Aluminum fluoride (AlF₃) is an essential industrial material widely used in aluminum electrolysis and ceramics, yet its performance depends critically on the powder properties of its precursor, aluminum fluoride trihydrate (AFT). However, conventional AFT crystals suffer from irregular morphologies, leading to poor flowability, low bulk density, and severe caking. In this study, we successfully prepared highly spherical AFT particles in an additive-free aqueous solution. Through integrated offline and in-situ analyses, we elucidated the AFT spherical agglomeration mechanism dominated by an "agglomeration-abrasion" process. Guided by this mechanism, key process parameters, including temperature, stirring rate, and residence time, were systematically optimized using response surface methodology. Under the optimized conditions, the resulting AFT particles achieved an average circularity of 90.74% and a high yield of 85.7%. Compared to commercial powders, the optimized spherical AFT exhibited maximum improvements of 30.1% in bulk density and 41.4% in flowability, along with significantly enhanced anti-caking properties. The combination of spherical morphology and high yield enhances batch capacity while offering potential for continuous production, providing a green and cost-effective route for the industrial manufacturing of high-quality AFT powders.

In this study, magnetite nanoparticles (Fe₃O₄) were surface-engineered with a biobased carboxymethyl inulin (CMI) coating to develop a recyclable inhibitor for controlling mineral scale formation through interfacial interactions. The Fe₃O₄@CMI nanocomposite was synthesized via co-precipitation, achieving a uniform ~59 wt% polymer layer without altering the cubic spinel structure of magnetite. Comprehensive surface and interface characterization by XRD, FTIR, TGA, VSM, and SEM confirmed the preservation of superparamagnetic properties and effective polymer anchoring via carboxylate-iron interactions. The coated nanoparticles exhibited strong affinity for scaling ions, disrupting crystal nucleation and growth at the solid-liquid interface, as evidenced by morphological transformations of gypsum, calcite, and barite deposits. Under both static and high-pressure-high-temperature dynamic conditions, Fe₃O₄@CMI achieved complete gypsum inhibition at concentrations as low as 1-5 ppm and maintained full efficiency over multiple magnetic recovery cycles. Enhanced calcium compatibility in saline brines further underscores the stability of the modified surface, preventing secondary precipitation and enabling reliable reuse. These results highlight the critical role of interface engineering in tailoring nanoparticle-scale crystal interactions for sustainable and low-discharge chemicals for oilfield scale management.

Hydrogen generation during thermal runaway significantly elevates the risk of explosive combustion in lithium-ion batteries. Although hydrogen generated from binders constitutes a minor fraction, its absolute quantity remains substantial in large-scale stationary energy storage systems. Moreover, binder decomposition occurs during the later stages of thermal runaway with rapid reaction rates, further raising the danger level. Herein, graphite anode with polyacrylonitrile binder is in situ cyclized to eliminate the active hydrogen, while maintaining superior cohesiveness. On one hand, cyclized polyacrylonitrile with largely reduced hydrogen atoms can prevent binder-induced hydrogen generation and realize a reduction of hydrogen fraction by over 23%. As the three-dimensional cross-linking binders increase the thermal stability of anodes, the peak decomposition temperature of solid electrolyte interphase is increased from 150 to 200 ℃ to above 200 ℃, while the peak reaction temperature between lithiated graphite and the electrolyte is delayed by at least 15 ℃. On the other hand, the transformation from linear to cyclic molecular structures of cyclized polyacrylonitrile enables uniform and tight encapsulation of graphite and enhanced cohesiveness. Capacity retentions of 97% after 200 cycles in half cells and 72% after 800 cycles in full cells are achieved.

This manuscript mainly proposed an effective method to well disperse the composite conductive agent which is composed of carbon nanotubes (CNTs) and graphene (Gr) in lithium-ion battery (LIB) slurry. Electrochemical Impedance Spectroscopy (EIS), Scanning Electron Microscopy (SEM) and gravitational sedimentation (GS) are employed to characterize the electrochemical, morphological and stability characterizations of LIB slurry, respectively. Specifically, electrochemical characterizations of LIB electrode slurries are performed by fitting Nyquist plots with a 10-parameter EEC, and quantitative morphological analysis of SEM images is conducted using a Mask R-CNN instance segmentation algorithm, both of which were proposed in our prior published research works. Consequently, the dispersion characterizations of LIB slurry are able to be summarized as follows: LiCoO₂ particles are well dispersed in LIB slurry at φ_com2 = 0.5%, by contrast, the composite conductive agent achieves superior coating and networking of LiCoO₂ particles under the conditions of both φ_com2 = 0.5% and m_CNTs:m_Gr = 4:1, due to the maximized CNTs-Gr synergistic effect. Meanwhile, the formed three-dimensional "long-range" conductive network maintains the stability of its internal skeleton structure during the sedimentation of LIB slurry. This finding holds significant potential to advance the application of CNTs/Gr composite conductive agents in LIB slurry.

Li₄Ti₅O₁₂-TiO₂ nanocomposites represent highly promising materials for energy storage applications owing to their attractive electrochemical properties. However, precisely optimizing their morphology and compositions is essential. In this study, the effects of lithium content on the synthesis of the Li₄Ti₅O₁₂-TiO₂ nanocomposites prepared by the hydrothermal method were investigated. The samples were prepared using different molar ratios of LiOH·H₂O: tertbutyl titanate (TBT) (4:5, 6:5, 8:5, 10:5, and 12:5) using a hydrothermal process at 180 ℃ for 12 h, followed by a calcination step. The microstructure, phase analysis, and morphology of the samples were investigated using X-ray diffraction (XRD), Raman spectroscopy, and field-emission scanning electron microscopy (FESEM) analyses. XRD results showed a phase evolution from an anatase-rich TiO₂ (at a ratio of 4:5) to a Li₄Ti₅O₁₂-dominated nanocomposite (at a ratio of 12:5) with a minor TiO₂ rutile phase. Also, the crystallite size of the Li₄Ti₅O₁₂ phase first increased to a maximum value of 47.3 nm and then decreased to 20-21 nm at higher ratios. FESEM images revealed a growth in particle size of the samples from 138 to 196 nm, by increasing the ratio from 4:5 to 6:5, and then a reduction of particle size to about 55 nm by using higher ratios. The results showed that for achieving Li₄Ti₅O₁₂-TiO₂ rutile nanocomposites with nanoscale particles, higher LiOH·H₂O:TBT ratios are preferred.

To investigate the ignition and combustion mechanisms of boron agglomerates in oxygen-free steam for water ramjet applications, a laser ignition single-particle experimental system was established. The combustion process was found to comprise four sequential stages: preheating and structural loosening, molten collapse, micro-explosion combustion, and quasi-steady combustion. The results indicate that steam can act as an oxidizer to support vigorous boron combustion. Its unique chemical role (reacting with B₂O₃ to form volatile HBO₂) effectively accelerates the removal of the surface oxide layer, resulting in a relatively thin molten shell. Entrapped steam continuously reacts with internal boron, generating gaseous products (H₂, etc.) that trigger a distinct micro-explosion mode characterized by sustained ejection rather than the expansion-dominated behavior observed in air. Kinetic analysis reveals that the quasi-steady combustion stage is diffusion-controlled, with a burning rate constant comparable to that in air. A quantitative evaluation based on volume change yields a final combustion efficiency of approximately 39.1% in pure steam. These single-particle-level observations provide essential experimental evidence for understanding boron combustion mechanisms and for designing boron-based water-reactive fuel systems.

Supercritical water gasification (SCWG) is a highly promising technology. A fundamental aspect of SCWG involves the flow of supercritical water (SCW) around interactive particles, which is inherently complex due to the presence of the wake effect. This study numerically investigates particle wake characteristics and wake-particle interactions in high-viscosity supercritical water (SCW) via an adaptive lattice Boltzmann method (LBM, N/D = 30, coarse-fine ratio 0.025:0.060) to support supercritical water gasification (SCWG) reactor optimization. The adaptive LBM effectively balances accuracy and efficiency, resolving SCW's steep viscosity gradients and fine wake structures well. Interparticle distance (L/D) is the dominant factor for particle drag, affecting trailing particles far more significantly, with three interaction regimes (strong: L/D = 0-2, moderate: 2-4, weak: ≥4). SCW's high viscosity amplifies wake overlap at L/D ≤ 2, minimizing trailing particle pressure drag and suppressing vortex shedding; increasing L/D weakens shielding, elevates drag, and makes trailing particles behave like isolated ones. Interparticle angle raises drag ratios, inducing distinct vortex structures at 30°-60° and 60°-90°, with identical drag at 90°. SCW wake symmetry and vortex shedding show Re-dependent transitions, with critical Re = 92 corresponding to the minimum trailing particle drag ratio. A drag ratio correlation with L/D and Re is also established. This work provides a reliable numerical tool for SCW particle interactions and theoretical guidance for SCWG reactor optimization, with future work focusing on particle swarms and experimental validation.

Polycaprolactone (PCL) microspheres are emerging as versatile biomaterials for minimally invasive soft tissue augmentation due to their tunable biodegradability and favorable biocompatibility. Nevertheless, the extent to which monodispersity governs the functional performance of PCL microspheres, particularly in modulating host tissue responses and regenerative efficacy, remains poorly understood. Herein, we propose a method to controllably prepare monodisperse oil-in-water (O/W) droplet templates using coaxial flow-focusing microfluidics, and then obtaining monodisperse PCL microspheres with programmable sizes via solvent evaporation. The droplet dimensions are inversely regulated by the outer-to-inner phase flow rate ratio, while PCL concentration in the organic phase exerts minimal influence on initial droplet size but markedly reduces the volume shrinkage during solidification, yielding microspheres that better retain their geometries. Notably, the resultant PCL microspheres can maintain structural integrity and size uniformity over two-month period under physiologically mimetic conditions. Comprehensive biocompatibility assessments reveal that PCL microspheres exhibit negligible hemolytic activity and cytotoxicity, demonstrating excellent hemocompatibility and cytocompatibility. Notably, in a rabbit soft tissue implantation model, monodisperse PCL microspheres with an average diameter of 42 μm elicit attenuated foreign body reactions and potentiate endogenous collagen deposition relative to the polydisperse microsphere control group. These results provide useful guidance for the application of PCL microspheres in soft tissue augmentation.

This study compares the performance of a new three-channel coaxial nozzle with a conventional Schlick nozzle in fluidized bed particle coating. The new nozzle produces droplets with a Sauter mean diameter of around 10 μm, offering a middle ground between aerosol and conventional nozzles. Yields of processes, coating coverages of particles, coating thickness and surface roughness were compared for the same experimental conditions of these nozzles. Non-porous glass particles (mean diameter 653 μm) and porous γ-Al₂O₃ particles (mean diameter 610 μm) were used as cores, with an aqueous sodium benzoate (NaB) solution as the coating liquid. A scanning electron microscope (SEM) was utilized to capture images of the particles after each experiment. To analyze the coverage on the particle surfaces, MATLAB image processing was applied to SEM images of coated particles. Moreover, these images were used to determine the surface roughness of the coating. In addition to manual measurements of coating thickness on particles by image processing, some coated γ-Al₂O₃ particles were sectioned to measure the coating thickness by ImageJ. The manual thickness measurements were supplemented by results obtained by laser scattering. The coating process by means of the new nozzle was also compared with an aerosol coating process which has droplet size with a mean diameter of around 1 μm, in terms of process yield, product coating coverage and thickness. The new nozzle acts as an intermediate between the aerosol generator and the conventional Schlick nozzle in terms of droplet size. These findings suggest that the new nozzle has significant potential for use in fluidized particle coating, as an alternative to conventional nozzle, offering smaller droplet size.

Shear-induced particle migration in the internal die flows of concentrated particulate suspensions during slot coating processes was investigated using a diffusive flux model implemented within three-dimensional computational fluid dynamics simulations. Comparative simulations demonstrated that particle migration markedly altered the internal flow characteristics and particle distributions inside the slot dies. Inhomogeneous particle distributions at the feed inlet were found to modify the flow behavior in the chamber region and profoundly affect the velocity and particle concentration fields in the slit region. These changes critically influenced the die exit velocity and concentration profiles, which governed the uniformity of the wet coating thickness. The insights obtained from this study offer practical guidance for die design and process control to achieve a uniform coating thickness and stable slot coating operation.