Modification Of Pore Structure Research Articles

Influence of geometric shape, pore structure and surface modification of recycled fine aggregate on the rheology behaviour and strength development of mortar

The complex physical properties of recycled fine aggregate affect the rheological and mechanical properties of mortar, thereby limiting its application in cement-based materials. This paper evaluated the geometric shape and pore structure of natural fine aggregate (NFA), recycled fine aggregate (RFA), and recycled fine aggregate modified by water glass (MRFA), and studied its water absorption and bulk density. The influence of complex physical properties of RFA before and after modification on the rheological behavior, strength development, and microscopic properties of mortar was analyzed. The rheological tests were carried out on the fresh mortar with 7 mixes, and the compressive strength and flexural strength of hardened mortar after curing for 3, 7 and 28 days were tested. The results shown that the modification of water glass has improved the water absorption and geometric shape of RFA to some extent, resulting in a small increase in the apparent viscosity and yield stress of recycled mortar compared to NFA mortar. When the replacement level of RFA was less than 30 %, the compressive strength of recycled mortar was 13 % higher than that of NFA mortar. As the replacement level increased to 40 %, the incorporation of water glass also helped to improve the mortar strength. The irregular geometric shape and high water absorption of RFA were conducive to achieving dense mechanical bonding and reducing the Ca/Si ratio in the interface transition zone.

Amino-modified biochar-silica hybrid aerogels with ordered pore structure templated by cellulose nanocrystals for highly efficient and selective CO2 capture

Carbon dioxide (CO2) emissions from the combustion of fossil fuels are contributing to global climate change and ocean acidification, and the development of low-cost, highly efficient CO2 capture adsorbents for the reduction of CO2 concentrations is now a matter of urgency. Herein, we developed amine-modified biochar-silica hybrid aerogels template cellulose nanocrystals (CNCs) for CO2 capture. CNCs can self-assemble into an ordered lamellar structure and maintain their original structure after calcination in N2 atmosphere. At the same time, we chemically modified the hybrid aerogels with amines. The ordered pore structure and chemical modification effectively enhanced the CO2 adsorption capacity and rate of hybrid aerogels. The test showed that our material exhibited high adsorption properties of 2.81 mmol g−1 (0 °C, 1 bar). This work offers research ideas and methods for fabricating amine-modified biochar-silica hybrid aerogels for CO2 capture.

Active carbon monoliths from soft brown coal: A systematic study of their preparation, pore structure modification and characterization

High surface area active carbons in a ‘honeycomb monolith’ (HM) configuration can be prepared directly from soft brown coal by a novel approach. Kneading the coal into a plasticine consistency enables it to be extruded in HM form, then dried, carbonized and activated, retaining its structural integrity throughout these steps. Unlike higher rank coals, soft brown coal, which inherently contains relatively high oxygen functional group concentrations and high moisture contents, develops a strong H-bonding network during kneading. This opens the way to a novel and simpler method of preparing activated carbons in a monolith configuration. A systematic study was therefore conducted to evaluate the potential of these monoliths for being converted into higher value activated carbons by a low-cost process. Carbon honeycomb monoliths HMs from brown coal were modified by carbon dioxide (CO2) activation with a uniform domain size over a wider range of activation conditions (1–3 h, 750–950 °C) and the products were characterized by N2 adsorption (surface area and porosity), SEM, TEM, Raman spectroscopy, XPS and elemental analysis. The optimum conditions for development of porosity, aromaticity and a graphitizing structure were activation at 900 °C for 3 h. Interestingly, higher temperatures did not yield additional benefits. These materials should be useful in applications requiring highly ordered carbon.

Atomistic insights into the effect of temperature on capillary transport of water molecules in epoxy-modified calcium silicate hydrate nanopore: diffusion, kinetics, and mechanism

The movement of water molecules at the atomic scale within the calcium silicate hydrate (C–S–H) gel pores serves a dual role: it creates an environment for harmful chemical reactions within the pores and functions as a carrier for the transport of detrimental ions, thereby affects the mechanical properties and durability of cementitious materials. However, direct experimental observation poses substantial challenges. This study offers new insights into how temperature (253 K, 273 K, 293 K, and 313 K) affects the capillary transport of water molecules in epoxy-modified C–S–H. The findings demonstrate that the pore size undergoes continuous changes during immersion due to epoxy clustering or detachment, resulting in three scenarios: narrowing of epoxy/C–S–H channels (253 K, 273 K), channel blockage (293 K), and complete detachment (313 K). Moreover, the interactions between water molecules and epoxy lead to epoxy detachment or cluster formation on the C–S–H surface. As the temperature increases, the interaction between C–S–H and cross-linked epoxy resin weakens. The coordination between C–S–H and epoxy resin decreases, while the coordination with water increases. This paper provides valuable insights into the transport behavior of liquids within the epoxy-modified C–S–H pores of cement-based materials. It contributes to a better understanding of how liquids move and interact within the modified pore structure, which is beneficial for enhancing the performance and properties of cement-based materials.

Enhancement of mechanical properties of oil well cement by nano-SiO2/h-BN

In this study, high-strength oil-well cement with hybrid nanosilica (NS) and nanohexagonal boron nitride (h-BN) additives was prepared to reduce effectively the environmental pollution caused by fluid leakage from oil wells owing to weakened cementing rings and extend the lifetimes of oil wells. It was confirmed that NS/h-BN can enhanced the mechanical strength of oil-well cement at 7 and 28 days. The effects of NS and h-BN on the mechanical properties of oil-well cement at 7 days (d) and 28 d were investigated by varying the nanomaterial content to determine the weight percentages of the nanomaterials that optimized the mechanical properties. The experimental results showed that the ideal ratio content of nanomaterials was 2.5 wt% NS and 0.5 wt% h-BN, and the minimum porosity measured by a low-field nuclear magnetic resonance test was 16.48%, which was 50.24% lower than that of the blank group. After 28 d of curing, the compressive, flexural, and splitting tensile strengths were 12.15 MPa/25.99%, 3.75 MPa/42.86%, and 1.39 MPa/41.25% higher than those of the blank group. The mechanical strength of the oil-well cement increased with the NS content, whereas with the increase in h-BN content, sequential rising and falling tendencies were observed. The microstructure, pore structure, and hybridization modification mechanism of the NS/h-BN oil-well cement were analyzed using X-ray diffraction, thermogravimetric analysis, and scanning electron microscopy. This high-mechanical strength and low-porosity hybrid nanomaterial oil-well cement system can provide an experimental basis for the application of novel high-strength cement types in oil fields.

Pore structure modification of ZIF-8 by ligand exchange for separation mono- and di-branched isomers of hexane via thermodynamic and kinetic mechanism

Isomeric C6 alkanes are high-quality raw materials for producing high octane gasoline. Among them, the octane number of di-branched C6 alkanes is significantly higher than that of mono-branched C6 alkanes. Therefore, efficient and economical separation of mono- and di-branched C6 alkanes has received widespread attention. Herein, ZIF-8 with mixed ligands (named as ZIF-8-IM) was successfully synthesized by exchanging some 2-methylimidazole (MIM) ligands in the framework of ZIF-8 with imidazole (IM), and the microstructure of ZIF-8-IM were analyzed from N2 adsorption. Adsorption thermodynamic and kinetic properties of n-hexane (nHEX), 3-methylpentane (3MP) and 2,3-dimethylbutane (23DMB) on ZIF-8-IM were determined by IGA-100 intelligent weight analyzer. Column breakthrough experiments were carried out to confirm the separation performance of of 3MP/23DMB binary mixture and nHEX/3MP/23DMB ternary mixture on ZIF-8-IM and ZIF-8. Results show that the microporous structure of ZIF-8 is changed by ligand exchange, which means the most probable pore diameters at 1.08 nm and 1.34 nm of ZIF-8 are converted to 1.06 nm and 1.19 nm of ZIF-8-IM. The adsorption equilibrium and kinetic characteristics of mono-branched 3MP are significantly enhanced due to the microstructural changes in ZIF-8-IM. The equilibrium adsorption capacity of 3MP on ZIF-8-IM is 1.6 times that of 23DMB, and the diffusional time constant is 4–13 times that of 23DMB. By relying on the synergistic effect of thermodynamic and kinetic characteristics, efficient adsorption and separation of 3MP/23DMB mixtures can be achieved with a separation factor of 2.24 on ZIF-8-IM. In addition, ZIF-8-IM can also achieve clear separation of nHEX/3MP/23DMB ternary mixtures, obtaining individual nHEX, 3MP, and 23DMB products. The results of this study show excellent application prospects in the production of the raw materials for high octane gasoline and molecular oil refining processes.

Nanoarchitectonics of fulvic acid based oxygen-rich hierarchical porous carbon with high specific surface area as supercapacitor electrodes

The pore structure of carbon materials strongly influences the electrochemical performance of carbon electrodes. Thus, carbon material pore structure modification methods need to be further explored to improve carbon electrode performance. In this work, fulvic acid is used as a carbon precursor to prepare oxygen-rich hierarchical porous carbon (OAHPC) by H2O2 oxidation followed by synergistic activation with KOH. H2O2 oxidation significantly increases the oxygen functional groups on the surface of the fulvic acid, which helps coordinate the KOH activation process. The prepared OAHPC has a mesopore ratio of 67.77%, a specific surface area (SSA) of 3362 m2·g−1, a total pore volume of 2.23 cm3·g−1, and an oxygen content of 34.01 wt%. The OAHPC is used as a supercapacitor electrode material in a three-electrode system. This OAHPC electrode displays a high specific capacitance of 453 F·g−1 at 0.2 A·g−1 in 6 M KOH as well as outstanding cyclic stability (86.8% capacitance retention after 5000 cycles). This method provides a new strategy for adjusting the pore structure of porous carbon materials.

Effects of zeolitic imidazolate framework-8 nanoparticles on physicomechanical properties and microstructure of limestone calcined clay cement mortar

The limitations of limestone calcined clay cement (LC3) include its low mechanical strength and high drying shrinkage, in addition to its durability, which has not been addressed well in previous studies. Therefore, the objective of the present study was to investigate the feasibility of enhancing the durability and physical and mechanical properties of LC3 mortar by incorporating zeolitic imidazolate framework-8 (ZIF-8) nanoparticles. Six mixes of LC3 mortar with 0, 0.1, 0.3, 0.5, 0.7, and 0.9 wt% ZIF-8 were prepared and tested. The microstructure of the LC3-ZIF-8 mortar was characterized using X-ray diffraction (XRD), scanning electron microscopy (SEM), and Raman spectroscopy. The optimal ZIF-8 content was 0.5 wt%, at which the workability was significantly reduced, and the tensile and flexural strengths were increased. Although the LC3-ZIF-8 mortar exhibited a lower compressive strength than the unmodified LC3 mortar, the former had higher flexural and tensile strengths because of the positive effect of ZIF-8 on promoting calcium hydroxide (CH) and monocarboaluminate (Mc). These findings were consistent with the SEM, XRD, and Raman spectroscopy results. The water absorption and drying shrinkage rates of the LC3-ZIF-8 mortar were lower than those of the unmodified LC3 mortar owing to the modification of the LC3 mortar pore structure upon the addition of ZIF-8 nanoparticles. This study provides a better insight into the feasibility of utilizing ZIF-8 nanoparticles as reinforcement for LC3-based materials.

The Effect of Cementitious Materials on the Engineering Properties and Pore Structure of Concrete with Recycled Fine Aggregate.

With the rapid development of urbanization, the construction industry consumes a lot of cement and produces a large amount of construction waste. To overcome this situation, the rational use of recycled aggregate produced from waste concrete is one of solutions. In some countries, the building industry has approved the use of recycled coarse aggregates in concrete, with some limits. However, practically all existing standards and regulations prohibit the use of recycled fine aggregate (RFA) in concrete. Therefore, study on improving the performance of RFA concrete is vital. In this study, the effects of fly ash and GGBS on concrete with RFA were investigated. Compressive strength, pore structure, drying shrinkage and accelerated carbonation were tested. The correlation between the pore structure and properties of concrete was analyzed. The results show that adding fly ash and GGBS to RFA concrete increased its compressive strength, modified pore structure, reduced drying shrinkage, and even achieved higher compressive strength and lower drying shrinkage than normal concrete. The compressive strength was mainly affected by the capillary pores, and the carbonation was mainly affected by the gel pores.

Use of Magnesium Silicate Contaminated with Organic Compounds in Ceramic Materials as a Pore Modifier.

This study investigated the use of organic compound waste (OCW) contaminated magnesium silicate/diatomite in ceramics. Substituting part of the clay (between 5 and 20 wt.%) with OCW modifies a pore structure and enhances the ceramic product's thermal conductivity, density, and frost resistance. Prepared samples were tested at 1000-1060 °C temperatures and their structural parameters and Maage factor, useful for frost resistance prediction, were evaluated. Results show that OCW modifies the porous structure and improves the insulating properties of the ceramic body. Increasing OCW content up to 15% in the ceramic body decreases density by up to 15.0%, and thermal conductivity by up to 42.5%, because of the modified pore structure. According to structural parameters calculation, the higher frost resistance can be predicted for ceramic bodies containing 5-10% of OCW, according to Maage factor calculation ceramic bodies containing 5-20% of OCW are frost resistant. Designed ceramic products can be attractive for use in construction due to improved energy efficiency and reduced energy consumption in buildings due to their low thermal conductivity, satisfactory mechanical strength, and sustainability based on predicted frost resistance.

Effect of multi-walled carbon nanotubes on durability of high-strength slag-based geopolymer

The effect of multi-walled carbon nanotubes (MWCNTs) on the durability of high-strength slag-based geopolymers was investigated. The control variables were the MWCNT content and MWCNT/dispersant and water-cement ratios. A total of 144 specimens were exposed to carbonization, freeze-thaw cycles, and chloride migration (RCM). The microstructure of the geopolymers before and after durability testing was observed using scanning electron microscopy (SEM). The modification of pore structure of geopolymer by MWCNTs was measured by mercury intrusion porosimetry (MIP). The composition of the materials was analyzed using X-ray diffraction (XRD), and the contents of the materials were determined quantitatively using thermal gravimetric analysis (TG). When the MWCNT content and water-cement and MWCNTs/sodium dodecyl sulfonate (SDS) ratios were 0.45 wt%, 0.55, and 2.5:1, respectively, the carbonization depth and carbonization strength of the geopolymers were 69% and 176% of those the control group, respectively. The loss rate and relative dynamic elastic modulus after freeze-thaw were 28% and 121% of those of the control group, respectively. The Cl− diffusion depth and diffusion coefficient were 63% and 84% of those of the control group, respectively. Water-cement ratio affected the internal structure and crystallinity of geopolymer. MWCNTs mixed with SDS to modify geopolymers, the main function of MWCNTs was to densify the matrix and improve the internal cracks and pores. However, the excess SDS caused structural foaming and reduced the durability of the geopolymer.

CO2 capture from biogas by biomass-based adsorbents: A review

• Recent advances in biogas upgrading by biomass-based adsorbents are reviewed. • An overview of the production process through activation, and characteristics of adsorbent. • Recyclability and selectivity of biomass-based adsorbents for CO 2 capture have been studied. • Selection of appropriate chemical additives can be considerably enhanced the CO 2 adsorption capacities. Biogas is one of the most important renewable energy sources containing methane, carbon dioxide, and small amounts of other gases and water. Raw biogas cannot be used because CO 2 and other inert gases reduce the energy content of biogas and calorific value. Biogas upgrading significantly improves the quality of biogas by removing CO 2 . One of the leading technologies of biogas enrichment is using an adsorption method on activated carbons due to their high selectivity for removing CO 2 . Activated carbon is a good choice due to its high adsorption capacity at atmospheric pressure, lower cost, hydrophobic properties, high surface area, and the ability to modify pore structure and surface performance. On the other hand, the massive production of agricultural waste and biomass negatively affects the environment, so recycling biowaste into valuable materials is essential economically and environmentally. To recycle and convert biowaste, activated carbon is simply made through carbonization and can be used as suitable adsorbents for separating gaseous mixtures, including CH 4 /CO 2 . In this review, bio-based adsorbents were investigated in porosity, morphology, composition, selectivity, and CO 2 capture to upgrade biogas.

Effects of microplastics on evaporation dynamics in porous media

Microplastics (MPs) pollution is an emerging threat to soil ecosystems. The present study aims to investigate the impacts of MPs on soil water evaporation dynamics and patterns. Two series of laboratory experiments were conducted using sand particles and clay mixed with different MPs to investigate how evaporation dynamics and patterns are influenced by the presence of MPs. Quartz sand including 0, 0.75, 1.5, and 4.5% of Polyethylene (PE) and Polyvinylchloride (PVC) were used to evaluate MPs effects on evaporation rates while bentonite mixed with sand and 0, 0.75, 1.5, 4.5, 6, 8, and 10% of PE and PVC were used to investigate evaporation-induced cracking patterns. The experiments were conducted under controlled laboratory conditions in a climate chamber at constant ambient temperature. Our results suggest that the addition of MPs led to more water evaporation compared to the samples without MPs. Microscopic imaging and analysis enabled us to evaluate the possible MPs effects on the modification of soil characteristics and pore structure affecting the evaporation behavior. Moreover, although increasing MPs concentrations appeared to induce only minor effects on the crack morphology formed as a result of evaporation from the mixture of sand and bentonite, the type of MPs (PE vs PVC) had more notable effects on the drying-induced cracking patterns. The reported experimental data and analysis extend our physical understanding of the parameters influencing soil water evaporation in the presence of MPs.

The preparation and property analysis of B4C modified inorganic amorphous aluminum phosphates-based intumescent flame retardant coating

In response to high environmental requirements, an incombustible inorganic intumescent flame retardant coating was prepared from amorphous aluminum phosphate emulsion as the matrix, with boron carbide as the modifier. The influence of boron carbide (B4C)on the fire resistance performance and physic-chemical properties of coatings were studied by means of large panel combustion method, smoke density test, Fourier transformed infra-red analysis (FTIR), thermogravimetric analysis (TGA), X-ray diffraction (XRD), scanning electron microscopy (SEM), specific surface area (BET method) and pore size analysis. With the addition of 0.75 wt% B4C, the backside temperature of APB3 coating (aluminum phosphate-based coating modified with 0.75 wt% B4C) after an hour was only 140 ℃, 33.4 % lower than that of blank APB0 coating. And the smoke density (Ds) of APB3 was only 64.73 %, 36.3 % lower than that of blank APB0. The foaming expansion caused by decomposition reactions, the structural improvement caused by boron carbide oxidation, and the formation of ablative resistant ceramics and glass were the main reasons for excellent flame retardant and thermal insulation performance. Remarkably, the melting B2O3 generated from the oxidation of B4C could repair cracks, modify pore structure, improve the integrity of closed pores, increase the specific surface area of porous structure, and promote the formation of borosilicate glass. Due to the structural integrity of the outermost coating surface caused by the oxidation of B4C and the construction of borosilicate glass, much gas was shielded inside the coating, making the coating more eco-friendly. Besides, APB3 coating has good water resistance. After immersion in water for 360 h, the reduction rate of fire resistance performance of the coating was only 17.1 %. This work provides theoretical guidance for broadening the types of intumescent coatings and promotes the development of inorganic green coatings.

Fibrous porous mullite ceramics modified by mullite whiskers for thermal insulation and sound absorption

In order to meet the demand for thermal insulation and sound absorption, fibrous porous mullite ceramics (FPMC) with high porosity and an interconnected pore structure were prepared, followed by a pore structure modification with in situ grown mullite whiskers on the three-dimensional framework of the FPMC. The resultant hierarchical material exhibited superior sound absorption performance in the low-to-medium frequency to most reported sound-absorbing materials, as well as a sufficient compressive strength of 1.26 MPa with low thermal conductivity of 0.117 W·m−1·K−1. Moreover, the effects of solid content and mullite whiskers on the microstructure and physical properties of the material were analyzed. The increase of solid content led to increased compressive strength and thermal conductivity and decreased frequency corresponding to the first sound absorption peak. The thermal conductivity and compressive strength of the material increased as the mullite whiskers grew, while the median pore size decreased.

Pore structure modification and characterization of carbon adsorbent prepared by high-sulfur anthracite blending coal

ABSTRACT High sulfur anthracite has high research value and application prospects in the preparation of carbon adsorbent due to its excellent coal quality conditions, but the pore structure changes and sulfur migration dynamics in the preparation process are not clear. In this paper, using SEM, pore structure analysis, Raman, FTIR and XPS, the feasibility of preparing carbon adsorbent from high-sulfur coal blending was analyzed from the perspective of apparent morphology, pore structure parameters, graphite crystal structure, and functional groups and content, while the occurrence form of sulfur in carbon adsorbent was explored. The results showed that the carbon adsorbent prepared from high-sulfur anthracite was mainly microporous, and the specific surface area was up to 1103.23 m2/g, which was the highest among the known high-sulfur coal materials. The degree of disorder of raw coal and the size of graphite crystal particles synergistically formed a rich pore structure. Sulfur in coal mainly exists in the form of thiophene and sulfide. An increase in the bituminous coal proportion promotes the transformation of carbon adsorbent to an alkaline environment. Thiophene sulfur is removed at 900°C, and sulfide is transformed into sulfoxide and sulfone under steam oxidation and Fe catalysis.

Enhancement of perovskites performance for coal tar decomposition by pore structure and acid-base modification

Catalytic cracking is an efficient way to replace conventional combustion to remove coal tar deposited at the gas outlet of COREX melter gasifier. This work prepared a series of LaNi0.8Fe0.2O3 perovskites (Ni 0.8) with different pore structures via the hard-template method and applied in the catalytic cracking of coal tar was operated at 700 °C to evaluate the performance of perovskites. Ni 0.8 prepared via MCM-48 template (MCM-0.8) exhibited the high specific surface area (SSA) of 90.2 m2/g and pore volume of 0.3 cm3/g, accounting for its highest gas yield (51.8 mmol/gcoal) and complete tar removal. The remarkable oxidation capacity of MCM-0.8 resulted in its highest CO2 yield (11.2 mmol/gcoal) and selectivity for oxygenated compounds in tar (71.1 %). Three mesoporous Ni 0.8 participated in the catalytic reactions as the acid-base bifunctional catalysts. Ni 0.8 prepared via SBA-15 template (SBA-0.8) showed a great hydrocracking activity due to its strongest acidity of 1.87 mmol/g. All the synthesized perovskites possessed a good reactant selectivity, and the tarry product selectivity over different perovskites was influenced by the synergistic effect of acidity and the reactant diffusion inside the catalyst channels.

Pore Structure Modification of Pitch‐Derived Hard Carbon for Enhanced Pore Filling Sodium Storage

The pore structure of hard carbon has an important influence on its sodium storage performance. Herein, pitch‐derived hard carbons with different pore structures have been prepared via the combination of physical activation and vapor carbon coating. It reveals that the open pores favor the slope capacity while the closed pores can promote the plateau capacity, which consolidates the pore‐filling mechanism of hard carbon during the sodium storage in the plateau region. HC1400‐5 h@PP with rich closed micropores can deliver a reversible specific capacity of 299.1 mAh g−1 with initial Coulombic efficiency of 81.1%. The plateau capacity accounts for 66.6% of the total capacity. Ex situ Raman and galvanostatic intermittent titration investigations show that there exists an energy barrier for the Na deposition in the closed pores, leading to the rapid decay of plateau capacity at a high current density.

A comparative study of micro-CT and mercury intrusion techniques for predicting permeability and surface area evolution during chemical dissolution

In this paper, we report on experimental and computational studies investigating the evolution of pore structure and permeability of a microporous carbonate rock during chemical dissolution using information provided from X-ray micro-computed tomography (µ-CT) and mercury intrusion porosimetry (MIP) techniques. We consider a chemical dissolution in a core sample by a nonacidic solution wherein a quasi-uniform modification of pore structure occurred. First, we conduct a comparative analysis on the capabilities and limitations of the µ-CT and MIP methods to quantify the evolution of pore size and pore surface area. In particular, we incorporate micropores into the calculations of the pore size-related parameters to highlight the uncertainties that ignoring microporosity causes. In the second part of the paper, we present predictive results on the fractional changes in the permeability of the rock using the Katz-Thompson (KT) and Kozeny-Carman (KC) models. The predictions are based on two characteristic parameters of the pore phase, i.e., the critical pore diameter and the specific pore surface area, and two characteristic macro-scale properties, i.e., porosity and formation factor, all calculated from both the MIP and µ-CT methods. The predicted changes in permeability are compared with those calculated directly on the images using the lattice-Boltzmann (LB) flow simulation on segmented images. The effect of changes in microporosity is also assessed to investigate its role in permeability evolution. The results showed that the KT model could reasonably predict the fractional changes in permeability in terms of the pore structure and macroscale parameters calculated from the MIP and µ-CT methods.

Utilization of coal liquefaction solid residue waste as an effective additive for enhanced catalytic performance

The co-liquefaction of lignite and heavy residues is regarded as a promising technique for upgrading inferior feedstock, but is limited in the long-term by several engineering challenges that must be overcome before commercialization, in particular to the excessive catalyst consumption and production of solid residue (SR) waste. Herein, the SR waste was transformed into a favorable catalytic additive via a simple activation method that simultaneously decreased the required hydrogenation-catalyst dosage and enabled the resulting hazardous wastes to be utilized. The inorganic minerals contained within coal had a positive influence on the hydro-conversion of the co-liquefaction system and the dispersion of SRs, which motivated us to exploit the enriched minerals in SRs by further activation treatments. The application of activated SRs as cheap additives resulted in an enhanced catalytic performance in co-liquefaction reactions, with a sharp decrease in the required hydrogenation catalyst dosage of nearly 60%. The exposure of iron sulfides in activated SRs following the partial removal of organic carbonaceous matter and silica-alumina minerals provided additional catalytic activity for promoting hydrogenation reactions and aromatic-aliphatic bond cleavages. Furthermore, the modified pore structure of activated SRs with a sharply increased surface area was beneficial for restricting coke deposition on the surface of hydrogenation catalysts and reacted coals, and thus improved the catalytic environment of reaction systems with a relatively economic catalyst dosage.