Direct synthesis of submicron FeNi particles via spray pyrolysis using various reduction agents

Advances in Aerosol Nanostructuring: Functions and Control of Next-Generation Particles

Nanostructured particles (NSPs), with their remarkable properties at the nanoscale, possess key functions required for unlocking a sustainable future. Fabricating these particles using aerosol methods and spraying processes enables precise control over the particle morphology, structure, composition, and crystallinity during in-flight transformation. In this Perspective, the significant impact of NSPs on technological advancement for energy and environmental applications is discussed. Furthermore, incorporating in situ/operando assessment techniques alongside machine and deep learning is explored. Finally, the future development trends and the perspective on the advancing NSPs synthesis via aerosol process are elaborated for further driving innovations for supersmart and carbon-neutral society.

Nanostructuring silica-iron core-shell particles in a one-step aerosol process

Silica-coated iron (Fe@SiO2) particles have attracted considerable interest as a potential powder core material due to their distinctive advantages, including higher magnetic saturation and enhanced electrical resistance. In this study, the submicron-sized core-shell Fe@SiO2 particles were successfully synthesized in a single step via an aerosol process using a spray pyrolysis method assisted by a swirler connector for the first time. Changing the reducing agent concentration (supplied H2) and tuning the number of core (Fe) particles were investigated to achieve the desired Fe@SiO2 particles. The results indicated that an excessive number of cores led to the appearance of FeO crystals due to insufficient reduction. Conversely, an insufficient number of cores resulted in a thicker SiO2 shell, which hindered the penetration of the supplied H2 gas. Furthermore, the produced Fe@SiO2 particles exhibited soft-ferromagnetic characteristics with an excellent magnetic saturation value of 2.04 T, which is close to the standard theoretical value of 2.15 T. This work contributes new insights into the production of core-shell Fe@SiO2 particles, expanding their applicability to advanced soft-magnetic materials.

Exploring the Challenges of Calcium Looping Integrated with Methane Bireforming for Enhanced Carbon Capture and Utilization

The urgent need to mitigate greenhouse gas emissions and combat climate change has driven research in carbon capture and utilization (CCU) technologies. Among these, calcium looping (CaL) has emerged as a prominent candidate for CO2 capture. This study aimed to explore the novel integration of CaL with methane bireforming (BRM) using CaO-Ni/CeO2 as dual-function material (DFM) and investigated the challenges and opportunities associated with the process. Implementing a calcium looping-bireforming (CaL-BRM) process revealed distinct differences compared to methane dry reforming (DRM). Notably, methane conversion occurred at higher temperatures, likely due to competition with the formation of Ca(OH)2. Meanwhile, the conversion of CO2 was delayed, possibly because hydroxide species on the CaO surfaces hindered the availability of CO2 for methane reforming. To address these challenges, Ni/CeO2 and CaO-Ni/CeO2 catalysts were employed in conventional catalytic gas-phase BRM and methane steam reforming (SRM) reactions. The results demonstrated that the presence of CaO significantly influenced BRM efficiency due to the Ca(OH)2 formation, as was evident by the results of the characterization on the postreaction catalysts and the parallel study of SRM. This study contributes valuable insights into the feasibility and potential of CaL-BRM, advancing the development of sustainable CCU technologies.

Synthesis of Submicron-Sized Spherical Silica-Coated Iron Nickel Particles with Adjustable Shell Thickness via Swirler Connector-Assisted Spray Pyrolysis

Silica-coated iron nickel (FeNi@SiO2) particles have attracted significant attention because of their potential applications in electronic devices. In this work, submicron-sized spherical FeNi@SiO2 particles with precisely controllable shell thickness were successfully synthesized for the first time using a swirler connector-assisted spray pyrolysis system, comprising a preheater, specific connector, and main heater. The results indicated that the thickness of the SiO2 shell can be tuned from 3 to 23 nm by adjusting the parameter conditions (i.e., preheater temperature, SiO2 supplied amount). Furthermore, our fabrication method consistently yielded a high coating ratio of more than 94%, indicating an excellent quality of the synthesized particles. Especially, to gain an in-depth understanding of the particle formation process of the FeNi@SiO2 particles, a plausible mechanism was also investigated. These findings highlight the importance of controlling the preheater and SiO2 supplied amount to obtain FeNi@SiO2 particles with desirable morphology and high coating quality.

Frequency Properties of Polymer Bonded Compacts Obtained from Ball Milled Permalloy Powders with Mo and Cu Additions

Nanocrystalline powders from the Permalloy family, Ni₇₅Fe₂₅, Ni₇₉Fe₁₆Mo₅, and Ni₇₇Fe₁₄Cu₅Mo₄, were obtained by mechanical alloying starting from elemental powders. All compositions were milled for up to 24 h in a high-energy planetary ball mill. The powders were single phase and nanocrystalline as determined by X-ray diffraction studies, with larger flatted particle sizes for Ni₇₅Fe₂₅ (about 400 μm) and Ni₇₇Fe₁₄Cu₅Mo₄ (about 470 μm), and smaller particle sizes for Ni₇₉Fe₁₆Mo₅ (about 170 μm). The homogeneity of the samples was verified by energy-dispersive X-ray spectroscopy (EDX). Soft magnetic composites were obtained by adding 3% of Araldite to the powders, followed by compaction at 700 MPa, and then polymerization. A very good powder covering by the polymer layer was proven by EDX elementals maps. The influence of composition change on the electrical resistivity of the compacts was studied. Hysteresis measurements in static and dynamic fields of up to 10 kHz were recorded, showing the influence of composition and particle size on the compact properties.

The Size Dependence of Microwave Permeability of Hollow Iron Particles

Hollow ferromagnetic powders of iron were obtained by means of ultrasonic spray pyrolysis. A variation in the conditions of the synthesis allows for the adjustment of the mean size of the hollow iron particles. Iron powders were obtained by this technique, starting from the aqueous solution of iron nitrate of two different concentrations: 10 and 20 wt.%. This was followed by a reduction in hydrogen. An increase in the concentration of the solution increased the mean particle size from 0.6 to 1.0 microns and widened particle size distribution, but still produced hollow particles. Larger particles appeared problematic for the reduction, although admixture of iron oxides did not decrease the microwave permeability of the material. The paraffin wax-based composites filled with obtained powders demonstrated broadband magnetic loss with a complex structure for lesser particles, and single-peak absorption for particles of 1 micron. Potential applications are 5G technology, electromagnetic compatibility designs, and magnetic field sensing.

A Sustainable Approach for Preparing Porous Carbon Spheres Derived from Kraft Lignin and Sodium Hydroxide as Highly Packed Thin Film Electrode Materials

A green synthetic strategy to design biomass-derived porous carbon electrode materials with precisely tailored structure and morphology has always been a challenging goal because these materials can fulfill the demands of next-generation supercapacitors and other electrochemical devices. Potassium hydroxide (KOH) is extensively utilized as an activator since it can produce porous carbon with high specific surface area and well-developed porous channels. The exploitation of sodium hydroxide (NaOH) as an activating agent is less referenced in the literature, although it offers some advantages over KOH in terms of low cost, less corrosiveness, and simple handling procedure, all of which are appealing particularly from an industrial viewpoint. The motivation for this present study is to fabricate porous carbon spheres in a sustainable manner via a spray drying approach followed by a carbonization process, using Kraft lignin as the carbon precursor and NaOH as an alternative activation agent instead of the high-cost and high-corrosive KOH for the first time. The structure of carbon particles can be accurately transitioned from a compact to hollow structure, and the surface textural properties can be easily tuned by altering the NaOH concentration. The obtained porous carbon spheres were applied as highly packed thin film electrode materials for supercapacitor devices. The specific capacitance value of porous carbon spheres with a highly compact structure (high packing density) is 66.5 F g^-1, which is higher than that of commercial activated carbon and other biomass-derived carbon. This work provides a green processing for producing low-cost and environment-friendly porous carbon spheres from abundant Kraft lignin and important insight for selecting NaOH as an activator to tailor the morphology and structure, which represents an economical and sustainable approach for energy storage devices.