Scalable Synthesis of a Porous Micro Si/Si-Ti Alloy Anode for Lithium-Ion Battery from Recovery of Titanium-Blast Furnace Slag

The extensive utilization of Si-anode-based lithium-ion batteries faces obstacles due to their substantial volume expansion, limited intrinsic conductivity, and low initial Coulombic efficiency (ICE). In this study, we present a straightforward, cost-effective, yet scalable method for producing a porous micro Si/Si-Ti alloy anode. This method utilizes titanium-blast furnace slag (TBFS) as a raw material and combines aluminothermic reduction with acid etching. By adjusting the Al:TBFS ratio, the specific surface area of the material can be facilely tailored, ranging from 25.89 to 43.23 m2 g-1, enhancing the ICE from 78.2 to 85.5%. The incorporation of the Si-Ti alloy skeleton and porous structure contributes to the enhanced cyclic stability (capacity retention from 50.7 to 96.9%) and conductivity (Rct from 107.7 to 76.6 Ω). The Si/Si-Ti anode exhibits excellent electrochemical performance, including delivering a specific capacity of 1161 mAh g-1 at 200 mA g-1 after 200 cycles and 1112 mAh g-1 at 500 mA g-1 after 100 cycles, with an improved ICE of 81.2%. This study introduces a successful methodology for designing novel Si anodes from recycling waste materials, providing valuable insights for future advancements in this area.

Aluminothermic Synthesis of Dispersed Electrides Based on Mayenite: XRD and EPR Study

The evolution of the structure and the phase composition of a dispersed mayenite at its interaction with metallic aluminum was studied in a temperature range from 900 to 1400 °C in both argon and air atmospheres. The aluminum loading was varied from 0 to 50 wt%. It was found that the addition of aluminum significantly affects the stability of the mayenite and other calcium aluminate phases within the studied temperature range. The formation of the electride state registered by the appearance of a characteristic electron paramagnetic resonance (EPR) signal from F+-like centers (g~1.994) in an argon atmosphere was shown to take place already at 1150 °C due to an aluminothermic reduction of this material. The super-narrow (Hp-p < 0.5 G) EPR spectra from F+-like centers, which were recently observed for the core−shell structures of the C12A7@C type only, were registered for mayenite for the first time. The results obtained in the present study testify firstly towards the possibility of significantly diminishing the temperatures required for the formation of the electride state in such systems and secondly towards the ability to stabilize the size of small electride nanoparticles within the synthesized calcium aluminate matrix.

Manganese and Aluminium Recovery from Ferromanganese Slag and Al White Dross by a High Temperature Smelting-Reduction Process

The recovery of Mn and Al from two industrial waste of ferromanganese and aluminum production processes was investigated via implementing a high temperature smelting—aluminothermic reduction process. The experiments were carried out with or without CaO flux addition, and two dross qualities. It was observed that the prepared mixtures of the materials yield homogeneous metal and slag products in terms of chemical composition and the distribution of phases. However, the separation of produced metal phase from the slag at elevated temperatures occurs when a higher amount of CaO is added. Viscosity calculations and equilibrium study indicated that the better metal and slag separation is obtained when the produced slag has lower viscosity and lower liquidus. It was found that the process yields Al-Mn-Si alloys, and it is accompanied with complete recovery of Mn, Si and Fe and the unreacted Al in the process. Moreover, the quality of metal product was less dependent on the slightly different dross quality, and the concentration of minor Ca in metal is slightly increased with significant increase of CaO in the slag phase.

Corrosion Properties of Mn-Based Alloys Obtained by Aluminothermic Reduction of Deep-Sea Nodules

Deep-sea manganese nodules are polymetallic oxidic ores that can be found on a seabed. Aluminothermic reduction is one of the possibilities of manganese nodules processing. This process obtains the polymetallic alloy with a high content of Mn and a varying content of Al, depending on the ratio between aluminum and nodules. The corrosion behaviors of three experimental Mn-based alloys produced by aluminothermic reduction with a content of Mn > 50 wt % were studied. The electrochemical testing in potable water and model seawater was used to explain the corrosion mechanism of Mn-based alloys. The results showed that the corrosion rate of experimental Mn-based alloy decreases with the increase in aluminum content in both potable water and model seawater. It was observed that the uniform corrosion of experimental Mn-based alloys is changed with an increase in aluminum content in alloy to localized corrosion, which was caused by microcells in an environment of model seawater. In contrast, the formation of a semi-protective layer of corrosion products was observed on the surface of Mn-based alloys with a higher content of aluminum in potable water. Moreover, the pitting corrosion of tested Mn-based alloys was observed neither in potable water nor in model seawater.

One-Pot Synthesis of Alumina-Titanium Diboride Composite Powder at Low Temperature

Alumina-titanium diboride (Al₂O₃-TiB₂) composite powders were synthesised via aluminothermic reduction of TiO₂ and B₂O₃, mediated by a molten chloride salt (NaCl, KCl, or MgCl₂). The effects of salt type, initial batch composition, and firing temperature/time on the phase formation and overall reaction extent were examined. Based on the results and equilibrium thermodynamic calculations, the mechanisms underpinning the reaction/synthesis processes were clarified. Given their evaporation losses at test temperatures, appropriately excessive amounts of Al and B₂O₃ are needed to complete the synthesis reaction. Following this, phase-pure Al₂O₃-TiB₂ composite powders composed of 0.3-0.6 μm Al₂O₃ and 30-60 nm TiB₂ particles were successfully fabricated in NaCl after 5 h at 1050 °C. By increasing the firing temperature to 1150 °C, the time required to complete the synthesis reaction could be reduced to 4 h, although the sizes of Al₂O₃ and TiB₂ particles in the resultant phase pure composite powder increased slightly to 1-2 μm and 100-200 nm, respectively.

Aluminothermic Reduction of Manganese Oxide from Selected MnO-Containing Slags

The aluminothermic reduction process of manganese oxide from different slags by aluminum was investigated using pure Al and two types of industrial Al dross. Two types of MnO-containing slags were used: a synthetic highly pure CaO-MnO slag and an industrial high carbon ferromanganese slag. Mixtures of Al and slag with more Al than the stoichiometry were heated and interacted in an induction furnace up to 1873 K, yielding molten metal and slag products. The characterization of the produced metal and slag phases indicated that the complete reduction of MnO occurs via the aluminothermic process. Moreover, as the Al content in the charge was high, it also completely reduced SiO₂ in the industrial ferromanganese slag. A small mass transport of Ca and Mg into the metal phase was also observed, which was shown to be affected by the slag chemistry. The obtained results indicated that the valorization of both Al dross and FeMn slag in a single process for the production of Mn, Mn-Al, and Mn-Al-Si alloys is possible. Moreover, the energy balance for the process indicated that the energy consumption of the process to produce Mn-Al alloys via the proposed process is insignificant due to the highly exothermic reactions at high temperatures.

Microsized Porous SiOx@C Composites Synthesized through Aluminothermic Reduction from Rice Husks and Used as Anode for Lithium-Ion Batteries

Microsized porous SiO_x@C composites used as anode for lithium-ion batteries (LIBs) are synthesized from rice husks (RHs) through low-temperature (700 °C) aluminothermic reduction. The resulting SiO_x@C composite shows mesoporous irregular particle morphology with a high specific surface area of 597.06 m²/g under the optimized reduction time. This porous SiO_x@C composite is constructed by SiO_x nanoparticles uniformly dispersed in the C matrix. When tested as anode material for LIBs, it displays considerable specific capacity (1230 mAh/g at a current density of 0.1 A/g) and excellent cyclic stability with capacity fading of less than 0.5% after 200 cycles at 0.8 A/g. The dramatic volume change for the Si anode during lithium-ion (Li⁺) insertion and extraction can be successfully buffered because of the formation of Li₂O and Li₄SiO₄ during initial lithiation process and carbon coating layer on the surface of SiO_x. The porous structure could also mitigate the volume change and mechanical strains and shorten the Li⁺ diffusion path length. These characteristics improve the cyclic stability of the electrode. This low-cost and environment-friendly SiO_x@C composite anode material exhibits great potential as an alternative for traditional graphite anodes.