Resistive Heating Research Articles

Conductive Polyethylene/Polyester Textiles with Temperature‐Strengthened Electromagnetic Interference Shielding Efficiency

The advancement of electromagnetic interference (EMI) shielding materials provides reliable protection for the communication technology. However, the performance of conventional EMI shielding materials is significantly diminished in high‐temperature conditions. Herein, an efficient method is proposed to prepare conductive fabrics with temperature‐strengthened EMI shielding performance via chemical plating technique. The as‐prepared polyethylene/polyester‐metallized fabric (PMF) coated with Ni–W–P alloy exhibits outstanding EMI shielding effectiveness (SE) in X band, which is strengthened from 16 to 59 dB with temperature raising from room temperature to 130 °C. Particularly, the corresponding temperature‐strengthened shielding behaviors are investigated through simulations in Computer Simulation Technology. Additionally, PMF presents excellent corrosion resistance (corrosion voltage [Ecoor] of −0.324 V and corrosion current [Icoor] of −6.760 A·cm−2) and admirable Joule heating performance, reaching maximum temperature of 74 °C at only 1.5 V. Therefore, the as‐prepared PMF endows enormous potential in EMI protection under high temperature and harsh environments.

Comparison with Carnot battery of an alternate thermal electricity storage charged by concentrated photovoltaic thermal system and resistance heater

In Carnot Batteries (pumped thermal electricity storage), which is known as a low-cost electricity storage method, electrical energy is stored as thermal energy and then converted back into electrical energy using a heat pump and a heat engine, respectively. In the studies carried out to date, different heat source scenarios, heat storage methods, and methods to improve heat pump and heat engine cycles have been applied to increase efficiency and reduce the cost of the Carnot Battery. This study’s novelty was using a concentrated photovoltaic thermal system and resistance heaters instead of a heat pump for the charge cycle in thermal electricity storage. This novel thermal electricity storage design aimed to reduce the levelized cost of storage of the system by eliminating the need for a heat pump and reducing the volume of the water storage tank. First, parametric analyses were performed for the specific variables of both energy storage systems. Afterward, the Carnot Battery and the proposed system were compared for the same electricity storage capacity. For charge/discharge times ranging from 4 h to 8 h and electricity storage capacities ranging from 0.5 MW to 2 MW, a 31.8 % to 58 % increase in round-trip efficiency and a 7.13 % to 20.67 % decrease in levelized cost of energy storage were achieved with the novel design.

Engineering morphological architecture of superhydrophobic/hydrophilic composite membrane for efficient photothermal membrane distillation

The viability and efficacy of photothermal membrane distillation (PMD) is still uncertain due to its inherent energy-efficiency and throughput mass flux limitation. Herein, we develop a delamination-free multilayer photothermal membrane that simultaneously imparts slashed mass transfer resistance, enhanced photothermal effect and strong water-repellency by engineering morphological architecture. Using a one-step programmed dual-channel electrospinning followed by an electrostatic spraying technique, the proposed membrane is composited by a thick water-intrudable hydrophilic supporting layer, a thin hydrophobic layer, and an ultrathin Ti3C2Tx MXene-engineered superhydrophobic layer. It is proposed that the morphological architecture engineering could render mitigation of mass transfer resistance, firm water-repellency, and robust heat localization. Hence, in addition to superior flux of 1.27 L m−2 h−1 (inlet feed/permeate at 20/20 °C) and 15.89 L m−2 h−1 (inlet feed/permeate at 50/20 °C), prominent solar efficiency (76.34 % and 96.45 %) of the proposed composite membrane (DS15-M) also was achieved during PMD operation (1.0 kW m−2). Moreover, the DS15-M showcased not only robust wetting resistance and long-term consistency, but also obviously mitigated temperature polarization effect during the PMD operation. This research work emphasizes the important role of morphological architecture in rendering performance enhancement, which is a significant implication in engineering membrane architecture for PMD application.

Interaction of liquid titanium with zirconates and titanates of some alkaline earth metals

Abstract The article presents the results of a study of the interaction of titanium melt with of zirconates BaZrO3 and SrZrO3, as well as titanate SrTiO3 under vacuum conditions and in an inert atmosphere at normal pressure. An original titanium heating method was used during the experiments. It eliminated the melt circulation at the interface between the solid and liquid phases. The method was based on resistive electrical heating of a Grade 2 titanium alloy rod or strip pressed into BaZrO3, SrZrO3 and SrTiO3 powders. Studied the structure, elemental, and phase composition of the products formed during various (up to 300 s) contact of titanium melt with surface zirconates and titaniums. The phase composition was compared with the products obtained by heating compacts from a mixture of titanium powders with BaZrO3, SrZrO3 and SrTiO3 powders. It was shown based on the results obtained that titanium, upon contact with these ceramic materials dissolves zirconium and oxygen and reduces barium and strontium to a metallic state. Barium and strontium evaporated due to the high vapor pressure at the experimental temperature, and caused the melt to splash or form a vapor layer that reduced the interaction rate of the melt with the ceramic. When a titanium melt interacted with BaZrO3 and SrZrO3 intermediate phases were not formed in quantities sufficient for their identification. The Sr3Zr2O7 phase was formed in small quantities during heating a mixture of Ti+SrZrO3 powders. When a titanium melt interacted with SrTiO3, a layer of an intermediate phase was formed, similar in composition to TiO2. Equations for the chemical reaction of the interaction of titanium with the indicated zirconates and titanate were compiled based on the experimental data obtained. It has been shown that titanium melt weted the surface of BaZrO3, SrZrO3 powders well and poorly weted the surface of SrTiO3 powder.

Fast-airflow tumble clothes dryer with small thermoelectric heat pump: Experimental evaluation

Residential clothes drying accounts for about 5 % of the total residential-sector energy consumption in the United States. Most dryers use electric resistance heaters to dry clothes and have low efficiencies. Higher-efficiency dryers that use vapor compression heat pumps are expensive and complex and have not gained a large market share in the United States. A novel tumble clothes dryer using a small thermoelectric heat pump with faster airflow than typical dryers is presented in this work. The benchtop performance of the thermoelectric heat pump and high-speed blower are presented, and the development of the prototype dryer is described. The dryer was tested for efficiency and dry time for a range of airflow rates and applied currents to the thermoelectric heat pump. The combined efficiency factor was 5.09–6.29 lbBDW/kWh (specific moisture extraction rate of 1.23–1.53 kgw/kWh) with 100–138 min dry times for these tests. The measured efficiency was 36 %–68 % greater than the minimum efficiency standard in the United States, and compared with vapor compression heat pump–based clothes dryers, the prototype dryer had less expensive, less complex components and did not use refrigerants. The performance of this small thermoelectric heat pump clothes dryer is also compared with previous iterations of the thermoelectric tumble clothes dryer described in the literature.

Experimental study of four-step thermal swing adsorption cycle to upgrade biogas obtained from anaerobic digestion

Biogas is a renewable source of energy that when upgraded can be adopted as a reliable and sustainable alternative. This study evaluates the performance of thermal swing adsorption technology applying resistive heating, in upgrading biogas obtained from anaerobic digestion to biomethane. Commercial coconut shell-based activated carbon was used as an adsorbent in the four-step cycle process to capture carbon dioxide, using a fabricated adsorption model. The influence of minor gas constituents of biogas in carbon dioxide breakthrough curves was analyzed. Dynamic adsorption tests were carried out to evaluate the system performance in carbon dioxide capture. The maximum regeneration temperature of 60 ℃ was found to have peak carbon dioxide concentration of 39% in the waste gas, maximum energy requirements of 0.1538kWh per cycle, and an energy efficiency of 87%. This is a good trade-off between adsorbent recovery and system energy efficiency. The adoption of thermal swing adsorption technology in biogas upgrading systems is a viable alternative for water-deficient regions.

Food Production in Ergonomically Designed Unit with Low Energy Consuming Thick Film Hot Plate

The Trans-Himalayan region of Ladakh is a cold desert where the temperature drops as low as -45°C, which makes the cultivation of fresh food almost impossible. The region is strategically very important as it borders two countries China and Pakistan. The unavailability of fresh food causes nutritional deficiency in the deployed troops and locals, affecting their performance. Cultivation of fresh food is very difficult due to the average low temperature and mountainous soil of the region. Transportation of fresh food to such forward locations causes decaying of nutrition besides the difficulty of reaching such snow-bound mountainous locations. Nutritious micro-greens grown in media under controlled conditions look perfect solutions for meeting nutritional requirements. The present study focuses on year-round cultivation of nutritious micro-green (2-3 times more nutritious than mature counterparts) with low energy consuming thick-film hot plate for necessary temperature maintenance in properly designed portable structures to reduce dependency on packaged food which are the causes of many diseases. The study involves the development of a thick film energy-efficient micro-climate maintenance technology-based system for the maintenance of temperature along with phase-wise development of suitable cultivation structure and standardization of the number of such plates and sizing of the portable unit.These hotplates produce heat based on the principle of Joule heating or resistive heating and the power of a hotplate is equal to I2R. The hotplates are capable of raising the surface temperature to 90°C –100°C at the expense of only 8W power consumption and maintenance of average temperature in the range of 18°C to 20°C at -25°C to -40°C outside ambient temperature. The region receives the highest solar irradiance along with annual average of 7-8 hours of sunshine duration and hence a solar-based technology can fulfill the energy supply of 8W with ease.The study revealed that a suitable temperature can be maintained for growing variety of nutritious micro-green in a triple layer-based multitier structure integrated with low energy consuming (~8 W), small (50.8 mm (x) 50.8 mm), efficient, and lightweight thick film technology.Thick-film hot plate integrated standardized unit is capable of producing an average of 1000grams/trial/unit in a short period of 8-12 days during the winter period of 6-8 months for the targeted supply of 8-10grams/person/day with total energy consumption of approximately 20-25Kw/trial at ~3350 m to ~5400 m Altitude.

Ultrathin near-infrared transmitting films enabled by deprotonation-induced intramolecular charge transfer of a dopant

Near-infrared transparent films demonstrate important applications in many fields, but how to eliminate light interference from ultraviolet-visible region and how to tackle the trade-off effect between film thickness and transmittance remain as challenges. Herein, we report a near-infrared transparent film that achieves high-efficient combination of thin thickness (16 μm), suitable cut-off wavelength (890 nm), and ideal transmittance (TNIR > 90%, TVis < 1%). Moreover, the film is photo-chemically stable, heating resistance and moisture insensitive. The key component of the film is a complex of a specially designed boron compound containing a perylene monoimide unit (PMI-CBN) with an organic base 1,8-diazabicyclo[5,4,0]undec-7-ene. The complex depicts red-shifted absorption from 709 to 943 nm owing to deprotonation of the N-H group of PMI-CBN. Dispersion of the complex in polymethyl methacrylate results in the high-performance film. As demos, the film is successfully used for night vision imaging and information encryption.

Efficient anti-frosting enabled by femtosecond laser-induced salt-philic and superhydrophobic surface

Frost formation is a normal phase transition phenomenon in cold climates, while it usually brings certain troubles to human lives and production. Therefore, it is of great significance to develop frost resistant materials and key technologies. Here, a salt-philic and superhydrophobic surface is designed on a PDMS substrate by femtosecond laser direct writing technology in combination with salt–ethanol–water mixtures droplet treatment. The laser-treated PDMS embedded salt (LTP-S) surface exhibits superhydrophobicity, which alone is a property that can resist the formation of frost and enables a self-cleaning effect. Meanwhile, the salt coating further enhances the frost resistance of the surface by reducing the freezing point temperature. The LTP-S surface is revealed to perform well in frosting-defrosting cycles, washing resistance, chemical corrosion resistance, heating resistance, and long-term air exposure tests as a highly efficient and stable anti-frosting surface. This work demonstrates a facile strategy to fabricate a salt-philic and superhydrophobic surface for efficient anti-frosting.

A kinetic comparison between in situ hybrid microwave and conventional magnetising roasting of low-grade iron ore composite pellet

This article aims to comprehensively summarise the essential aspects of reduction kinetics in magnetising roasting of low-grade iron ore–coal composite pellets in the hybrid microwave and conventional furnace. The influence of crucial process parameters like temperature, time, and heating methods, including traditional and hybrid microwave heating, is explored. Investigating the impact of low-grade iron ore and coal quality on reduction kinetics is conducted to identify optimal heating methods for upgrading low-grade iron ore to blast furnace grade through magnetising roasting. The study uses diverse gas–solid reaction models to assess the reduction mechanism (Fe2O3 to Fe3O4). Results indicate the success of the contracting volume model for microwave heating, while conventional heating transitions from phase-boundary chemical control to diffusion control. XRD confirms magnetite dominance post-reduction, while scanning electron microscopy analysis establishes microwave crack-assisted efficiency over conventional heating for ease of reduction. A comparative study of apparent activation energy reveals the hybrid microwave method's four-fold lower (36.71 kJ/mol) than conventional resistance heating (156.19 kJ/mol). This underscores the potential of microwave heating for enhanced reduction kinetics and low-grade iron ore material processing applications.

Quantitative sustainability assessment for in-situ electrical resistance heating coupled with steam enhanced extraction: An effective approach for the development of green remediation technologies

There is a lack of quantitative methodology for the sustainability assessment based on field data in the process of innovative technology development for groundwater remediation. This study developed a quantitative assessment framework, a model based on the life cycle assessment integrated with best management practices (LCA-BMPs), to evaluate the environmental, economic, and social sustainability of in-situ electrical resistance heating coupled with steam enhanced extraction (ERH-SEE), an innovative technology being demonstrated in the field. The results indicated that ERH-SEE offered better environmental sustainability performance compared to ERH only, with a reduction in carbon emissions by 52.6 %. ERH-SEE also significantly reduces human toxicity, resource consumption, and ecosystem impacts under the same remediation scenarios. The further assessment indicated that if taking the renewable energy share in energy structure in different countries into consideration, higher shares of renewable energy used in energy supplies can substantially reduce the environmental footprint of the studied scenarios. The economic sustainability assessment results showed that ERH-SEE was more sustainable than ERH only, as it reduces direct economic costs by 35.7 % and provides higher levels of worker employment. Regarding the social sustainability, ERH-SEE involved more complex operational procedures and presented more health risk exposure scenarios compared to ERH only, resulting in slightly more pronounced worker safety issues. Based on the final normalized results, the overall sustainability results of ERH-SEE and ERH only were 78.4 and 61.5, respectively, demonstrating that the sustainability performance of ERH-SEE was better than ERH only. It can be concluded that the application of ERH-SEE in groundwater remediation where significant heterogeneities occur in subsurface can increase the sustainability in developing countries, due to the lower percentage in renewable electricity in the energy supply. This study provided new insights into the technology development for the remediation of soil and groundwater contamination.

Cylindrical compression of thin wires by irradiation with a Joule-class short-pulse laser

Equation of state measurements at Jovian or stellar conditions are currently conducted by dynamic shock compression driven by multi-kilojoule multi-beam nanosecond-duration lasers. These experiments require precise design of the target and specific tailoring of the spatial and temporal laser profiles to reach the highest pressures. At the same time, the studies are limited by the low repetition rate of the lasers. Here, we show that by the irradiation of a thin wire with single-beam Joule-class short-pulse laser, a converging cylindrical shock is generated compressing the wire material to conditions relevant to the above applications. The shockwave was observed using Phase Contrast Imaging employing a hard X-ray Free Electron Laser with unprecedented temporal and spatial sensitivity. The data collected for Cu wires is in agreement with hydrodynamic simulations of an ablative shock launched by highly impulsive and transient resistive heating of the wire surface. The subsequent cylindrical shockwave travels toward the wire axis and is predicted to reach a compression factor of 9 and pressures above 800 Mbar. Simulations for astrophysical relevant materials underline the potential of this compression technique as a new tool for high energy density studies at high repetition rates.

Study of Heat Distribution in Railway Switch Using Resistive Heater in Cold Climate Conditions

Study of Heat Distribution in Railway Switch Using Resistive Heater in Cold Climate Conditions

Real-scale experiments of resistive heating laminate composite panels for radiant heating in railway vehicles

Railways, as one of the representative mass transit systems, are vulnerable to highly contagious respiratory diseases due to their operation in densely populated environments. Notably, the current convective heating system creates an environment susceptible to virus transmission within railway vehicles. To improve this situation, there have been attempts to introduce radiant heating systems to reduce the risk of virus transmission and create a comfortable indoor environment. Previous studies focused on developing radiant heating composite material for railway vehicles by incorporating a carbon fiber heating element within a glass fiber composite to enable heat generation through joule heating. However, this development was limited to the specimen level. In contrast, this study aims to demonstrate their applicability and performance for actual railway vehicle parts at the component level. Specifically, resin flow and manufacturability were analyzed to assess applicability to railway vehicles. Additionally, heating performance and heat flow characteristics were evaluated to determine heating effects. Based on these results, it is anticipated that the application of multifunctional composite materials in the railway industry will improve the vulnerability to winter viruses and indoor environments and expand the utilization of multifunctional composite materials in various fields.

Decarbonization of siderite in the water-rich upper mantle

The aqueous fluids within subducted slabs have the potential to influence the form of carbonate presence and the carbon cycling process. Experiments were performed on resistive heating diamond anvil cell using siderite crystals and grains with water under conditions of pressure as high as 11.4 GPa and temperatures reaching up to 530 °C. These experiments aimed to simulate geological reactions that may occur within a depth range of 340 km in subducted slabs. Raman spectroscopy was employed to monitor the reactions and microscale phenomena within the sample chamber as pressure and temperature increase. The recovered products were analyzed using scanning electron microscopy and transmission electron microscopy. The results indicate that at 0.8 GPa and 108°C, a Fischer-Tropsch Type (FTT) reaction occurred on the sample surface, resulting in the formation of organic compound formaldehyde, followed by the observation of formic acid. At higher pressures and temperatures (3.5 GPa, 420°C), the formation of γ-Fe2O3 and γ-FeOOH was observed on the sample surface, accompanied by the release of CO2 and H2. Transmission electron microscope analysis of the quenched product powders indicated that the generated iron oxides were consistent with the phases observed at high pressure and temperature conditions. High pressure and temperature dissolution experiments of siderite in water reveal that carbon may be released into the mantle wedge entirely in the form of CO2 in warm subducted slabs and cold subducted slabs that subduct to depths of 75 km. The released CO2 participates in the carbon cycle of the island arc volcanic systems in the upper mantle at depths of 70–120 km and accelerates the transfer of subducted carbon to the Earth’s surface.

Comparison of Parabolic Troughs and Solar Photovoltaic as Solar Field Technology in Dispatchable Solar Power Plants

The use of thermal energy storage (TES) technologies, as means to provide dispatchability to thermally driven solar power production, has long stood as the main argument for the interest and potential competitiveness of Concentrated Solar Power (CSP) when compared to other non-dispatchable alternatives. Whereas reductions of the Levelized Cost of Electricity (LCOE) are observed for CSP in recent years, the notable LCOE reduction observed along this decade in large-scale solar photovoltaics (PV) plants is set to break the taboo of "power-to-heat-to-power" approaches, as its potential economic performance outcasts the associated thermodynamic inefficiency. The possibility of using available resistive heating technologies and components in PV-TES combinations, renders the configuration of a conventional CSP plant suitable for the replacement of a thermal conversion solar field by a photovoltaic field presenting further the possibility of delocalization and/or spatial distribution of the solar field (e.g. on a Carnot Battery configuration). As dispatchability no longer stands as an exclusive argument in favor of CSP over PV, the present article addresses the boundary conditions for the competitiveness of each technology as the champion of dispatchable solar power fields. The impact of both land and electrical heater costs variation in the variation of LCOE for PV-TES plants is much more modest than that observed for the impact of CSP solar field cost variations in the variation of LCOE for CSP plants, which leans for the latter and at present costs, towards better competitiveness for plant designs with a storage capacity in excess of 10.0 FLH (for GHI values in excess of 2100-2200 kWh∙m-2∙year-1).

Thermal–Electrical–Mechanical Coupled Finite Element Models for Battery Electric Vehicle

The safety of lithium-ion batteries is critical to the safety of battery electric vehicles (BEVs). The purpose of this work is to develop a method to predict battery thermal runaway in full electric vehicle crash simulation. The thermal–electrical–mechanical-coupled finite element analysis is used to model an individual lithium-ion battery cell, a battery module, a battery pack, and a battery electric vehicle with 24 battery modules in a live circuit connection. The lithium-ion battery is modeled using a representative approach, with each internal battery component individually modeled to represent its geometric shape and realistic thermal, mechanical, and electrical properties. A resistance heating solver and Randles circuit model built with a generalized voltage source are used to simulate the electrical behavior of the battery. The thermal simulation of the battery considers the heat capacity and thermal conductivity of different cell components, as well as heat conduction, radiation, and convection at their interfaces. The mechanical property of battery cell and battery module models is validated using spherical punch tests. The electrical property of the battery cell and battery module models is verified against CircuitLab simulation in an external short-circuit test. The simulation results for the battery module’s internal resistance are consistent with both experimental data and literature values. The multi-physics coupling phenomenon is demonstrated with a cylindrical compression simulation on the battery module. The multi-physics BEV model with 24 live battery modules is used to simulate the external short-circuit test and the side pole impact test. The simulation run time is less than 24 h. The results demonstrated the feasibility of using a representative battery model and multi-physics analysis to predict battery thermal runaway in full electric vehicle crash analysis.

High strength low alloy steel joint fabricated by laser welding with real-time high-frequency resistance heating

The balance between softening and hardening is still a great challenge for the laser welding of the high strength low alloy steel. For example, welding with low heat input was commonly used to avoid softening, but it would inversely harden the joint and introduce the undesired welding defects such as hydrogen-induced cracks. This work proposed a simple and robust processing technique, denominated High Frequency electric cooperated Laser Welding. Laser heat source was combined with high-frequency electric heat source to balance heat input distribution and reconcile the contradiction between softening and hardening in the welding of high strength low alloy steel. As a structural material sensitive to welding softening and hardening, S690QL steel was adopted to show the fundamental advancement of the new process. Benefitted from the skin effect and proximity effect of high-frequency current that improve the heat input distribution and the regulation of the high-frequency heat input proportion, the martensite content in the heat affected zone was greatly reduced, whilst the grain size was limited to a low value. Under the high-frequency heat input proportion of 47.1 %, lower bainite distributed throughout the heat affected zone. The softening and hardening issues of the joint therefore have been improved simultaneously: the tensile strength of the joint was almost equal to that of the base material, the impact energy of weld seam and the heat affected zone reached 77.6 J and 66.2 J respectively.

Experimental study on heat storage characteristics of an air-sand moving bed heat exchanger

The air-sand moving bed heat exchanger, designed for storing fluctuating medium-temperature gas waste heat, offers significant potential for energy conservation and carbon reduction in industrial settings. However, its operational characteristics are insufficiently explored. This study investigates the heat storage process involving direct contact and cross-flow of air and quartz sand within a rectangular heat exchanger chamber. Comprehensive analyses were conducted to explore flow resistance characteristics, temperature response, and heat storage performance. Results indicate that pressure drop increases with higher air velocity and temperature, and lower air pressure, particle diameter. The relative discrepancy between fitted pressure drops and experimental data is below 10%. The primary heat transfer zone exists during particle descent. As the air-particle mass flow ratio increases, the descent rate of this zone along the airflow direction slows. Additionally, higher air temperatures elevate the optimal air-particle mass flow ratio. With inlet temperatures for air and particles set at 350 °C and 30 °C respectively, and a mass flow ratio of 0.81, an exergy efficiency of 58.93% and a power density of 600.64 kW·m−3 are achieved. These findings offer crucial insights for air-sand moving bed heat exchangers for medium-temperature gas waste heat recovery.

TiO2/Se heterojunction photovoltaic device made from Se/Te/Se stacked precursor

This paper presents an innovative approach for forming crystallized selenium (c-Se) using a Se/Te/Se stacked precursor. The aim is to enhance the adhesion between the TiO2 and Se layers to improve the power conversion efficiency of TiO2/Se heterojunction photovoltaic devices. Our previous study revealed that the accumulation of Te near the TiO2/Se interface resulted in insufficient shunt resistance, leading to increased dark leakage current. This issue arises because Te possesses a high carrier density (∼1018 cm−3) and narrow bandgap energy (0.26 eV). However, a Te additive layer remains necessary to passivate the unbonded TiO2/Se interface and to maximize the adhesion between the absorber and the substrate. Previous research on Se-based photovoltaic devices demonstrated that an extremely thin (∼0.5 nm) and homogeneous Te adhesion layer could be formed beneath the Se photo-absorbing layer and subsequently crystallized through air-annealing post-deposition. However, achieving precise and homogeneous sub-nanometer Te films using a compact resistance heating evaporation system in a laboratory setting proved challenging so far. To address these limitations, we propose a novel technique for forming the Se absorber layer by post-annealing a stacked 1st-Se/Te/2nd-Se precursor on a TiO2 window layer. Through experimentation, we achieved the highest power conversion efficiency of 4.49 % without antireflective coating, accompanied by Voc 0.795V, JSC 11.13 mA/cm2, and FF 0.507 when the 1st-Se thickness was 5 nm. Furthermore, the impact of decreasing Te/(Te + Se) near the TiO2 window layer on photovoltaic performance was theoretically predicted using modelling by SCAPS-1D. Overall, this work introduces a promising method for enhancing the formation of c-Se, improving adhesion between TiO2 and Se layers, and enhancing the power conversion efficiency of TiO2/Se heterojunction photovoltaic devices.