The Chinese Journal of Process Engineering

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The Chinese Journal of Process Engineering. 2026, 26(2): 0.

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Research progress in recycling of end-of-life crystalline silicon photovoltaic modules

Yueyue GUO Yulong HU Yi'an LIU Lei ZHAO Songlin RAN Xing JIN

The Chinese Journal of Process Engineering. 2026, 26(2): 109-124. DOI: 10.12034/j.issn.1009-606X.225170

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The accelerated global transition toward renewable energy structures has precipitated a surge in photovoltaic module installations, intensifying environmental governance pressures associated with decommissioned crystalline silicon modules. This review systematically examines resource recovery technology systems and policy pathways for end-of-life crystalline silicon photovoltaic modules, with a focused emphasis on the efficient reclamation of valuable metals and the construction of circular economy models. By analyzing the energy efficiency of three main recycling technologies—mechanical, thermal, and chemical treatment, this work reveals their economic and technical limits. Mechanical processes, like high-voltage pulse crushing, can concentrate metals, but their efficiency is constrained by material separation rates. Thermal treatment (400~600℃) can recover high-purity materials (glass purity>98.5%), but it faces challenges of high energy consumption and the treatment of fluorine-containing exhaust gases. Chemical treatment (e.g., using a toluene solvent system) offers significant advantages in achieving high purity (>99%) in silicon wafer recycling, but it poses risks of secondary pollution and cost concerns. This work also explores the recovery of valuable metals from end-of-life crystalline silicon photovoltaic modules, outlining the challenges and prospects in this area.

Research progress in optimization of zinc anode for aqueous zinc-ion batteries by two-dimensional materials

Fuyu LI Xiaoying ZHANG Yongjia LI

The Chinese Journal of Process Engineering. 2026, 26(2): 125-138. DOI: 10.12034/j.issn.1009-606X.225192

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Aqueous zinc-ion batteries (AZIBs) have emerged as a promising candidate for large-scale energy storage systems due to their inherent advantages, including high safety, cost-effectiveness, environmental compatibility, and relatively high energy density. However, the practical application of AZIBs is hindered by several challenges associated with zinc anodes, such as uncontrolled dendrite formation, corrosion, and hydrogen evolution reactions during cycling, which significantly degrade battery performance and lifespan. To address these issues, researchers have explored various modification strategies, among which the application of two-dimensional (2D) materials has gained considerable attention. Two-dimensional materials, characterized by their atomic-level thickness, large specific surface area, abundant active sites, superior mechanical strength, and unique electrochemical properties, exhibit great potential in optimizing zinc anodes. Notably, graphene and two-dimensional transition metal carbides/nitrides (MXenes) have been widely investigated due to their excellent conductivity, structural stability, and tunable surface chemistry. This review systematically summarizes the recent advancements in 2D material-based modification strategies for zinc anodes, focusing on protective layer construction, host material design, electrolyte additives, and separator functionalization. These approaches effectively enhance zinc deposition uniformity, suppress side reactions, and improve anode reversibility. Furthermore, the challenges and future prospects of 2D materials in AZIBs are discussed, providing insights for the development of high-performance zinc-based energy storage systems.

Analysis of steady-state pressure drop calculation coefficient in feeding outlet acceleration section of dense phase pneumatic conveying

Yiming ZHANG Jiawei ZHOU Yedong WEI Yongxin LI Kuidong GAO

The Chinese Journal of Process Engineering. 2026, 26(2): 139-149. DOI: 10.12034/j.issn.1009-606X.225138

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The primary objective of pneumatic conveying system design is to achieve energy-efficient, continuous, and stable material transportation, where the system performance is fundamentally governed by pressure drop characteristics. Although dense-phase pneumatic conveying exhibits superior transport efficiency and energy-saving potential compared to dilute-phase systems, its industrial application is constrained by complex gas-solid flow dynamics. These dynamics induce significant pressure fluctuations and unstable pressure drops, particularly in the horizontal conveying section downstream of the feeding outlet, which must be prioritized in system optimization. This study employs carbon black masterbatch as the experimental material and utilizes a pneumatic conveying cycle test bench to investigate the pressure drop characteristics in the horizontal feeding outlet section of the dense-phase system, focusing on steady-state pressure drop characteristic. Experimental protocols involve modulating rotary valve frequencies to generate solid-gas ratios ranging from 12 to 32, enabling the acquisition of pressure drop variation data in the feeding outlet section. Further analysis and prediction of total acceleration section pressure drop are conducted using empirical formulas and response surface methodology (RSM). The results show that the pressure drop of filling shoe is dominant in the pressure drop change of the filling shoe acceleration section L12, and both of them increase approximately linearly with the increase of solid-gas ratio. In the feeding outlet acceleration section L23, the prediction model of the pressure drop calculation coefficient (solid-phase friction coefficient) model is established by response surface method. When the solid-gas ratio is 12~26, the relative error between the model predicted pressure drop and the experimental value is within 15%. However, when the solid-gas ratio is 26~32, the pressure drop exhibits unstable fluctuation characteristics, and the prediction method based on the additional pressure drop method is no longer applicable.

Experiment and numerical simulation of heat transfer characteristics of plastic particles melting process

Lulu TENG Na YE Jingkuan HUANG Lijie YIN

The Chinese Journal of Process Engineering. 2026, 26(2): 150-160. DOI: 10.12034/j.issn.1009-606X.225167

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The melted plastic has high viscosity and low thermal conductivity. In the field of thermal disposal, the melting behavior significantly impacts reactor heat transfer and operational performance. In this study, it was experimentally found that the pyrolysis of plastics was characterized by three stages of "melting-boiling-pyrolysis", in which the phase change enthalpy absorption caused significant changes in the reactor's temperature distribution. A three-dimensional melting model for plastic particles was developed based on the volume of fluid (VOF) model coupled with the enthalpy-porosity method. This model simulated the melting behavior of plastic particles under hot gas flow heating conditions, focusing on analyzing the effects of particle size and shape on temperature distribution, melting rate, and interfacial heat transfer during melting. It was found that there was a distinct internal temperature gradient within particles during melting, with the melting rate initially increasing and then decreasing over time. Compared to spherical particles with a diameter of 10 mm, increasing the particle diameter by 50% extended the melting time by approximately 20 seconds. The heat flow at the gas-liquid interface during melting initially increased and then decreased over time. The total heat required for complete melting was proportional to mass. The total heat for melting 20 mm spherical particles was approximately eight times that of 10 mm particles. The melting rate of different shapes of particles was affected by the windward area and specific surface area, etc. At the same mass, cylindrical and rectangular particles had faster melting rate than spherical particles, and the melting time was reduced by 22.7% and 18.2%, respectively, compared with that of spherical particles. The results provide a theoretical basis for the optimization of pyrolysis reactor design.

Microstructure and mechanical properties of pure tungsten fabricated by selective electron beam melting

Xiaohui YIN Tao ZHU Jianguo MA Zhihong LIU Zhiyong WANG

The Chinese Journal of Process Engineering. 2026, 26(2): 161-169. DOI: 10.12034/j.issn.1009-606X.225104

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In order to explore novel pathways for preparing pure tungsten as a plasma?facing material in fusion reactor divertors and related components, this study investigates the correlation between microstructure and mechanical properties of pure tungsten fabricated via selective electron beam melting (SEBM). By employing SEBM, high?density tungsten specimens were produced, enabling an in?depth examination of the mechanism underlying microcrack initiation. Furthermore, both horizontal (X?Y) and vertical (X?Z) planes of the as?built parts were subjected to microstructural characterization and mechanical testing. The findings revealed that the density of pure tungsten fabricated by SEBM reached 99.3%. The corresponding Vickers hardness attained values as high as 430.44 HV0.3, while the compressive strength was measured to be up to 1790 MPa. Observations of the horizontal plane indicated that the dominant microstructural features were polygonal, cell?like grains; in contrast, the vertical plane exhibited elongated, columnar grains. Fracture surface analysis showed a river?like morphology, representing a characteristic brittle fracture mode.The anisotropic nature of the microstructure gave rise to observable differences in performance. Microcrack formation was predominantly attributed to the recurrent thermal cycles inherent in the SEBM process, which induced pronounced thermal gradient stresses. Consequently, dislocation movement and rearrangement occurred near subgrain boundaries, culminating in local stress concentrations that facilitated microcrack formation. In essence, this study underscored the effectiveness of SEBM for achieving near?full?density tungsten components and elucidated how microstructural evolution, driven by repeated thermal cycling, influenced both mechanical properties and failure mechanisms.

Insulation structure design and performance optimization of FeSiAl soft magnetic composites through aspect ratio engineering

Jun WANG Kaixuan LI Hao HE Zhaoyang WU Haichuan WANG Hui KONG Huaqin HUANG

The Chinese Journal of Process Engineering. 2026, 26(2): 170-181. DOI: 10.12034/j.issn.1009-606X.225123

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To address the persistent challenge of balancing magnetic permeability and core loss in soft magnetic composites (SMCs) fabricated from conventional spherical particles for high-frequency applications, this study proposes an innovative strategy using flaky FeSiAl particles as the base material. A novel FeSiAl/Al2O3 composite is synthesized by integrating interfacial chemical reactions with magnetic field-assisted orientation. A dense and uniform Al2O3 insulation layer is formed in situ via the reaction between the FeSiAl particle surface and a NaOH-based system. Subsequently, the application of an external magnetic field facilitates the alignment of flaky particles along the easy magnetization axis, thereby constructing a layered insulating architecture. The results demonstrate that the particle aspect ratio plays a crucial role in determining the morphology, thickness uniformity, and adhesion quality of the Al2O3 layer, which in turn influences the magnetic properties of the composites. Particularly, the sample with an aspect ratio of 141 achieves a highly continuous insulation layer, exhibiting an excellent combination of effective permeability (126.3), low power loss (108.0 kW/m3), and high electrical resistivity (331.1 Ω?m). Density functional theory (DFT) simulations reveal that strong covalent bonding at the FeSiAl/Al2O3 interface significantly enhance interfacial stability and reduces charge carrier mobility. Furthermore, a three-dimensional separation model based on Bertotti's loss theory is applied to quantify hysteresis, eddy current, and excess losses under varying particle geometries. The study provides in-depth insights into the structure-property relationship by correlating particle shape with magnetic behavior, confirming that optimized aspect ratio engineering can effectively suppress magnetic dilution and enhance energy efficiency. This study not only reveals the critical influence of the aspect ratio of flaky particles on the regulation of microstructure and the optimization of electromagnetic performance, but also establishes a solid theoretical foundation and a feasible technological pathway for the design and fabrication of high-frequency, low-loss soft magnetic composites, demonstrating significant potential for practical engineering applications in advanced electromagnetic systems and energy-efficient devices.

Effect of sulfolane on the absorption and desorption of SO₂ by BHEP aqueous solution

Fengyu WEI Wenchao DONG Yu ZHENG Guangze XU Wenguo SU Xiaoliang SONG

The Chinese Journal of Process Engineering. 2026, 26(2): 182-191. DOI: 10.12034/j.issn.1009-606X.225139

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A mixed absorbent of N,N'-bis(2-hydroxyethyl) piperazine (BHEP) and sulfolane (SUF) was developed for reducing energy consumption in desulfurization. The effects of SUF dosage and inlet SO2 volume concentration on absorption-desorption performance and regeneration energy consumption were investigated, and the synergistic mechanism between SUF and BHEP for SO2 absorption by the BHEP-SUF system was also explored. The results demonstrated that with an increase in SUF dosage, both the saturated absorption capacity (AQ) and effective absorption capacity (EQ) increased first and then decreased, while the regeneration energy consumption (Q) exhibited a continuous decrease. The higher the inlet SO2 volume concentration, the greater AQ and EQ, and the lower the regeneration energy consumption. When 5wt% SUF was added to the aqueous solution of 20wt% BHEP-4.5wt% H2SO4, the AQ and desorption efficiency (DE) were increased by 2.4% and 3.7%, respectively, after four recycling runs. Furthermore, Q was reduced by 9.0%, and the condensate was decreased by approximately 22.9% during desorption. This implied that the decrease in energy consumption was primarily attributed to the reduction in water vaporization induced by SUF. 13C NMR and 1H NMR results indicated that the protonation reaction between BHEP and H+ was not affected by SUF. Molecular dynamics simulation results showed that SUF attenuated the self-agglomeration of BHEP molecules, thereby enhancing their reactivity toward SO2. The BHEP-SUF mixed absorbent not only possesses a high SO2 absorption capacity, but also achieves low regeneration energy consumption, thus showing great application potential for SO2 capture.

Study on purification performance of Span85/SDS-based composite absorbents for oil fume

Weichen XU Shiyin SUN Mengjie CAO Shuangde LI Yunfa CHEN

The Chinese Journal of Process Engineering. 2026, 26(2): 192-202. DOI: 10.12034/j.issn.1009-606X.225116

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Wet absorption technology is widely employed in the absorption of oil fumes due to its low cost and operational simplicity, with the absorption liquid playing a crucial role in determining absorption performance. To address the low absorption efficiency of conventional absorption liquids, this study developed a composite absorption system by combining the anionic surfactant sodium dodecyl sulfate (SDS) with the nonionic surfactant sorbitan trioleate (Span85) at optimized mass ratios, supplemented with sodium hypochlorite as an oxidizing agent. The absorption efficiency was evaluated through measurements of particulate matter concentration using a laser particle counter and non-methane hydrocarbon (NMHC) concentration via flame ionization detection (FID). Firstly, influence of surfactant mass ratios on static oil emulsification performance was investigated. Secondly, the effects of absorption liquid type, concentration, and gas-liquid volume ratio on the absorption efficiencies of NMHC and particulate matter were systematically examined. Experimental results demonstrated that the surfactant mixture with a hydrophilic-lipophilic balance (HLB) value of 6, achieved by regulating the Span85-SDS mass ratios, exhibited the optimal oil emulsification and dispersion abilities. The composite absorption liquid showed significantly superior absorption performance compared to single-surfactant solutions or commercial alternatives. Maximum absorption efficiencies of 90.8%, 91.2%, and 94.4% for NMHC, PM2.5, and PM10, respectively, were achieved under optimal conditions with a total surfactant concentration of 1000 mg/L and a gas-liquid volume ratio of 5. The enhanced absorption performance was attributed to the synergistic effects between NMHC oxidation by the oxidizing agent and improved particulate matter dispersion through surfactant action. This study provides a viable strategy for formulating high-performance absorption liquids for oil fume purification, demonstrating that optimized surfactant combinations with the appropriate addition of an oxidizer can effectively address both gaseous and particulate pollutants in oil fume emissions. The findings offer practical guidance for the development of efficient and cost-effective absorption systems for commercial kitchen emission control.

Pyrolysis behavior and kinetic characteristics of coal with different metamorphic degrees based on TG-FTIR

Bobo SONG Xiaowei ZHAI Haifei LIN Kai WANG Teng MA

The Chinese Journal of Process Engineering. 2026, 26(2): 203-211. DOI: 10.12034/j.issn.1009-606X.225310

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Coal structure and reaction conditions are the main factors influencing coal pyrolysis reactions. To investigate the pyrolysis characteristics of coals with different metamorphic degrees, three typical coal samples (lignite, bituminous coal, and anthracite) were selected as research objects. Thermogravimetric analysis experiments were conducted under four heating rate conditions to analyze the pyrolysis behavior of coals under different reaction conditions. The evolution of functional groups was analyzed by in-situ infrared test. The change law of reaction activation energy was calculated by the modified Kissinger-Akahira-Sunose (KAS) method. The results showed that the reaction behavior of coal at different temperatures can be divided into the water evaporation stage, gas desorption stage, slow decomposition stage, rapid pyrolysis stage, and condensation stage. The greater the degree of metamorphism, the higher the characteristic temperature and the lower the reaction degree. The pyrolysis temperature difference between anthracite and lignite reached 104.3℃. At 1000℃, the residual masses of the three coal samples were 58.19%, 65.90%, and 89.49%, respectively. The heating rate primarily influences the degree of reaction in coal samples at specific temperatures, without fundamentally altering the reactions that may occur during coal pyrolysis. A higher heating rate results in a narrower and sharper differential thermogravimetry (DTG) peak, accompanied by a lower reaction extent at the same temperature. After entering the pyrolysis stage, the activation energy for lignite and bituminous coal exhibits minimal variation, remaining at approximately 210 and 255 kJ/mol, respectively. Anthracite exhibited a high degree of aromatic ring condensation, molecular symmetry, and low reactivity. Its functional groups demonstrate low absorbance and exhibit delayed response patterns relative to other coal samples. Upon entering the pyrolysis stage, it must overcome a higher reaction energy barrier to sustain the reaction.

Study on reduction behavior and kinetic of boron-bearing iron ore pellets under different atmospheres

Shixin ZHU Xingwang LI Hongtao WANG Jie LEI Hongming LONG

The Chinese Journal of Process Engineering. 2026, 26(2): 212-222. DOI: 10.12034/j.issn.1009-606X.225057

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Utilization of low-grade iron ore in the production of pellets is of great significance for reducing the production cost of blast furnaces with high-proportion pellets. By appropriate beneficiation, the iron grade of boron-bearing ore can exceed 50%, which is suitable for the production of pellets. In this study, the boron-bearing iron ore pellets were selected as the research object, and the reduction behavior as well as the kinetics of pellets under CO atmosphere were experimentally investigated. Simultaneously, the mechanism for the reduction process was elucidated. Meanwhile, the difference of pellets reduction behavior between the CO atmosphere and the H2 atmosphere was revealed. The results demonstrated that as the reduction temperature rose from 700℃ to 950℃, the final reduction degree of pellets under CO atmosphere was enhanced from 26.85% to 53.56%. Simultaneously, the variation in the reduction rate of pellets depended on the temperature. At low temperature (700~800℃), the reduction rate of pellets was firstly increased and then decreased, and the maximum value was reached at (60~80) min. Furthermore, at high temperature (850~950℃), the reduction rate was rapidly boosted to the maximum value at the initial reaction stage (within 10 min), and followed by a decreasing trend. Meanwhile, under the same reduction conditions, the reduction degree of pellets under H2 atmosphere was significantly greater than that under CO atmosphere. In addition, the reduction process of boron-bearing iron ore pellets under CO can be well described by f(x)=3(1-x)2/3. Based on this model, the apparent activation energy and pre-exponential factor were calculated, which were 29.2953 kJ/mol and 0.028629 ?min-1, respectively. This work could provide theoretical foundation and data support for the application of boron-bearing iron ore in the production of pellets.

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