Scalable Synthesis of Porous SiFe@C Composite with Excellent Lithium Storage.

Utilizing cost-effective raw materials to prepare high-performance silicon-based anode materials for lithium-ion batteries (LIBs) is both challenging and attractive. Herein, a porous SiFe@C (pSiFe@C) composite derived from low-cost ferrosilicon is prepared via a scalable three-step procedure, including ball milling, partial etching, and carbon layer coating. The pSiFe@C material integrates the advantages of the mesoporous structure, the partially retained FeSi2 conductive phase, and a uniform carbon layer (12-16 nm), which can substantially alleviate the huge volume expansion effect in the repeated lithium-ion insertion/extraction processes, effectively stabilizing the solid-electrolyte interphase (SEI) film and markedly enhancing the overall electronic conductivity of the material. Benefiting from the rational structure, the obtained pSiFe@C hybrid material delivers a reversible capacity of 1162.1 mAh g-1 after 200 cycles at 500 mA g-1 , with a higher initial coulombic efficiency of 82.30 %. In addition, it shows large discharge capacities of 803.1 and 600.0 mAh g-1 after 500 cycles at 2 and 4 A g-1 , respectively, manifesting an excellent electrochemical lithium storage. This work provides a good prospect for the commercial production of silicon-based anode materials for LIBs with a high lithium-storage capacity.

Scalable Production of Si Nanoparticles Directly from Low Grade Sources for Lithium-Ion Battery Anode.

Silicon, one of the most promising candidates as lithium-ion battery anode, has attracted much attention due to its high theoretical capacity, abundant existence, and mature infrastructure. Recently, Si nanostructures-based lithium-ion battery anode, with sophisticated structure designs and process development, has made significant progress. However, low cost and scalable processes to produce these Si nanostructures remained as a challenge, which limits the widespread applications. Herein, we demonstrate that Si nanoparticles with controlled size can be massively produced directly from low grade Si sources through a scalable high energy mechanical milling process. In addition, we systematically studied Si nanoparticles produced from two major low grade Si sources, metallurgical silicon (∼99 wt % Si, $1/kg) and ferrosilicon (∼83 wt % Si, $0.6/kg). It is found that nanoparticles produced from ferrosilicon sources contain FeSi2, which can serve as a buffer layer to alleviate the mechanical fractures of volume expansion, whereas nanoparticles from metallurgical Si sources have higher capacity and better kinetic properties because of higher purity and better electronic transport properties. Ferrosilicon nanoparticles and metallurgical Si nanoparticles demonstrate over 100 stable deep cycling after carbon coating with the reversible capacities of 1360 mAh g(-1) and 1205 mAh g(-1), respectively. Therefore, our approach provides a new strategy for cost-effective, energy-efficient, large scale synthesis of functional Si electrode materials.

Characteristics of waste automotive glasses as silica resource in ferrosilicon synthesis.

This fundamental research on end-of-life automotive glasses, which are difficult to recycle, is aimed at understanding the chemical and physical characteristics of waste glasses as a resource of silica to produce ferrosilicon. Laboratory experiments at 1550°C were carried out using different automotive glasses and the results compared with those obtained with pure silica. In situ images of slag-metal separation showed similar behaviour for waste glasses and silica-bearing pellets. Though X-ray diffraction (XRD) showed different slag compositions for glass and silica-bearing pellets, formation of ferrosilicon was confirmed. Synthesized ferrosilicon alloy from waste glasses and silica were compared by Raman, X-ray photoelectron spectroscopy and scanning electron microscopy (SEM) analysis. Silicon concentration in the synthesized alloys showed almost 92% silicon recovery from the silica-bearing pellet and 74-92% silicon recoveries from various waste glass pellets. The polyvinyl butyral (PVB) plastic layer in the windshield glass decomposed at low temperature and did not show any detrimental effect on ferrosilicon synthesis. This innovative approach of using waste automotive glasses as a silica source for ferrosilicon production has the potential to create sustainable pathways, which will reduce specialty glass waste in landfill.

Particle size distributions of particulate emissions from the ferroalloy industry evaluated by electrical low pressure impactor (ELPI).

The present article presents a comprehensive evaluation of the potential use of an Electrical Low Pressure Impactor (ELPI) in the ferroalloy industry with respect to indoor air quality and fugitive emission control. The ELPI was used to assess particulate emission properties, particularly of the fine particles (Dp ≤ 1 µm), which in turn may enable more satisfactory risk assessments for the indoor working conditions in the ferroalloy industry. An ELPI has been applied to characterize the fume in two different ferroalloy plants, one producing silicomanganese (SiMn) alloys and one producing ferrosilicon (FeSi) alloys. The impactor classifies the particles according to their aerodynamic diameter and gives real-time particle size distributions (PSD). The PSD based on both number and mass concentrations are shown and compared. Collected particles have also been analyzed by transmission and scanning electron microscopy with energy dispersive spectroscopy. From the ELPI classification, particle size distributions in the range 7 nm - 10 µm have been established for industrial SiMn and FeSi fumes. Due to the extremely low masses of the ultrafine particles, the number and mass concentration PSD are significantly different. The average aerodynamic diameters for the FeSi and the SiMn fume particles were 0.17 and 0.10 µm, respectively. Based on this work, the ELPI is identified as a valuable tool for the evaluation of airborne particulate matter in the indoor air of metallurgical production sites. The method is well suited for real-time assessment of morphology (particle shape), particle size, and particle size distribution of aerosols.

Physical modeling of two-phase liquid-gas processes occurring in the refining ladle for Fe-Si alloy refining process.

The article presents the results of research carried out using a water model of a refining ladle for the Fe-Si ferroalloys treatment. These studies were aimed at improving the efficiency of refining and homogenization of liquid Fe-Si ferroalloy in the refining ladle by using a new method of blowing gas through a system of nozzles installed at the bottom of the ladle. The obtained results allowed to determine the proper location of the plug at the bottom of the refining ladle and the possibility of using combined blowing. The tests were carried out for a refining ladle with a capacity of 3 m3 using a physical model on a linear scale of 1:3. The gas flow rate used in the model corresponded proportionally to the value previously used in industrial practice and amounted to 26.8 l/min. Experiments were performed for both combined blowing applications and through a purging plug at the bottom of the ladle. In the case of combined blowing, the volume of the gas stream was divided into two blowing sources (lance and purging plug). As a result of laboratory tests, one of the variants was selected and tested in industrial conditions. These studies confirmed the improvement in the efficiency of refining treatment of the FeSi alloy in terms of reducing the carbon and aluminum content in the alloy.x.

The effect of different carbon reductants on the production of ferrosilicon 75% on an industrial scale in an electric arc furnace.

Ferrosilicon production is based on the carbothermal reduction of silica and iron oxide in submerged electric arc furnaces. The reducing process of iron oxide and silicon oxide is carried out by the carbon contained in carbon materials such as coal, charcoal, semi-coke, and all types of coke. Based on its inherent and functional characteristics, the kind of carbon material can be effective in the ferrosilicon production process and furnace energy consumption. Therefore, in this work, which was performed by Iran Ferrosilice company, in a long period of 5 years, the effects of seven combinations of different carbon materials on the electrical and metallurgical performance of the process were investigated. The results showed that the minimum value of energy coefficient per ton (8.46 MWh/ton) was obtained using combination 5 (consisting of 55% coal, 30% semi-coke, 5% charcoal, and wood chips). The use of wood chips reduced the energy consumption by 3.03 MWh/ton. The composition consisting of 50% coal, 35% semi-coke, 15% charcoal, and wood chips had the highest Si% of 73.64% and the lowest Al% of 1.54%. Finally, by evaluating all the results, especially the reduction of energy consumption and recovery of Si, compound 5 was introduced as the optimal compound in the ferrosilicon production process.

3D Printing Soft Magnet: Binder Study for Vat Photopolymerization of Ferrosilicon Magnetic Composites.

Liquid Crystal Display (LCD) masking is a 3D printing technique that can produce soft magnetic composite parts to high resolution and complexity for robotics and energy electronics applications. This additive manufacturing technique has the potential to produce larger, lighter-weight, more efficient, and more durable parts for automotive and mechanical applications. This study conducted a binder study to create a low-viscosity and stiff binder capable of loading at least 60 v/v% Fe-6.5 wt%Si particles. Percolation Theory was applied to anticipate the magnetic interaction of suspended particles. A series of binders were formulated, with adjustments to diluent ratios. The behavior of the binders was assessed by studying their rheological properties, conversion rates, and mechanical properties. A post-cure study was conducted across various energy settings using UV, thermal, and a combination of both energy sources to find the combination that provided the best mechanical properties. As a result, 64 v/v% Fe-6.5 wt%Si loading was achieved and cured using UV light of 405 nm wavelength. Vibrating Sample Spectroscopy (VSM) was used to characterize the composite's magnetic behavior, and a significant increase in saturation magnetization and negligible change in coercivity was observed when the added load exceeded the percolation threshold.

Ozonation catalysed by ferrosilicon for the degradation of ibuprofen in water.

The search for optimal catalysts to improve the working efficiency of ozonation has always been an important issue in the research field of advanced oxidation processes. In this study, a novel catalyst, ferrosilicon, was selected as the catalyst in heterogeneous catalytic ozonation to degrade ibuprofen (IBP) in water and treat real pharmaceutical wastewater. During the procedure, 45#ferrosilicon exhibited the best catalytic activity. Under the optimized experimental conditions, the IBP removal reached 75%, which was a great improvement compared to the 37% removal by ozone alone. The 45#-ferrosilicon-catalysed ozonation also achieved 68% TOC removal for real pharmaceutical wastewater, which was 31% higher than that by ozone alone. The degradation pathway of IBP was proposed using GC/MS. The EPR test proved that the main active species in the system were free active radicals •OH, and the measured accumulative •OH amount was 102 µmol. The characterization results show that the nascent metallic oxides, hydroxides, and hydroxyoxides on the ferrosilicon surface facilitated the decomposition of ozone molecules and generation of free active radicals. The removal of target organic contaminants in the water was mainly attributed to the oxidization of these highly active species.

Exposure to Ultrafine Particles in the Ferroalloy Industry Using a Logbook Method.

BACKGROUND: It is difficult to assess workers' exposure to ultrafine particles (UFP) due to the lack of personal sampling equipment available for this particle fraction. The logbook method has been proposed as a general method for exposure assessment. This method measures the time and concentration components of the time-weighted average concentration separately and could be suitable for investigation of UFP exposure. OBJECTIVES: In this study, we have assessed workers' exposure to UFP in a ferrosilicon plant. The main tasks of the furnace workers were identified, and the logbook method was used in combination with stationary measurements of UFP taken as close to the identified task areas as possible. In order to verify the results, respirable particles were collected using stationary sampling in close proximity to the UFP measuring instrument, and personal full-shift sampling of respirable particles was performed simultaneously. Thus, exposure to respirable particles determined using the logbook method could be compared to the results of standard measurement. METHODS: The particle number concentration of ultrafine particles was determined using a NanoScan SMPS. Respirable particle concentration and exposure were determined using a sampling train consisting of a pump, filter, filter cassettes, and SKC Cyclone for the respirable fraction. Attendance times for workers at each work location were registered via thorough observations made by the research team. RESULTS: The logbook method for exposure estimation based on stationary sampling equipment made it possible to calculate UFP exposure for workers operating the furnaces at a ferrosilicon plant. The mid-size furnace and the large furnace were evaluated separately. The workers operating the largest furnace were exposed to 1.47 × 104 particles/cm3, while workers operating the mid-size furnace were exposed to 2.06 × 104 particles/cm3, with a mean of 1.74 × 104 particles/cm3. Substantial contributions from the casting area, ladle transport corridor, and both tapping areas were made. Exposure to respirable particles was 2.04 mg/m3 (logbook); 2.26 mg/m3 (personal sampling) for workers operating the large-sized furnace, 3.24 mg/m3 (logbook); 2.44 mg/m3 (personal sampling) for workers operating the medium-sized furnace, and 2.57 mg/m3 (logbook); 2.53 mg/m3(personal sampling) on average of all tappers. The average ratio of these two methods' results was 1.02, which indicates that the logbook method could be used as a substitute for personal sampling when it is not possible to perform personal sampling, at least within this industry. CONCLUSIONS: The logbook method is a useful supplement for exposure assessment of UFP, able to identify the most polluted areas of the workplace and the contribution of different work tasks to the total exposure of workers, enabling companies to take action to reduce exposure.

Fabrication and Characterization of Short Silicon Nitride Fibers from Direct Nitridation of Ferrosilicon in N2 Atmosphere.

Short silicon nitride fibers were fabricated by direct nitridation of ferrosilicon in N2 atmosphere, and their structure and possible growth mechanism were characterized and investigated. The rod-like fibers which were α-Si3N4 with a low degree of crystallization and a high aspect ratio had a diameter of about 4 µm and a length close to a few millimeters. Belt-like fibers with a width about 5 µm and a thickness about 1 µm were also found in the nitrides. Scanning electron microscope (SEM), transmission electron microscope (TEM), high resolution transmission electron microscope (HRTEM), and selected area electron diffraction (SAED) investigations indicated that the fibers were single-crystalline α-Si3N4 with few amorphous distributed in the edge region, and the fibers grew by vapor⁻liquid⁻solid (VLS) mechanism.