Pub Date : 2026-03-01Epub Date: 2026-02-09DOI: 10.1016/j.apt.2026.105190
Sina Ghaderi, Majid Mesbah, Sahand Majidi
The present study is the first attempt to enhance the performance characteristics of high-efficiency compact cyclones, a novel configuration recently introduced by the current research team, through the application of passive techniques. Performance enhancement is achieved by incorporating spiral flow-guiding vanes into the baseline cyclone design. The effects of vane parameters, specifically relative depth and pitch ratios, are investigated with respect to key performance metrics, including separation efficiency, cut-point diameter, and pressure drop. Furthermore, comprehensive numerical analyses are conducted for both the continuous and discrete phases to elucidate the mechanisms by which these geometric modifications influence the flow field and particle trajectories. The results reveal a significant improvement in separation efficiency and a reduction in cut-point diameter when guide vanes with greater depth and smaller pitch ratios are employed. Notably, the proposed modification enhances the cyclone’s ability to capture micron-sized particles, offering a promising partial solution for improving fine particle filtration in cyclone separators.
{"title":"Unexplored Integration of Flow-Guiding vanes in a High-Capacity compact Cyclone: A numerical investigation","authors":"Sina Ghaderi, Majid Mesbah, Sahand Majidi","doi":"10.1016/j.apt.2026.105190","DOIUrl":"10.1016/j.apt.2026.105190","url":null,"abstract":"<div><div>The present study is the first attempt to enhance the performance characteristics of high-efficiency compact cyclones, a novel configuration recently introduced by the current research team, through the application of passive techniques. Performance enhancement is achieved by incorporating spiral flow-guiding vanes into the baseline cyclone design. The effects of vane parameters, specifically relative depth and pitch ratios, are investigated with respect to key performance metrics, including separation efficiency, cut-point diameter, and pressure drop. Furthermore, comprehensive numerical analyses are conducted for both the continuous and discrete phases to elucidate the mechanisms by which these geometric modifications influence the flow field and particle trajectories. The results reveal a significant improvement in separation efficiency and a reduction in cut-point diameter when guide vanes with greater depth and smaller pitch ratios are employed. Notably, the proposed modification enhances the cyclone’s ability to capture micron-sized particles, offering a promising partial solution for improving fine particle filtration in cyclone separators.</div></div>","PeriodicalId":7232,"journal":{"name":"Advanced Powder Technology","volume":"37 3","pages":"Article 105190"},"PeriodicalIF":4.2,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146187122","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}
The growing demand for lithium-ion batteries necessitates the development of sustainable methods for extracting lithium. Geothermal brines offer a promising source of lithium, but their complex ionic composition poses a challenge to selective recovery. Hydrogen manganese oxide (HMO, H4Mn5O12) exhibits exceptional lithium selectivity but suffers from structural instability and manganese dissolution during cycling. To address this, zirconium (Zr) was incorporated into the spinel framework, synthesizing Li4Mn4.5Zr0.5O12 (LMZO) via single-step calcination (450 °C, 6 h). Acid treatment converted LMZO to H4Mn4.5Zr0.5O12 (HMZO), characterized using EDS, SEM, BET, and FTIR. HMZO demonstrated a 35 mg/g lithium adsorption capacity with only 0.78% manganese dissolution. After five adsorption–desorption cycles, it retained a capacity of 25.89 mg/g, highlighting enhanced stability. Kinetic analysis revealed pseudo-second-order adsorption, while equilibrium data fit the Freundlich isotherm, indicating heterogeneous ion exchange. Thermodynamically, the process was endothermic and entropy-driven, with improved performance at higher temperatures. This Zr-stabilized sieve combines high selectivity, minimal manganese loss, and excellent recyclability, offering a sustainable pathway for lithium extraction from geothermal brines and advancing green energy storage.
对锂离子电池日益增长的需求要求开发可持续的锂提取方法。地热盐水提供了一个很有前途的锂来源，但其复杂的离子组成对选择性回收提出了挑战。氢锰氧化物（HMO, H4Mn5O12）表现出优异的锂选择性，但在循环过程中存在结构不稳定性和锰溶解问题。为了解决这个问题，我们将锆（Zr）加入尖晶石框架中，通过单步煅烧（450 °C, 6 h）合成了Li4Mn4.5Zr0.5O12 （LMZO）。酸处理将LMZO转化为H4Mn4.5Zr0.5O12 (HMZO)，并用EDS、SEM、BET和FTIR对其进行了表征。HMZO对锂的吸附量为35 mg/g，锰的溶解率仅为0.78%。经过5次吸附-解吸循环后，其吸附容量为25.89 mg/g，稳定性增强。动力学分析显示为准二级吸附，而平衡数据符合Freundlich等温线，表明离子交换是非均相的。热力学上，该过程是吸热和熵驱动的，在更高的温度下性能得到改善。这种锆稳定筛结合了高选择性、最小锰损失和优异的可回收性，为从地热盐水中提取锂提供了可持续的途径，并推进了绿色能源储存。
{"title":"Lithium recovery from aqueous solution using zirconium-enhanced ion sieve","authors":"Agyare Asante , Abigail Berardi , Jayla Standin , Elliott Walker , D. Bhagawan , Sandeep Kumar","doi":"10.1016/j.apt.2025.105134","DOIUrl":"10.1016/j.apt.2025.105134","url":null,"abstract":"<div><div>The growing demand for lithium-ion batteries necessitates the development of sustainable methods for extracting lithium. Geothermal brines offer a promising source of lithium, but their complex ionic composition poses a challenge to selective recovery. Hydrogen manganese oxide (HMO, H<sub>4</sub>Mn<sub>5</sub>O<sub>12</sub>) exhibits exceptional lithium selectivity but suffers from structural instability and manganese dissolution during cycling. To address this, zirconium (Zr) was incorporated into the spinel framework, synthesizing Li<sub>4</sub>Mn<sub>4</sub>.<sub>5</sub>Zr<sub>0</sub>.<sub>5</sub>O<sub>12</sub> (LMZO) via single-step calcination (450 °C, 6 h). Acid treatment converted LMZO to H<sub>4</sub>Mn<sub>4</sub>.<sub>5</sub>Zr<sub>0</sub>.<sub>5</sub>O<sub>12</sub> (HMZO), characterized using EDS, SEM, BET, and FTIR. HMZO demonstrated a 35 mg/g lithium adsorption capacity with only 0.78% manganese dissolution. After five adsorption–desorption cycles, it retained a capacity of 25.89 mg/g, highlighting enhanced stability. Kinetic analysis revealed pseudo-second-order adsorption, while equilibrium data fit the Freundlich isotherm, indicating heterogeneous ion exchange. Thermodynamically, the process was endothermic and entropy-driven, with improved performance at higher temperatures. This Zr-stabilized sieve combines high selectivity, minimal manganese loss, and excellent recyclability, offering a sustainable pathway for lithium extraction from geothermal brines and advancing green energy storage.</div></div>","PeriodicalId":7232,"journal":{"name":"Advanced Powder Technology","volume":"37 3","pages":"Article 105134"},"PeriodicalIF":4.2,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147403165","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}
The initiation of the reduction process induces intricate alterations in the surface properties of the minerals, thereby exerting a pronounced influence on their flotation performance. The chemical bonds on the quartz surface display partial ionic and partial covalent character. The Al–O bonds on the surfaces of diaspore and the Mn–O bonds in new generated manganosite exhibited a higher ionic character and this results in an increase in active sited and enhanced adsorption reactivity. Quartz underwent no lattice reconstruction during roasting. The phase transformation of diaspore to new generated aluminium oxide was accompanied by an increase in both porosity and pore size. These structural modifications were likely responsible for the higher reagent consumption observed during the flotation of the roasted product. For pyrolusite, the surface of the roasted product became smoother and denser compared to that of the raw ore. The decreased specific surface area and the altered pore structure hindered the formation of a stable hydrophobic film, adversely affecting flotation performance. The contact angles of the roasted products were consistently smaller than those of the raw ore, confirming that reduction roasting enhanced the surface hydrophilicity of the minerals, making them more difficult to float.
{"title":"Research on the differences in physicochemical properties and flotation behavior of pyrolusite, quartz, and diaspore before and after phase transformation","authors":"Chenlu Chen , Xun Wang , Xian Xie , Xiong Tong , Shuai Yuan , Ruiqi Xie","doi":"10.1016/j.apt.2026.105204","DOIUrl":"10.1016/j.apt.2026.105204","url":null,"abstract":"<div><div>The initiation of the reduction process induces intricate alterations in the surface properties of the minerals, thereby exerting a pronounced influence on their flotation performance. The chemical bonds on the quartz surface display<!--> <!-->partial ionic and partial covalent character. The Al–O bonds on the surfaces of diaspore and the Mn–O bonds in new generated manganosite exhibited a higher ionic character and this results in an increase in active sited and enhanced adsorption reactivity. Quartz underwent no lattice reconstruction during roasting. The phase transformation of diaspore to new generated aluminium oxide was accompanied by an increase in both porosity and pore size. These structural modifications were likely responsible for the higher reagent consumption observed during the flotation of the roasted product. For pyrolusite, the surface of the roasted product became smoother and denser compared to that of the raw ore. The decreased specific surface area and the altered pore structure hindered the formation of a stable hydrophobic film, adversely affecting flotation performance. The contact angles of the roasted products were consistently smaller than those of the raw ore, confirming that reduction roasting enhanced the surface hydrophilicity of the minerals, making them more difficult to float.</div></div>","PeriodicalId":7232,"journal":{"name":"Advanced Powder Technology","volume":"37 3","pages":"Article 105204"},"PeriodicalIF":4.2,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147403166","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}
Pub Date : 2026-03-01Epub Date: 2026-02-07DOI: 10.1016/j.apt.2026.105188
Keivan Naderi , Parham Soltani , Yu Song
The control of fine particulate matter (PM) emissions in industrial processes requires filtration media that balance high particle removal efficiency with acceptable pressure drop under realistic operating conditions. In this study, the thermal calendering of needle-punched polypropylene nonwoven filter media was quantitatively optimized by examining the effects of calendering temperature (115–145 °C) and roller pressure (1.2–6.8 bar) using an RSM-CCD approach. Filtration performance was evaluated in accordance with ISO 11057 for particle sizes in the range of 0.3–13 µm, representative of industrial dust aerosols. 3D microstructural characterization using X-ray µCT revealed systematic calendering-induced densification, with mean pore size decreasing from approximately 74 µm to 14 µm and tortuosity increasing from about 1.4 to 2.7. These structural changes led to an increase in overall filtration efficiency from 54.7% to 92.8%, accompanied by an increase in pressure drop from 36 Pa to 61.8 Pa. To balance the trade-off between efficiency and pressure drop, optimization was performed using the quality factor as a unified performance metric. The optimized calendering conditions (131 °C and 6.9 bar) resulted in a filtration efficiency of 92.4%, a pressure drop of 53.76 Pa, and a quality factor of 0.048 Pa−1.
{"title":"Quantitative optimization of calendering process parameters for industrial nonwoven filter media using µCT-based structural and filtration analysis","authors":"Keivan Naderi , Parham Soltani , Yu Song","doi":"10.1016/j.apt.2026.105188","DOIUrl":"10.1016/j.apt.2026.105188","url":null,"abstract":"<div><div>The control of fine particulate matter (PM) emissions in industrial processes requires filtration media that balance high particle removal efficiency with acceptable pressure drop under realistic operating conditions. In this study, the thermal calendering of needle-punched polypropylene nonwoven filter media was quantitatively optimized by examining the effects of calendering temperature (115–145 °C) and roller pressure (1.2–6.8 bar) using an RSM-CCD approach. Filtration performance was evaluated in accordance with ISO 11057 for particle sizes in the range of 0.3–13 µm, representative of industrial dust aerosols. 3D microstructural characterization using X-ray µCT revealed systematic calendering-induced densification, with mean pore size decreasing from approximately 74 µm to 14 µm and tortuosity increasing from about 1.4 to 2.7. These structural changes led to an increase in overall filtration efficiency from 54.7% to 92.8%, accompanied by an increase in pressure drop from 36 Pa to 61.8 Pa. To balance the trade-off between efficiency and pressure drop, optimization was performed using the quality factor as a unified performance metric. The optimized calendering conditions (131 °C and 6.9 bar) resulted in a filtration efficiency of 92.4%, a pressure drop of 53.76 Pa, and a quality factor of 0.048 Pa<sup>−1</sup>.</div></div>","PeriodicalId":7232,"journal":{"name":"Advanced Powder Technology","volume":"37 3","pages":"Article 105188"},"PeriodicalIF":4.2,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146187031","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}
Partially laterised Khondalite (PLK) rock is a solid overburden material produced when bauxite is mined. PLK rock is gaining importance as a critical resource after the maximum removal of iron values by different physical and chemical beneficiation techniques for industrial applications. The present paper focuses on iron removal from PLK rock by leaching with HCl using the Response Surface Methodology (RSM) technique. PLK rock is influenced by different variables such as acid content, pulp density, temperature and time. In RSM, Central Composite Design is used as a process optimisation for maximum removal of iron. 3D graphs are utilised to illustrate the influence of the process variables for iron removal. The study indicates that the optimum conditions for leaching to reduce the iron concentration (to less than 2 %) are 70 °C temperature, 4 hr. time, 4.5 mol. concentration, and 12.5% pulp density. Thus, the value added product obtained can be utilised as a critical resource for refractory and ceramic applications.
{"title":"Iron removal from PLK rock: An optimisation study using response surface methodology","authors":"Satyasish Rout , Purushotham Sudikondala , Santosh Deb Barma , Prasanta Kumar Baskey , Eswaraiah Chinthapudi","doi":"10.1016/j.apt.2026.105202","DOIUrl":"10.1016/j.apt.2026.105202","url":null,"abstract":"<div><div>Partially laterised Khondalite (PLK) rock is a solid overburden material produced when bauxite is mined. PLK rock is gaining importance as a critical resource after the maximum removal of iron values by different physical and chemical beneficiation techniques for industrial applications. The present paper focuses on iron removal from PLK rock by leaching with HCl using the Response Surface Methodology (RSM) technique. PLK rock is influenced by different variables such as acid content, pulp density, temperature and time. In RSM, Central Composite Design is used as a process optimisation for maximum removal of iron. 3D graphs are utilised to illustrate the influence of the process variables for iron removal. The study indicates that the optimum conditions for leaching to reduce the iron concentration (to less than 2 %) are 70 °C temperature, 4 hr. time, 4.5 mol. concentration, and 12.5% pulp density. Thus, the value added product obtained can be utilised as a critical resource for refractory and ceramic applications.</div></div>","PeriodicalId":7232,"journal":{"name":"Advanced Powder Technology","volume":"37 3","pages":"Article 105202"},"PeriodicalIF":4.2,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146187033","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}
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