable Energy","volume":"8 1","pages":"71 - 88"},"PeriodicalIF":0.0,"publicationDate":"2026-01-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147559467","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Optimizing calorific value of energy briquettes from agricultural biomass: a novel approach utilizing maize and cassava residues","authors":"Jacques Romain Njimou,&nbsp;Grâce Murielle Ngami Danga,&nbsp;Musongo Balike,&nbsp;Zara Haman,&nbsp;Esther Maurelle Ngouyamnsa-Ghenmi,&nbsp;Rives Mallet Tcheulo Njike,&nbsp;Oben Bessem Genola,&nbsp;André Talla,&nbsp;Nkeng George Elambo","doi":"10.1007/s42768-025-00268-9","DOIUrl":"10.1007/s42768-025-00268-9","url":null,"abstract":"<div><p>This study presents an optimized methodology for transforming agricultural residues (maize husks, cobs, straws, spathes, and cassava waste) into energy briquettes. Ten types of briquettes were produced by varying residue proportions and applying pyrolysis (400–600 °C) with a 10% clay binder. The carbonized material was crushed, sieved, mixed with binder, molded, and sun-dried for 48 h. Physicochemical properties (moisture, ash, volatile matter, and fixed carbon) and mechanical properties (compressive strength and friability) were evaluated. Maize-based briquettes demonstrated superior calorific values (3800–4800 kcal/kg), lower moisture content (6%–12%), and higher fixed carbon (up to 25%) compared to cassava-based and mixed briquettes. A high ash content (15%–22%) was observed due to the clay binder, and compressive strength remained consistently below 10 MPa, indicating areas for improvement. Statistical modeling using Minitab software identified optimal conditions: a moisture content of 6% and a fixed carbon content of 25% could yield a maximum calorific value of 5468.18 kcal/kg. These findings underscore the potential of agricultural waste briquettes as a sustainable energy source, while also highlighting the need for further optimization in binder selection and mechanical performance.</p><h3>Graphical abstract</h3>\u0000<div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":807,"journal":{"name":"Waste Disposal & Sustainable Energy","volume":"8 1","pages":"89 - 103"},"PeriodicalIF":0.0,"publicationDate":"2026-01-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147559469","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation of PTA-/TWAS-/HVOF-NiCr coatings against high-temperature corrosion in waste-to-energy superheater","authors":"Xiuju Zhang,&nbsp;Huan Liu,&nbsp;Anqi Song,&nbsp;Geyi Wang,&nbsp;Hong Yao","doi":"10.1007/s42768-025-00267-w","DOIUrl":"10.1007/s42768-025-00267-w","url":null,"abstract":"<div><p>This study systematically presents the corrosion performance of plasma transferred arc (PTA) cladding, twin wire arc spraying (TWAS) and high-velocity oxygen-fuel (HVOF) spraying coatings through field trials in a 400 t/d waste-to-energy plant. The results revealed that the high-temperature superheater (HTS) tube exhibited significantly more severe corrosion than the low-temperature superheater (LTS) tube did, primarily due to the higher Cl content in its deposits and elevated tube wall temperature, which promoted the formation of volatile metal chlorides rather than protective oxides. The 2700 h field trial showed that the PTA-NiCr1 coating can be used in both the LTS and HTS areas. The HVOF-NiCr1 coating was competent in the LTS area and performed well on the HTS tube only in the first 900 h, whereas the TWAS-NiCr1 coating was not suitable even in the less corrosive LTS area. Based on microstructure characterization and thermodynamic calculations, the mechanism by which the preparation technique affects the corrosion resistance of the three coatings was further elucidated. The PTA-NiCr1 coating formed a dense dual-layer oxide with a Ni-rich outer layer and Cr-rich inner layer, contributing to the superior corrosion resistance. The Cr oxides formed in the HVOF-NiCr1 coating reacted with NaCl and KCl vapors to generate non-protective chromates, leading to reduced corrosion resistance. The low density of the TWAS-NiCr1 coating enabled the penetration of Cl₂ and O₂ gases into its interior, inducing Fe oxidation in the substrate and thereby increasing the risk of coating delamination.</p><h3>Graphical abstract</h3>\u0000<div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":807,"journal":{"name":"Waste Disposal & Sustainable Energy","volume":"8 1","pages":"1 - 21"},"PeriodicalIF":0.0,"publicationDate":"2026-01-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147559075","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}