Addition Of Catalyst Research Articles

Partial upgrading of heavy oils by catalytic aquathermal visbreaking with dispersed iron oxide catalysts

The impact of water and red mud-like Fe oxide catalysts on aquavisbreaking (AVB) of heavy-oils was studied under various circumstances. Vacuum residue (VR) was employed as a good substitute for low-viscous bitumen grades. The reaction products were separated into SARA fractions using open-column liquid chromatography (OCLC), and boiling point groups were classified using thermogravimetric analysis (TGA). In addition, Fourier-transform infrared (FTIR) spectroscopy was used to study the structural features of VR and its derivatives. It was observed that the thermal visbreaking of VR led to a severe coke formation with asphaltene (ASP) to coke selectivity over 130 %, while the addition of water and Fe catalyst could increase the conversion of ASP to liquid oil products while inhibiting coke formation, resulting in improved conversion of ASP. Furthermore, the structural properties of spent catalysts recovered after reactions were analyzed using X-ray absorption near edge structure (XANES) and X-ray diffraction (XRD) to identify the active phase, confirming that the Fe precursor is converted to a 20–30 nm Fe2O3 and Fe3O4 during VR AVB. Moreover, the addition of carbon additives to AVB further improved the dispersion of ASP and catalyst particles, contributing to the decrease of the selectivity for ASP conversion to coke by 50 %.

Visible-Light-Driven Method for the Selective Synthesis of Amides and N-Acylureas from Carboxylic Acids and Thioureas.

In this work, we developed a visible-light-driven method for the selective synthesis of amides and N-acylureas from carboxylic acids and thioureas. This protocol was featured as avoidance of additional oxidants and transition metal catalysts, simple manipulations, low cost, broad substrate scope, and good functional group tolerance. As only oxygen serves as the oxidation reagent, this method provides a promising synthesis candidate for the formation of N-aryl amides and N-acylureas, including late-stage functionalization of complex pharmaceutical molecules and biologically active molecules.

Catalyst-free sustainable epoxy vitrimers with fire safety offered by phosphorus-containing compounds

In this study, we designed and incorporated a phosphorus-rich compound, DPT, which possesses inherent catalytic properties, into a typically sustainable epoxy vitrimer. This innovative strategy enables the fabrication of flame retarded epoxy vitrimers that require no additional catalysts. DPT was synthesized through a reaction between triethanolamine (TEA) and dibenzyl chlorophosphonate (DPCP). The successful synthesis of DPT is attested to by FTIR and NMR analyses. DPT effectively accelerated the curing process of the epoxy vitrimers, yielding materials with exceptional mechanical strength and inherent self-healing abilities. Notably, the pHRR of epoxy vitrimer incorporated with DPT is reduced to 296.3 kW/m2, showing a remarkable 54% reduction compared to that of the epoxy vitrimer catalyzed by conventional catalysts. The THR is also decreased from 84.3 to 42.4 MJ/m2. Comprehensive analyses using cone calorimetry and TG-FTIR revealed that DPT effectively inhibits the emission of toxic gases. Crucially, the presence of DPT in the epoxy matrix facilitated the formation of a dense and stable phosphorus-laden carbon layer, which not only enhanced flame retardancy but also imparted exceptional smoke suppression capabilities. These findings underscore the potential of DPT for developing high-performance, catalyst-free, flame-retardant epoxy vitrimers.

Anomalous CatalyticPerformance on Non-Active-Site Carbon Substrate.

Carbon-based nanomaterials are gaining attention in electrocatalysis. This study investigates the inherent nitrate reduction activity (NO3RR) of commercial carbon paper as a substrate. Results showed that carbon paper, without additional catalysts, achieved approximately 80.42% NH3Faradaic efficiency (FE) at -2.1 V vs. Hg/HgO in alkaline conditions, 83.51% NH3FE at -1.9 V vs. Ag/AgCl in neutral conditions, and 14.53% NH3FE at -1.9 V vs. MSE in acidic conditions. Density Functional Theory (DFT) calculations revealed energy barriers of 2.66 eV, 0.95 eV, and 1.37 eV, respectively. Molecular physisorption on the carbon paper surface generates an induced electric field, promoting charge transfer between the carbon paper and the adsorbed molecules, thus enhancing the activity of the carbon paper. These findings highlight the importance of considering the intrinsic catalytic properties of carbon substrates in catalyst design and evaluation, as overlooking these properties can lead to inaccurate performance assessments. This study emphasizes the need for a comprehensive approach to optimize catalytic systems.

Unique flake-shaped sulfur morphology favored by the binder-free electrophoretically deposited TiO2 layer as a promising cathode structure for Li-S batteries

Metal oxides have been extensively studied as catalyst additives in Li-S batteries due to their high affinity for soluble lithium polysulfides (LiPSs). The present study developed a novel carbon nanomaterials- and binder-free 3D sulfur host by electrophoretic deposition (EPD) of TiO2 nanoparticles on carbon fiber paper (CFP). Benefiting from the unique well-connected TiO2 porous layer formed by EPD, the initial discharge capacity of Li-S battery was increased from 1160 mAh g−1 in conventional cast TiO2/binder/S cathode (Cast:CFP/PVDF/TiO2/S) to 1310 mAh g−1 in the EPD:CFP/TiO2/S cathode, along with an overpotential drop of 16 %. Electron microscopic studies at 100% state-of-charge (SoC) revealed that while notorious sulfur particulates were formed on Cast:CFP/PVDF/TiO2/S, the surface of EPD:CFP/TiO2/S was covered with flake-shaped sulfur precipitates. The formation of sulfur flakes effectively suppressed pulverization in EPD:CFP/TiO2/S, leading to superior electrochemical performance and cycle life. Microstructural studies and real-time EIS investigations revealed that sulfur flakes nucleated across the Li2S matrix at the initial stages of charge and grew vertically from the sulfur/TiO2 interface. The preferential growth mechanism of sulfur flakes was attributed to the superior surface conductance of the EPD-TiO2 film enabled by the ordered clusters formed during EPD, enhancing the kinetics of electrocatalytic reactions of polysulfides at the TiO2/sulfur interface. Our results show that developing novel methods to modify the morphology of secondary sulfur upon cycling is critical for enhancing charge-discharge performance in Li-S batteries.

Flame retardant epoxy vitrimers employing a Meldrum's acid-functionalized and phosphorus-containing bisphenol compound as the cross-linking agent for conventional epoxy

In addition to recycling and reprocessing features, designs of vitrimers possessing critical properties required for conventional cross-linked polymers are of interest. In this work, a newly designed Meldrum's acid (MA)-functionalized and phosphorus-containing bisphenol compound (P-MADV) compound is synthesized. Employing P-MADV as a curing agent, simultaneous formation of permanent and dynamic covalent linkages through one-pot reaction has been achieved in formation of flame retardant epoxy resin vitrimers. The newly synthesized P-MADV compound is an effective cross-linking agent for commercially-available epoxy resins for synthesis of flame-retardant epoxy vitrimers through the conventional cross-linking conditions and processes. The cross-linked epoxy vitrimer passes the flame test under UL 94V-0 specification contributed from the phosphorus-containing groups. The flame retardant vitrimer also exhibits a storage modulus of 1.2 GPa at 50 °C and a Tg (tanδ peak) of 185 °C, which are comparable to the values found with conventional phenolic novolac-cross-linked epoxy resin (storage modulus: 1.6 GPa; Tg: 155 °C). Without addition of catalysts for dynamic bond exchanging reaction, the cross-linked epoxy vitrimer shows stress relaxation time of 397 s at 230 °C and an activation energy of stress relaxation of 97.8 kJ mol−1. The dynamic features warrant the epoxy vitrimer being recyclable under thermally pressing at 230 °C and 16 MPa for 1 h. The recycled samples exhibit thermal and mechanical properties being comparable to the pristine resin. This work has demonstrated an attractive approach for preparation of flame retardant epoxy resin vitrimers in viewpoints of both manufacturing processes and resins properties.

Synthesis of N-Sulfonyl Formamidines by Direct Condensation between Sulfonamide and Formamide Enabled by a Photogenerated Vilsmeier-Type Reagent.

Herein, we report the synthesis of N-sulfonyl formamidines from carbon tetrabromide and formamide under UVA irradiation without any additional catalysts. This approach represents a straightforward methodology for accessing this class of structural units and has been applied to a wide range of readily available sulfonamides and formamides, providing the corresponding products in moderate to excellent yields (30 examples, 16-99% yields). Mechanistic investigations associated with previous reports suggest the implication of an activated iminium intermediate (Vilsmeier-Haack reagent derivatives), obtained by the photoinduced reaction between carbon tetrabromide and formamides.

Viscosity Reduction of Heavy Oil Based on Rice Husk Char-Based Nanocatalysts of NiO/Fe2O3

In recent years, catalytic hydrothermal cracking has gained significant attention as an effective technology for reducing the viscosity of heavy oil in the field of heavy oil recovery. However, the current catalyst temperature window is relatively high, leading to high energy consumption in heavy oil extraction. The development of catalysts that can effectively reduce the viscosity of heavy oil at low temperatures is important to reduce energy consumption in the thermal recovery process of heavy oil. Biochar-based catalysts exhibit good low-temperature activity. Therefore, this study used modified rice husk char as a carrier to develop NiO-RHC, Fe2O3-RHC, and NiO/Fe2O3-RHC catalysts, and investigated their performance in low-temperature catalytic viscosity reduction. Various methods were used to characterize the physical and chemical properties of the catalysts, and the effects of catalyst type and addition amounts on the catalytic viscosity reduction reaction were examined. The results showed that the catalytic performance of the dual-active component catalyst was better than that of NiO-RHC and Fe2O3-RHC. Under the catalysis of NiO/Fe2O3-RHC, the viscosity of heavy oil decreased by 81.81%. As the catalyst addition amounts increased, the viscosity reduction rate of heavy oil also increased. The optimal catalyst addition amount was 1.00wt.%, and the heavy component content in the oil sample was reduced by 4.14% after the catalytic reaction. Finally, the mechanism of heavy oil viscosity reduction was analyzed. It was found that the breaking of C-S bonds was a significant factor in reducing heavy oil viscosity, and the S in H2S mainly came from thioether and sulfoxide sulfur. This study provides valuable references for further research on low-temperature viscosity reduction in heavy oil.

Catalytic modification of MgH2 hydrogen storage properties by La–Ni catalysts

In this paper, it is experimentally demonstrated that the La–Ni catalyst contributes to the hydrogen storage performance of MgH2. Firstly, La–Ni (La: Ni = 1: 5.7) catalysts are prepared by CaH2 reduction method, and then MgH2+x wt.% La–Ni (x = 0, 3, 5, 7) composite alloys were prepared by ball milling method. The present work focuses on the structural and hydrogen ab/desorption properties of the composite alloys, and analysis the modulatory effect and influence mechanism of different La–Ni catalyst additions on the hydrogen storage properties of MgH2. The findings show that the composite alloys have the same diffraction peaks and that the main phase of the composite alloys is the MgH2 phase, with the addition of the LaNi5 phase, the Mg2Ni phase and a small amount of Mg phase. The mutual reversible transformations of LaH3 and Mg2Ni and Mg2NiH4 play a catalytic role in the hydrogen ab/desorption process. Moreover, the addition of La–Ni catalyst plays a dramatic improvement effect on the kinetic performance of MgH2 ab/desorption. When the addition of La–Ni catalyst is 5 wt.%, the composite alloy exhibits the most excellent hydrogen uptake and release kinetics. The MgH2+5 wt.% La–Ni composite alloy absorbs 4.2 wt.% H2 within 2 min at 473 K and releases 3.43 wt.% H2 within 150 min at 503 K. Fitting the hydrogen release activation energy of the composite alloys shows that the hydrogen release activation energy of the composite alloys decreases first and then increases, and there is a minimum hydrogen release activation energy of 101.81 kJ/mol H2 when the addition amount x = 5 wt.%.

Aromatic Poly(dithioacetal)s: Spanning Degradability, Thermostability, and High Refractive Index Towards Eco-friendly Optics.

In the quest for eco-friendly optics, high refractive index polymers (HRIPs) with degradability have been one of the desirable optical materials for realizing eco-friendly and efficient lighting technologies. However, it has been challenging for HRIPs to simultaneously realize thermostability, high refractive index (RI), visible transparency, and efficient degradability, all of which are essential for their practical use. In this context, we herein focus on aromatic poly(dithioacetal)s, composed of visible-transparent yet degradable dithioacetal moieties and rigid diphenyl disulfide spacers, exhibiting moderately high Tg (> 60 °C), high RI (> 1.7), and colorless film features. In addition, poly(dithioacetal)s can balance (1) high stability under the operating conditions even upon heating and (2) quantitative degradability that can selectively yield cyclic low-molecular-weight products that can be further repolymerized upon further addition of an acid catalyst. These results provide a key concept for high refractive index polymers that allow on-demand degradability and recyclability without compromising their high potential thermal and optical properties.

Efficient cleavage of Cα[sbnd]Cβ bonds in lignin using tetrabutylammonium tetrafluoroborate as both the catalyst and auxiliary electrolyte

Lignin is a promising alternative to fossil resources due to its abundance of benzene ring monomers. However, the stability of the CαCβ bond in lignin has hindered its efficient depolymerization. Electrochemical methods for breaking this bond are not well-studied. This paper presents a novel approach for catalytic depolymerization of lignin to produce acetals under mild conditions, without the need for additional catalysts. Under room temperature and in an air atmosphere, the combination of tetrabutylammonium tetrafluoroborate (TBABF4) as an auxiliary electrolyte and methanol (MeOH) as a solvent has shown high selectivity in catalyzing the cleavage of CαCβ bonds in lignin. Over 90.0 % of the resulting products are acetals, with the optimal conditions being a substrate concentration of 0.02 M, TBABF4 concentration of 0.008 M, a constant current of 30 mA, and a reaction time of 3 h. This led to a substrate conversion rate of 95.8 % and a product yield of 98.0 % for benzaldehyde dimethyl acetal (Bda). The mechanism study reveals that the tributyl ammonium radical cation decomposed by TBABF4 is adsorbed on the electrode surface. Subsequently, the adsorbed O2 is activated to form superoxide anion radical active species through single electron transfer, which plays a crucial catalytic role. TBABF4 acts as both an auxiliary electrolyte and a catalyst in this process. This research introduces a novel approach for electrocatalytic depolymerization of inert CαCβ bonds in lignin, leading to the selective conversion into acetal chemicals.

Study on biomass and polymer catalytic co-pyrolysis product characteristics using machine learning and shapley additive explanations (SHAP)

Biomass and polymer catalytic co-pyrolysis can convert waste into higher-quality fuels, thereby reducing the use of fossil fuels to some extent. However, this process is an extremely complex thermochemical conversion, influenced by numerous factors such as feedstock properties, operational variables, and catalyst. Currently, experimental methods require substantial time and resource investment. Machine learning (ML) can fit and match input and output features based on existing data, achieving extremely high accuracy in the co-pyrolysis process. This study applies advanced ML models to study the biomass and polymer catalytic co-pyrolysis process, with a focus on the yield of pyrolysis products and the variations of the oxygen-containing components in the pyrolysis oil. The best-performing model is used for feature analysis of the correlation between inputs and outputs, based on game theory SHAP analysis. The results indicate a significant negative correlation between the polymer addition ratio and the generation of oxygen-containing components during the co-pyrolysis process. The addition of catalysts promotes the generation of pyrolysis gas during co-pyrolysis but suppresses the yield of pyrolysis oil. Additionally, catalysts significantly inhibit the formation of oxygenates in the pyrolysis oil. The XGBR model shows the highest performance in predicting pyrolysis oil yield, achieving R2 values of 0.98 during training phase and 0.91 during testing phase. The GBR model performs well in predicting the oxygenate composition of pyrolysis oil from small datasets.

Copper-Catalyzed Amination of Aryl Chlorides under Mild Reaction Conditions.

We report a mild method for the copper-catalyzed amination of aryl chlorides. Key to the success of the method was the use of highly sterically encumbered N1,N2-diaryl diamine ligands which resist catalyst deactivation, allowing reactions to proceed at significantly lower temperatures and with a broader scope than current protocols. A sequence of highly chemoselective C-N and C-O cross-coupling reactions were demonstrated, and mechanistic studies indicate that oxidative addition of the Cu catalyst to the aryl chlorides is rate-limiting. We anticipate that the design principles disclosed herein will help motivate further advances in Cu-catalyzed transformations of aryl chlorides.

3D carbon corrosion kinetic mechanism modeling study for proton exchange membrane fuel cells under localized flooding

Localized anode flooding often occurs in proton exchange membrane fuel cells (PEMFCs) during operation, which leads to localized H2 deficiency and triggers the carbon support corrosion in the catalyst layer, thus seriously weakening the performance and service life of PEMFCs. In this work, a 3D carbon corrosion kinetic mechanism model under localized anode flooding is developed to analyze in detail the multi-physics field distributions during carbon corrosion. The developed model is also coupled with a PEMFC performance model to focus on the carbon corrosion rate spatial distribution and its effect on the PEMFC performance. In addition, the effect of the cathode catalyst layer (CCL) added with oxygen evolution reaction (OER) catalyst on the carbon corrosion rate is analyzed in detail. Considering the particularly expensive OER catalysts and the non-uniform carbon corrosion distribution, a scheme of multi-area ordered adding with OER catalysts is further proposed to reduce the OER catalyst loading, and it is found that such a scheme can more effectively reduce the non-uniform carbon corrosion within the CCL. The electrochemical surface area loss is reduced by 7.38 % and the performance is improved by 5.69 % with scheme 2 compared to without the addition of OER catalyst.

Roles of Catalysts and Feedstock in Optimizing the Performance of Heavy Fraction Conversion Processes: Fluid Catalytic Cracking and Ebullated Bed Vacuum Residue Hydrocracking

Petroleum refining has been, is still, and is expected to remain in the next decades the main source of energy required to drive transport for mankind. The demand for automotive and aviation fuels has urged refiners to search for ways to extract more light oil products per barrel of crude oil. The heavy oil conversion processes of ebullated bed vacuum residue hydrocracking (EBVRHC) and fluid catalytic cracking (FCC) can assist refiners in their aim to produce more transportation fuels and feeds for petrochemistry from a ton of petroleum. However, a good understanding of the roles of feed quality and catalyst characteristics is needed to optimize the performance of both heavy oil conversion processes. Three knowledge discovery database techniques—intercriteria and regression analyses, and artificial neural networks—were used to evaluate the performance of commercial FCC and EBVRHC in processing 19 different heavy oils. Seven diverse FCC catalysts were assessed using a cascade and parallel fresh catalyst addition system in an EBVRHC unit. It was found that the vacuum residue conversion in the EBVRHC depended on feed reactivity, which, calculated on the basis of pilot plant tests, varied by 16.4%; the content of vacuum residue (VR) in the mixed EBVRHC unit feed (each 10% fluctuation in VR content leads to an alteration in VR conversion of 1.6%); the reaction temperature (a 1 °C deviation in reaction temperature is associated with a 0.8% shift in VR conversion); and the liquid hourly space velocity (0.01 h-1 change of LHSV leads to 0.85% conversion alteration). The vacuum gas oil conversion in the FCC unit was determined to correlate with feed crackability, which, calculated on the basis of pilot plant tests, varied by 8.2%, and the catalyst ΔCoke (each 0.03% ΔCoke increase reduces FCC conversion by 1%), which was unveiled to depend on FCC feed density and equilibrium FCC micro-activity. The developed correlations can be used to optimize the performance of FCC and EBVRHC units by selecting the appropriate feed slate and catalyst.

Experiment and density functional theory researches on (Mn, Hf) co-doped Ce-based applied surface catalysts for carbon monoxide oxidation and thermal stability

Catalyst addition can improve system after treatment efficiency of pollutants purification. In this study, the performance of (Mn, Hf) co-doped Ce-based catalysts has been investigated in oxidation to mitigate CO emission of engines. A series of Ce-Mn-Hf-Ox with different metal ratios (Ce: Mn: Hf = 8:1:1,7:2:1,7:1:2,6:1:3,6:2:2 and 6:3:1) catalysts were prepared. DFT (density functional theory) calculations were carried out to investigate the mechanism of applied surface catalytic reaction. XRD (X-ray Diffraction) analysis and SEM (Scanning Electron Microscope) revealed Mn and Hf doping increased the catalysts surface area contact with the CO gas with the catalytic performance improvement. XPS (X-ray Photoelectron Spectra), H2-TPR (Temperature-Programmed Reduction) and DFT calculations manifested the Mn and Hf doping would promote the formation of oxygen vacancy to enhance the catalytic performance for CO oxidation. The thermal stability of the catalysts increased with Hf content increasement. Ce6Mn3Hf1 had the highest catalytic activity with the favorable thermal stability according to the temperature-programmed oxidation of CO experiment. T10, T50 and T90 of CO oxidation were 156, 188 and 198 °C, which lost 4.82 % mass at 500°C and 6.18 % mass at 900 °C. Ce6Mn1Hf3Ox displayed the best thermal stability according to TG with the lowest catalytic activity.

Performance of oriented strand board bonded with a hybrid phenol-formaldehyde/polymeric methylene diphenyl diisocyanate adhesives system

A hybrid adhesive system composed of phenol-formaldehyde (PF) resin and polymeric methylene diphenyl diisocyanate (pMDI), modified with two types of alkaline catalysts, namely NaOH and CaCO3 at 20% (w/v), was used for manufacturing the oriented strand board (OSB) from sengon (Paraserianthes falcataria L. Nielsen) wood. The catalyst was added at a concentration of 1% of the solids content of PF adhesive, and pMDI was added at 2.5% and 5.0% of the PF adhesive solids content. Adding catalysts and cross-linking agents increased the solids content and viscosity of the adhesive and accelerated the gelation time. The water absorption of OSB increased with the addition of catalysts and crosslinking agents compared to the control PF. Still, the CaCO3 catalyst worked optimally in reducing the thickness swelling of OSB. The mechanical properties of the laboratory-fabricated OSB panels increased with the addition of catalyst and cross-linker, except for the modulus of elasticity parallel to the grain. The optimal performance of OSB was obtained by adding 1% CaCO3 and 2.5% pMDI based on the PF’s solids content.

Influence of Solid Alkaline Photocatalysts Irradiated with UV Light on Fuel Properties of Palm Oil Biodiesel.

TiO2 nanoparticles are full of porosity that can be impregnated with a strong alkaline catalyst CH3ONa to form a TiO2/CH3ONa catalyst. TiO2 of the anatase phase, which is a semiconductor material, has been a prominent photocatalyst due to its excited photocatalyst activity, chemical and biological stability, and nontoxicity. The CH3ONa compound has been widely used as a catalyst for transesterification. Although the synthesized photocatalyst TiO2 powder with CH3ONa is anticipated to greatly enhance the transesterification efficiency, leading to improving biodiesel properties, relevant studies have not been found. After the photocatalyst was prepared, a reactant mixture of palm oil, methanol, and heterogeneous catalyst TiO2/CH3ONa was illuminated by ultraviolet (UV) light from light-emitting diode (LED) lamps. The experimental results revealed that the formation of fatty acid methyl esters was significantly increased to 98.4% with ultraviolet-light illumination for the molar ratio of methanol/palm oil equal to 6 and 3 wt % catalyst addition. The decrease of the catalyst amount to 2 wt % resulted in a slight decrease of the fatty acid methyl esters to 97.06 wt %. The lowest kinematic viscosity and acid value and the highest distillation temperature, heating value, and cetane index were observed under the above reaction conditions. The distillation temperature and cetane index were increased while the acid value was decreased under ultraviolet illumination on the reactant mixture. Consequently, the optimum preparing conditions for biodiesel production were 6 and 3 wt % for the molar ratio of methanol/palm oil and catalyst addition under UV-light irradiation.

Direct CVD graphene growth onto surgical stainless steel for orthopedic implants

Graphene sheets were successfully grown for the first time on the surface of surgical stainless steel cylinders by direct APCVD process using methane, argon and hydrogen as precursor gases and without the addition of metal catalyst. The effects of deposition temperature, deposition time, and oxidation minimization through pre-vacuum processes, along with the use of an optimized sample holder, were analyzed. The obtained results are supported by Raman spectroscopy, X-ray photoelectron spectroscopy (XPS) and scanning electron microscopy (SEM) characterization techniques. These graphene covered cylinders are intended to be used as orthopedic implants and are going to be tested initially in rats.

Optimization of hydrogen-rich syngas from coal and sewage sludge co-gasification in supercritical water

Supercritical water gasification (SCWG) of coal and biomass waste complies with the structure of energy consumption and the targets for carbon peaking and carbon neutrality. In this work, the optimal blending ratio and thermochemical transformation characteristics of coal and sewage sludge (SS) co-gasification were explored experimentally at various temperatures (500–660 °C), residence time (0–40 min), feedstock concentrations (5–15 %), and catalyst utilization. The demethylation and dehydroxylation of intermediate products (aliphatic compounds, monocyclic aromatic hydrocarbons (MAHs)) improve the gasification performance under favorable experiment conditions (high temperature, long residence time, low feedstock concentration, and addition of catalysts). The optimal gasification results are an H2 yield of 38.36 mol/Kg and a 118.81 % increase of CGE (cold gas efficiency) in K2CO3-catalyzed gasification compared to the absence of the catalyst. Subsequently, the co-gasification mechanism of coal and SS was determined by the analysis of the three-phase product. Ultimately, a regression model was first established to obtain the practical optimization mechanism and yield prediction of hydrogen-rich syngas through response surface plots and regression equations. As verified in multiple experiments under varying situations, the regression model’s fitting accuracy yields an average relative error of 5.53 %.