Large-scale Industrial Applications Research Articles

Highly Conductive Alcohol-Processable n-Type Conducting Polymer Enabled by Finely Tuned Electrostatic Interactions for Green Organic Electronics.

Solution-processable conducting polymers open up a new era in organic electronics, fundamentally altering the processing methods of electronic devices. P-type conducting polymers, exemplified by aqueous solution-processed poly(3,4-ethylenedioxythiophene) : poly(styrenesulfonate) (PEDOT : PSS), have been successfully commercialized. However, the performance of electron-transporting (n-type) materials remains considerably poorer. One of the primary challenges lies in striking a balance between conductivity and solvent processability. At present, most n-type conducting polymers necessitate toxic solvents for processing, which contradicts environmentally sustainable principles and impedes their potential for large-scale industrial applications. Herein, we developed an alcohol-processable high-performance n-type conducting polymer, poly(3,7-dihydrobenzo[1,2-b : 4,5-b']difuran-2,6-dione): poly(2-ethyl-2-oxazoline) (PBFDO : PEOx), which utilized electrostatic interactions between PEOx and PBFDO to simultaneously achieve high conductivity and alcohol-processability. The PBFDO : PEOx films exhibited remarkable electrical conductivity exceeding 1000 S cm-1 with outstanding stability even at temperatures up to 250 °C, establishing it as a prominent green solvent-processed n-type conducting polymer that rivals the most advanced p-type counterparts. Various applications including organic thermoelectric, electrochemical transistor, and electrochromic devices were showcased, highlighting the broad potential of PBFDO : PEOx in advancing green organic electronics.

Antimicrobial Peptides: Mechanism, Expressions, and Optimization Strategies.

Antimicrobial peptides (AMPs) are favoured because of their broad-spectrum antimicrobial properties and because they do not easily develop microbial resistance. However, the low yield and difficult extraction processes of AMPs have become bottlenecks in large-scale industrial applications and scientific research. Microbial recombinant production may be the most economical and effective method of obtaining AMPs in large quantities. In this paper, we review the mechanism, summarize the current status of microbial recombinant production, and focus on strategies to improve the yield and activity of AMPs, in order to provide a reference for their large-scale production.

Design of high voltage power supply for SINEW mask

Abstract. Electrostatic Precipitation (ESP) is an effective method of removing particulates from the air. It is currently used in many large-scale industrial applications but sees little to no use in smaller-scale use-cases due to the difficulty of generating high voltage in small packages and safety concerns. This paper presents the motivation, design, and evaluation of a miniature DC high voltage (HVDC) power supply for application in small-scale ESP systems. The power supply's potential for portable ESP application is tested on The Smart, Individualized, Noncontact, Extended-Wear (SINEW) mask. The results show that the power supply operates with acceptable efficiency and generates the necessary high voltages and power necessary to drive ESP even on non-optimized geometries.

Converting Waste Polyethylene Terephthalate to High Value Monomers by Synergistic Catalysts.

Waste plastics accumulation, such as commonly used polyethylene terephthalate (PET), has caused serious environmental pollution and resource squander. Glycolysis is a reliable closed-loop PET recycling method, which limited by the high cost and complex catalysts preparation processes. Here we report a simple synergistic catalytic strategy by premixing zinc acetate and cheap alkalis in ethylene glycol, which could achieve complete glycolysis at 180 °C within 2 hours, and a bis(hydroxyethyl) terephthalate (BHET) yield of 86.4 %. This may be attributed to the free hydroxide ions not only enhancing the nucleophilicity of oxygen in ethylene glycol and making it easy to attack carbonyl groups, but also accelerating the swelling and dissolution of PET. Meanwhile, the in-situ generated Zn-glycolate and zinc oxide nanoparticles (ZnO NPs) activated the oxygen in the carbonyl group, making the carbon cations more electropositive. Further recycling experiments and techno-economic analysis indicated that our synergistic strategy significantly reduced industrial costs and expected to achieve large-scale industrial applications.

Enhancing nanofiltration performance with tannic acid and polyvinyl alcohol interlayers for improved water permeability and selective solute rejection

Global water shortages have significantly intensified the demand for efficient and sustainable water purification technologies. Nanofiltration (NF) plays a crucial role in desalination, providing distinct advantages by removing a variety of pollutants including heavy metals and organic compounds, all while consuming minimal energy. Traditional NF membranes often struggle to balance high rejection with satisfactory permeability. This study advances NF technology by utilizing polysulfone as a durable substrate and introducing tannic acid (TA)-polyvinyl alcohol (PVA) interlayer to enhance structural robustness and functional capabilities of membranes. Through streamlined one-step coating followed by precise interfacial polymerization, this approach optimizes monomer piperazine storage and dispersion on substrate, effectively controlling its diffusion rate, resulting in a thinner polyamide (PA) layer. These strategic enhancements not only lead to a significant increase in permeability to 216.3 L·m−2·h−1·MPa−1 and an impressive rejection for Na2SO4 of 99.04 % but also ensure enhanced long-term operational stability. The innovative TA-PVA interlayer sets new benchmarks for high-performance NF membranes by combining environmental friendliness with cost-effectiveness, making it ideal for large-scale industrial applications. This unique composition promotes sustainability and economic efficiency in water treatment technologies, and underscoring the vast potential for expanding the production and application of advanced NF systems.

Rational design of pulse-electrolysis protocols promotes molten-salt electrorefining

Molten-salt electrorefining (MSE) is currently the primary method for purifying many elements, offering promise for the sustainable upcycling of spent metals in the future. However, the conventional constant-current electrolysis protocol inevitably leads to deterioration of the microenvironment near the electrode, leading to reaction runaway and process inefficiency. In this work, we comprehensively studied for the first time the effect of constant- and pulse-electrolysis protocols on environmental evolution in electrode–electrolyte interfaces during the MSE of Ti, using a computer model. The results showed that compared to constant electrolysis, pulse-electrolysis protocols could effectively regulate the interfacial microenvironment and improve the electrorefining efficiency. Furthermore, a correlation between interfacial reconstruction and pulse parameters was established, indicating that the duty ratio was the key factor in inhibiting the deterioration of the interfacial microenvironment. To further verify the simulation results, the real-time morphological evolution of the electrodes during electrolysis was monitored by a novel in situ X-ray computed tomography (CT) technology under pulse-electrolysis protocols. The experimental results indicated that the pulse-electrolysis protocols enhanced the interfacial microenvironment and promoted electrolysis efficiency. Collectively, this work demonstrated that MSE could be effectively advanced by rationally designing the pulse-electrolysis protocols, facilitating its large-scale application in industry.

Realizing single-layer graphene by simultaneous crystallization and top-down etching of amorphous graphene-like carbon obtained via CVD

Continuous large-area graphene can be obtained on copper by utilizing solid polymer carbon sources (SPCS). However, the detailed conversion process and related mechanisms have been rarely reported. Here, a low-temperature chemical vapor deposition (CVD) combined with high-temperature hydrogen annealing (HTHA) method is designed to investigate the intricate evolution process from SPCS to amorphous graphene-like carbon (AGLC), and subsequently to single-layer graphene (SLG). During low-temperature CVD process, under catalysis of copper and auxiliary catalysis of hydrogen, the pyrolysis products of SPCS undergo nucleation and growth on copper, resulting in the formation of AGLC at 500 °C. During subsequent HTHA process above 1000 °C, the conversion of AGLC to continuous SLG can be achieved through simultaneous catalytic crystallization of copper and top-down etching of hydrogen, which sequentially undergoes coexistence stage of AGLC/few-layer graphene (FLG), followed by FLG formation stage. Under different stage and conditions, there exists a synergistic-competitive relationship between catalytic effect of copper and etching effect of hydrogen. The proposed conversion mechanism can provide fundamental insights into SLG synthesis via SPCS, which could facilitate further advancements in large-scale industrial applications of graphene.

Unlocking full potential of bamboo waster: Efficient co-production of xylooligosaccharides, lignin, and glucose through low-dosage mandelic acid hydrolysis with alkaline processing

Mandelic acid (MA), a natural and environmentally friendly organic acid, demonstrates high selectivity and efficiency in hydrolyzing hemicellulose, making it an excellent candidate for xylooligosaccharides (XOS) production at low acid dosages. Despite its potential, the application of MA for XOS production has not been evaluated. The study first investigated the effectiveness of MA in hydrolyzing hemicellulose in bamboo into XOS. Under optimized conditions (50 mM MA, 180 °C, 45 min), a high XOS yield of 65.9 % was achieved, with a total xylobiose and xylotriose yield of 43.5 %. Subsequent alkaline pretreatment enabled 92.1 % lignin removal from MA-pretreated bamboo. The recovered lignin exhibited a high purity of 95.2 % and retained fundamental structure and functional groups of native lignin. The resulting residue displayed enhanced crystallinity and accessibility, with reduced hydrophobicity and surface area lignin compared to untreated bamboo. At high substrate concentration of 20 %, cellulase hydrolysis resulted in a glucose conversion efficiency of 83.9 %. Overall, this integrated strategy offered an efficient approach for the co-production of valuable XOS, lignin, and glucose from bamboo. The efficient energy utilization and economic viability further highlighted the potential of this method for large-scale industrial applications, making it an attractive option for biomass valorization.

Manufacturing Single-Atom Alloy Catalysts for Selective CO2 Hydrogenation via Refinement of Isolated-Alloy-Islands.

Single-atom alloy (SAA) catalysts exhibit huge potential in heterogeneous catalysis. Manufacturing SAAs requires complex and expensive synthesis methods to precisely control the atomic scale dispersion to form diluted alloys with less active sites and easy sintering of host metal, which is still in the early stages of development. Here, we address these limitations with a straightforward strategy from a brand-new perspective involving the 'islanding effect' for manufacturing SAAs without dilution: homogeneous RuNi alloys were continuously refined to highly dispersed alloy-islands (~1 nm) with completely single-atom sites where the relative metal loading was as high as 40 %. Characterized by advanced atomic-resolution techniques, single Ru atoms were bonded with Ni as SAAs with extraordinary long-term stability and no sintering of the host metal. The SAAs exhibited 100 % CO selectivity, over 55 times reverse water-gas shift (RWGS) rate than the alloys with Ru cluster sites, and over 3-4 times higher than SAAs by the dilution strategy. This study reports a one-step manufacturing strategy for SAA's using the wetness impregnation method with durable high atomic efficiency and holds promise for large-scale industrial applications.

High-Selective Separation Recovery of Ni, Co, and Mn from the Spent LIBs Via Acid Dissolution and Multistage Oxidation Precipitation.

For recovering Ni, Co, and Mn from lithium-ion batteries, traditional chemical precipitation methods demonstrate low selectivity and significantly contribute to environmental pollution. This study proposes a separation recovery technique for transition metals, specifically Ni, Co, and Mn, from spent LIBs, involving "acid dissolution" and "multistage oxidation precipitation". More than 98 % of transition metals can be extracted from spent LIBs using a low acid concentration (0.5 M) without reducing agents. The feasibility of separating different metals via multistage oxidation precipitation, based on their different electrode potentials for oxidizing Me2+ (Me=Mn/Co/Ni), was confirmed. The combination of oxidizing agent S2O8 2- and the precipitant OH- was universally applied to the fractional precipitation of Mn, Co, and Ni respectively. About 99 % of Mn, 97.06 % Co, and 96.62 % Ni could be precipitated sequentially by changing the concentrations of S2O8 2- and the pH value of solution. XRD, XPS, XRF, ICP-MS and other methods were employed to elucidate the mechanism behind the multistage oxidation precipitation of target metal compounds, exploiting the differential electrode potentials for oxidizing Me2+ ions. This technique surpasses traditional solvent extraction in cost-effectiveness and selectivity, showing promise for large-scale industrial applications in recovering Mn, Co, and Ni.

Facile design of a crown ether-functionalized polymeric membrane for highly efficient lithium and magnesium separation during electrodialysis

Efficient separation of magnesium and lithium is essential for the extraction of lithium resources from salt-lake brines. However, the current membrane separation technologies are challenged by the membrane permeability-selectivity trade-off. Herein, we demonstrated a facile and practical approach to fabricate crown ether-functionalized polymeric membranes with excellent Li+/Mg2+ separation performance by incorporating 12-crown-4 rings into the cellulose triacetate polymer network. The tightly and regularly arranged polymer chains anchored the crown ether rings firmly in the membrane structure, thereby facilitating the formation of stable and highly selective cation transport channels inside the membrane. As a result, the prepared membrane achieved an ultrahigh Li+/Mg2+ separation factor of ∼872 and Li+ flux of 22.6 μmol m−2 s−1, which was much superior to that of commercial CIMS and reported membrane separation technologies. The good long-term stability of the fabricated membrane is promising for achieving efficient magnesium-lithium separation in large-scale industrial applications.

Distillery-Waste-Derived C-SiO2 Catalyst Support Reinforces Phenol Adsorption and Selective Hydrogenation.

Selective hydrogenation of lignin-derived phenolic compounds is an essential process for developing the sustainable chemical industry and reducing dependence on nonrenewable resources. Herein, a composite C-SiO2 material (DGC) was prepared via the stepwise pyrolysis and steam activation of the distiller's grains, a fermentation solid waste from the Chinese liquor industry. After Ru loading, Ru/DGC was used for the catalytic hydrogenation of phenol to cyclohexanol. Steam activation remarkably increased the hydrophilicity and specific surface area of DGC, introducing oxygen-containing functional groups on the surface of DGC, thereby promoting the adsorption of Ru3+ and phenol. Additionally, the large specific surface area facilitated the dispersion of the active metal. Furthermore, the steam activation of DGC promoted the graphitization of the carbon matrix and formed Si-H/Si-OH bonds on the SiO2 surface. The benzene ring of phenol interacted with the carbon matrix via π-π stacking, and the hydroxyl group of phenol interacted with SiO2 via hydrogen bonding. The synergistic interactions of phenol at the C-SiO2 interface enhanced phenol adsorption to promote the hydrogenation. Consequently, 100 % of phenol was hydrogenated to cyclohexanol at 60 °C within 30 min. Furthermore, the optimized catalyst exhibited high activity for phenol hydrogenation even after four reuse cycles. The outstanding stability of the catalyst and its requirement for mild reaction conditions favor its large-scale industrial applications.

Enhanced fatigue SN curve generation for gear bending fatigue life prediction using multi-objective optimization algorithms

This study presents a comprehensive methodology for fatigue life prediction and SN curve generation in gear systems, integrating specimen and product-level testing, simulations, and multi-objective optimization. The approach addresses the discrepancy between specimen-based testing and actual product performance through a novel multi-fidelity framework. To solve the proposed multi-objective optimization problem, several optimization algorithms were compared and analyzed, demonstrating the effectiveness of each approach in balancing different objectives. A key innovation is the development of an empirical formulation-based surrogate model, enabling efficient optimization while significantly reducing computational demands. The methodology covers both specimen and product-level testing along with simulations, offering a holistic solution for accurate fatigue life prediction. Extensive validation through experiments and comparison with commercial software confirms the reliability and practical applicability of the proposed method. This approach provides a sustainable and efficient solution for SN curve generation and fatigue life prediction in automotive gear train development, allowing for continuous improvement as new data becomes available. Its practicality and accuracy make it particularly valuable for early-stage design optimization and large-scale applications not only in the automotive industry but also in many other industries where gear fatigue analysis is critical.

Microwave-assisted catalytic dry reforming of methane with CO2 over nitrogen-doped catalysts derived from metal-organic frameworks

Dry reforming of methane (DRM) can convert CO2 into syngas for the production of fuels and chemicals, offering both environmental and energetic benefits. However, its large-scale industrial applications face challenges such as harsh reaction conditions and catalyst deactivation. In this study, metal–organic frameworks (MOFs) derived N-doped Ni-based bifunctional nanomaterials (Ni-Co/NC) were meticulously synthesized to function as microwave absorbers and catalysts. Efficient syngas production was achieved through the microwave-enhanced DRM process over Ni-Co/NC. The results showed that the Ni-Co/NC catalyst significantly increased the conversion of CH4 (∼93.2 %) and CO2 (∼94.8 %). By comparing the changes in the surface properties of the catalysts before and after N-doping, it was found that N-doping enhanced the interaction between the carrier and metal particles, improved the specific surface area and surface basicity, and inhibited the aggregation of metal particles, thereby enhancing catalytic activity. The reaction mechanism was investigated using in-situ infrared spectroscopy, revealing that the formation of intermediates such as carbonates, formates, O-H groups was crucial to improving catalytic activity and stability. Compared to conventional catalytic processes, the catalysts prepared in this study demonstrated stronger catalytic activity and stability in the microwave catalytic process.

Mild and rapid construction of Ti electrodes for efficient and corrosion-resistant oxidative catalysis at industrial-grade intensity

The development of cost-effective and corrosion-resistant catalytic electrodes for chlorine/oxygen evolution reaction (CER/OER) in large-scale industrial applications is a significant challenge. Herein, the sol–gel method is employed to achieve a uniform coating of ruthenium (Ru) doping copper (Cu) on titanium sheet (Ru + 20 %Cu@Ti), and the highly efficient industrial grade stable Ti dimensional stable anode can be quickly constructed at 723.15 K for 2 h. Cu doping reduces the vacancy formation energy of surface oxygen, promotes additional lattice oxygen vacancy assisted hydrolysis dissociation pathway, improves the selectivity and specific activity of CER at high concentration doping, and reduces the binding energy of OER intermediates (e.g., *OH, *O, and *OOH) at adjacent Ru active sites. The overpotentials require to reach the current density of 10 mA cm−2 for CER and OER were only 365 mV and 232 mV at the conditions of 5.0 M NaCl (pH = 7.0) and 1.0 M KOH + 0.5 M NaCl. More importantly, Ru + 20 %Cu@Ti demonstrates excellent stability, operates continuously for over 340h at industrial current density in neutral and alkaline electrolytes, and its strengthening life reaches 64 h, with ultra-low performance attenuation. Impressively, the designed applied electrode (8.0 cm ✕ 15.0 cm) achieves long-term CER at 0.2–0.3 A cm−2. Further industrial grade evaluation of CER shows that its chlorine extraction polarizability, enhances life and weight loss meet the requirements of industrial applications.

Efficient pure qP-wave modeling and reverse time migration in tilted transversely isotropic media calculated by a finite-difference approach

Subsurface anisotropy is commonly induced by shale layers, aligned cracks, and fine bedding and has a significant impact on seismic wave propagation. Ignoring anisotropic effects during seismic migration degrades image quality. Therefore, we derive a pure qP-wave equation with high accuracy for modeling seismic wave propagation in tilted transversely isotropic (TTI) media. However, the derived pure qP-wave equation requires a computationally expensive spectral-based method for performing numerical simulations. This is unsuitable for large-scale industrial applications, particularly 3D applications. For numerical efficiency, we first decompose the newly derived wave equation into some fractional differential operators and spatial derivatives. The spatial derivatives can be directly solved by conventional finite-difference (FD) approaches. Then, we use an asymptotic approximation to find an equivalent form of fractional differential operators, obtaining scalar operators that we can discretize with the FD method. Numerical tests show that our TTI pure qP-wave equation with an FD discretization can produce accurate and highly efficient wavefield simulations in TTI media. We also use our TTI pure qP-wave equation with an FD discretization as a forward engine to implement TTI reverse time migration (RTM). Synthetic examples and a field data test demonstrate that our TTI RTM can effectively correct the anisotropic effects, providing high-quality imaging results while maintaining good computational efficiency.

Enhanced biomass densification pretreatment using binary chemicals for efficient lignocellulosic valorization

Many effective pretreatment methods (such as dilute acid, dilute alkali, ionic liquids, etc.) have been developed for lignocellulose upgrading, but several defaults of low working mass, high sugar loss and extra cost of solid-liquid separation and water washing hinder their large-scale application in industry. Besides, the valorization of lignin-rich residue from pretreated biomass after hydrolysis or fermentation greatly contributes to the economy and sustainability of lignocellulosic biorefinery, which is usually underestimated. This study developed a densification pretreatment with binary chemicals (densifying lignocellulosic biomass with sulfuric acid (SA) and metal salt (MS) followed by autoclave treatment ((DLCA(SA-MS)), which was conducted under mild condition (121 °C) with a biomass working mass as high as 400 kg/m3. The DLCA(SA-MS) biomass achieved over 95% sugar retention, 90% enzymatic sugar conversion and a high concentration of fermentable sugar (212.3 g/L) with superior fermentability. Furthermore, bio-adsorbent derived from DLCA(SA-MS) biomass residue was highly adsorptive and suitable for dyeing wastewater treatment, providing a feasible and eco-friendly method for lignin-rich residue valorization. These findings indicated that DLCA(SA-MS) pretreatment enables the full-component utilization of biomass and boosts the economic viability of lignocellulosic biorefinery.

Enhanced Photocatalytic Hydrogen Production Activity Driven by TiO2/(MoP/CdS): Insights from Powder Particles to Thin Films.

Transitioning from powder photocatalysts to thin film photocatalysts is one of the necessary steps toward industrializing photocatalytic hydrogen production. Herein, we reported the integration of non-noble metal cocatalyst MoP decorated with TiO2 and CdS, forming TiO2/(MoP/CdS) for ultraviolet-visible light utilization. The designed powder TiO2/(MoP/CdS) composites achieved a superior hydrogen production rate of 42.2 mmol g-1 h-1, which is 30.1 times that of TiO2/CdS, performing the highest activity among the TiO2-CdS-based composite photocatalysts. Moreover, we fabricated a thin film from TiO2/(MoP/CdS) powder, which exhibited comparable photocatalytic activity for hydrogen production, achieving 35.5 mmol g-1 h-1 and maintaining long-term stability for 150 h. The outstanding performance was attributed to the ability of the TiO2/(MoP/CdS) composite photocatalysts to absorb both visible and ultraviolet light. Additionally, the heterojunction formed between TiO2 and CdS also played a significant role in the overall photocatalyst activity. This cost-effective catalyst holds promise for future large-scale industrial applications.

Rational Design and Modification of NphB for Cannabinoids Biosynthesis.

The rapidly growing field of cannabinoid research is gaining recognition for its impact in neuropsychopharmacology and mood regulation. However, prenyltransferase (NphB) (a key enzyme in cannabinoid precursor synthesis) still needs significant improvement in order to be usable in large-scale industrial applications due to low activity and limited product range. By rational design and high-throughput screening, NphB's catalytic efficiency and product diversity have been markedly enhanced, enabling direct production of a range of cannabinoids, without the need for traditional enzymatic conversions, thus broadening the production scope of cannabinoids, including cannabigerol (CBG), cannabigerolic acid (CBGA), cannabigerovarin (CBGV), and cannabigerovarinic acid (CBGVA). Notably, the W3 mutant achieved a 10.6-fold increase in CBG yield and exhibited a 10.3- and 20.8-fold enhancement in catalytic efficiency for CBGA and CBGV production, respectively. The W4 mutant also displayed an 9.3-fold increase in CBGVA activity. Molecular dynamics simulations revealed that strategic reconfiguration of the active site's hydrogen bonding network, disulfide bond formation, and enhanced hydrophobic interactions are pivotal for the improved synthetic efficiency of these NphB mutants. Our findings advance the understanding of enzyme optimization for cannabinoid synthesis and lay a foundation for the industrial-scale production of these valuable compounds.

Ultrasonic field-assisted metal additive manufacturing (U-FAAM): Mechanisms, research and future directions

Metal additive manufacturing (AM) is a disruptive technology that provides unprecedented design freedom and manufacturing flexibility for the forming of complex components. Despite its unparalleled advantages over traditional manufacturing methods, the existence of fatal issues still seriously hinders its large-scale industrial application. Against this backdrop, U-FAAM is emerging as a focus, integrating ultrasonic energy into conventional metal AM processes to harness distinctive advantages. This work offers an up-to-date, specialized review of U-FAAM, articulating the integrated modes, mechanisms, pivotal research achievements, and future development trends in a systematic manner. By synthesizing existing research, it highlights future directions in further optimizing process parameters, expanding material applicability, etc., to advance the industrial application and development of U-FAAM technology.