Reactor Pressure Research Articles

Порівняння майстер кривої з нормативним методом оцінки в'язкості руйнування металу корпусу реактора ВВЕР-1000

The paper considers the generalized temperature dependence of the stress intensity factor KJC in the WWER-1000 reactor pressure vessel metal, which was derived based on the surveillance test data for fracture toughness. The consistency of the shape of the Master curve and 95 % upper and lower confidence bounds with the experimental dependence of crack resistance parameters on temperature was studied. From the point of view of the level of conservatism and acceptability, a comparison of the normative curves of fracture toughness according to NPRR (Nuclear Power Rules and Regulations) G-7-002-86 and SOU NNEGC (Standard of organization of Ukraine, National Nuclear Energy Generating Company) 177:2019 with a 5 % confidence bound of the Master curve was carried out. The possibility of using RT0 temperature as a temperature index instead of TK for the normative fracture toughness curve of SOU NNEGC 177:2019 was considered.

Carbon Capture and Utilization Technology Development Opportunities Based on Biomethanation

The paper provides an overview of Power-to-Gas (P2G) technology using biomethanation and a proprietary biocatalyst. It addresses the issue of carbon dioxide (CO2) emissions from fossil fuel combustion and proposes the integration of Carbon Capture Utilization and Storage (CCUS) technologies with P2G processes. Currently, the integration of CCUS and P2G is in conceptual stage. The paper emphasizes the sensitivity of biocatalysts to contamination in feed gases, particularly the negative impact of oxygen on methanation processes. Findings from measurements conducted in 2022 using a lab-scale prototype approve that post-combustion technologies can be successfully integrated into P2G technologies through the utilization of biomethanation processes. Various parameters, such as Carbon Dioxide Conversion (CDC), Volumetric Methane Production (VVD), and Higher Heating Value (HHV), were calculated based on the measured datasets. The high CDC value of 96.65%(V/V) and 68.03%(V/V) of methane content indicates successful integration of the two technologies, while increasing the CO2 source and applying higher pressure in the biomethanation reactor can further enhance VVD. In conclusion, the paper highlights the potential of P2G technology based on biomethanation and its integration with CCUS processes. The results obtained from the lab-scale prototype demonstrate promising conversion rates and suggest avenues for improving VVD.

Understanding the effect of phosphorous on the ion-irradiation behaviour of RPV model steels using atom probe tomography and nanoindentation

Understanding the formation of the embrittling Mn-Ni-Si (MNS)-rich clusters in reactor pressure vessel (RPV) steels is of economic, environmental, and safety importance. Hence we investigated the influence of phosphorous (P) on the formation of MNS-rich clusters in RPV model steels employing atom probe tomography and nanoindentation tests. The atom probe tomography results show that the average number density and volume fraction of clusters decrease slightly with an increase in the bulk P content; however, higher bulk P led to a slight increase in the average diameter of the clusters. A higher amount of bulk P led to higher Cu in the clusters; suggesting synergy between Cu and P. An increase in the irradiation hardening values was observed due to higher bulk P content. This is attributed to the stabilisation of the self-interstitial atoms (SIA) clusters by P. A higher recovery for the sample containing higher bulk P indicated that the SIA clusters dissolved after post-irradiation annealing.

Morphologically tuned CuO-ZnO-CeO2 catalyst for CO2 hydrogenation to methanol.

Morphologically modified composite CuO-ZnO-CeO2 catalysts were synthesized using a single-step hydrothermal technique. The study highlights the influence of solvent on the structural and physico-chemical properties of the catalysts. Various techniques, such as XRD, FE-SEM, BET, XPS, and H2-TPR, were used to analyze the catalyst properties. Among the synthesized materials, the catalyst, prepared with a N,N-dimethyl formamide (DMF)-to-metal nitrates ratio of 20 (named as CZC-1), showed enhanced active sites in the form of surface features such as nanowire-like morphology, large surface area, low crystallite size, increased oxygen vacancies, and high CuO dispersion. A bench-scale fixed-bed flow reactor was used to examine the catalytic performance of the catalysts. At 225 °C reactor temperature, 30 bar reactor pressure, and with a space velocity of 6000 cm3 gcat-1 h-1, the CZC-1 catalyst showed 13.6% CO2 conversion and 74.1% methanol selectivity. In situ diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) analysis confirmed the carbonate-formate-methoxy reaction pathway for methanol formation using the CZC-1 catalyst.

Conversion of lignin-derived ketonic intermediate to biofuel products: Syngas-assisted vs. Conventional hydrotreating

A new strategy for the transformation of an intermediate of the lignin conversion process, namely cyclohexanone, to fuel-grade products is assessed in this study. In this regard, the conventional hydrodeoxygenation process (with pure hydrogen) was compared to an innovative one with a simulated lignin-derived syngas stream in a wide range of reaction conditions (300–400 °C, 1–15 bar, and small-to-large feed-to-catalyst ratios) and over commercial molybdenum-based (nickle‑molybdenum (NiMo) and cobalt‑molybdenum(CoMo)) catalysts. Cyclohexanone conversion, product distribution, deoxygenation efficacy, and heating value were compared in each case. Cyclohexanone was transformed into cyclohexane, cyclohexene, benzene, cresols, phenol, toluene, and bi-cyclic compounds, which are beneficial in jet-fuel processing. Increasing the reaction temperature and pressure intensified the conversion of cyclohexanone (up to 87.8% conversion at 400 °C and 15 bar over both NiMo and CoMo catalysts), whereas increasing the feed-to-catalyst ratio reduced it. Operating conditions and the reducing gas (pure hydrogen or syngas) had major impacts on the conversion of cyclohexanone, deoxygenation efficiency, product distribution, and the heating value of the final product blend. The results of this study claim that cyclohexanone conversion to fuel-grade hydrocarbons (up to 97.61% over NiMo and 74.71% over CoMo catalysts) is a beneficial route and the conventional hydrodeoxygenation process can be replaced with the syngas-assisted one with a small change in production capacity, still large positive impact on the sustainability and environmental footprints of lignin conversion to biofuels.

Dealkylation of alkylphenols in phenol oil on acid zeolites

The majority of the phenolic compounds in coal tar are alkyl-substituted phenols. To overcome the difficulty of separation, zeolites catalyzed dealkylation of alkylphenols was studied in a slurry-bed reactor. ZSM-5 displayed higher catalytic performance than other zeolites within a group of acidic zeolites with various topologies (including SAPO-34, ZSM-23, MCM-22, USY, and Mordenite). The yield of phenol gradually increased together with the zeolite acidity, but the types and yields of byproducts also increased in step with it. The pore size of the zeolites was a significant influence at similar acidity. The micropore of ZSM-5 inhibited some bimolecular processes, decreasing disproportionation/transalkylation as a result of transition state shape selection. In this study, the reaction paths of alkylphenols were investigated, based on the composition of products catalyzed by different zeolites, the distribution of products under different conditions, and the reaction process of various alkylphenols. Reaction process of alkylphenols included dealkylation, isomerization, disproportionation, transalkylation, and C-C cracking. Dealkylation took the place of isomerization as the primary reaction when the reaction temperature exceeded 350 °C. Disproportionation, transalkylation, and C-C cracking were exacerbated by excessive temperature. In addition, excessive reaction time and pressure can exacerbate side reactions, alkylphenols yields and coke deposition.

Temperature, pressure, and duration impacts on the optimal stiffening of carbonates aged in diammonium phosphate solution

Diammonium phosphate (DAP) has been proven effective in improving the stiffness of weak or acid-damaged carbonates, thereby preserving hydraulic fracture conductivity. The reaction between DAP and calcite in chalk formations primarily produces hydroxyapatite (HAP), which is stiffer than calcite. However, the optimal reaction outcomes vary greatly with factors such as DAP concentration and reaction conditions. This study investigated the DAP-calcite reaction duration, pressure, and temperature effects on the stiffness magnitude of soft Austin chalk. Also, the catalyst effect and depth of HAP formation were examined. The study involved the assessment of stiffness non-destructively (impulse hammering), mineralogy (XRD, SEM), and elemental composition (XRF). The study tested 15 different DAP-chalk reaction variations, where the pressure, temperature, aging time and catalyst addition were modified in each case. The samples' elastic stiffness distributions were then collected and compared to the pre-reaction ones. The results showed that the elastic stiffness increased in all treated samples, with an 181% maximum increase achieved after 72 h at 6.9 MPa and 75 °C. However, the pressure effect was minor compared to the temperature. The SEM images revealed different HAP morphology corresponding to different treatment conditions. Although the treated samples showed an increased intensity of phosphorus throughout the entire sample, the near-surface zone (4–6 mm) was the most affected, as inferred from the XRF elemental analysis. The study's findings can help optimize hydraulic fracturing operations in weak carbonate reservoirs, improving production rates and overall well performance.

Design and analysis of KA-130, the marine-based SMR for icebreakers

Designed for icebreakers, the KA-130 integral SMR provides a carbon-free solution for navigating the North Pole Route with nuclear propulsion. As an integral reactor, all primary components are integrated into the reactor pressure vessel, eliminating large-break loss-of-coolant accidents and enhancing reactor safety. The study evaluates its load following capability and demonstrates efficient load changes within two minutes. The safety analysis during small break loss-of-coolant accidents (SBLOCA) incorporates ship movements into the minimum critical heat flux ratio (MCHFR) calculations and includes a sensitivity analysis to identify significant scenarios. The most limiting case was the guillotine break at the safety injection line with low initial pressure, high core exit temperature and bottom-peaked core. The analysis shows that core flooding is maintained, and decay heat removal is successfully performed. Acceptance criteria, aligned with regulatory and KA-130 specific standards, ensure safety during and after SBLOCA, meeting MCHFR and collapsed water level conditions above the core.

Understanding the catalytic performance and deactivation behaviour of second-promoter doped Pt/WOx/γ-Al2O3 catalysts in the glycerol hydrogenolysis for selective and cleaner production of 1,3-propanediol

The selective aqueous-phase glycerol hydrogenolysis is a promising reaction to produce commercially useful 1,3-propanediol (1,3-PDO). The Pt-WOx bifunctional catalyst can catalyse the glycerol hydrogenolysis but the catalyst deactivation via sintering, metal leaching, and coking can predominantly occur in the aqueous phase reaction. In this work, the effect of reaction temperature, pressure and second promoter (Cu, Fe, Rh, Mn, Re, Ru, Ir, Sn, B, and P) on catalytic performance and deactivation behaviour of Pt/WOx/γ-Al2O3 was investigated. When doped with Rh, Mn, Re, Ru, Ir, B, and P, the second promoter boosts catalytic activity by promoting great dispersion of Pt on support and increasing Pt surface area. The increased Brønsted acid sites lead to selective synthesis of 1,3-PDO than 1,2-propanediol (1,2-PDO). The characterization studies of fresh and spent catalysts reveal that the main cause of catalyst deactivation is the Pt sintering, as interpreted based on XRD, CO chemisorption, and TEM analyses. The Pt sintering is affected depending on the second promoter that can either or reduce the interaction between Pt, WOx, and Al2O3. As an electron acceptor of Pt in Pt/WOx/γ-Al2O3, Re and Mn as second promoters resulted in increased Pt2+ on the catalytic surface, which strengthens the contact between Pt and γ-Al2O3 and WOx, resulting in a decrease in Pt sintering. The metal leaching and coking are not affected by the presence of second promoter. The catalyst modified with a second promoter possesses improved catalytic activity and 1,3-PDO production, however the stability continues to remain a challenge. The present work unravelled the determining parameters of catalytic activity and deactivation, thus providing a promising protocol toward effective catalysts for glycerol hydrogenolysis.

Comparison of PM-HIP to forged SA508 pressure vessel steel under high-dose neutron irradiation

Powder metallurgy with hot isostatic pressing (PM-HIP) is an advanced manufacturing process that is envisioned to replace forging for heavy nuclear components, including the reactor pressure vessel (RPV). But PM-HIP products must at least demonstrate comparable irradiation tolerance than forgings in order to be qualified for nuclear applications. The objective of this study is to directly compare PM-HIP to forged SA508 Grade 3 Class 1 low-alloy RPV steel at two neutron irradiation conditions: ∼0.5–1.0 displacements per atom (dpa) at ∼270 °C and ∼370 °C. PM-HIP SA508 experiences greater irradiation hardening and embrittlement (total elongation) than forged SA508. However, uniform elongation and approximate toughness are comparable across all irradiated materials, suggesting irradiated PM-HIP SA508 exhibits superior ductility at maximum load-bearing capacity. The irradiation hardening mechanism is linked to composition rather than fabrication method. Since PM-HIP SA508 has higher Mn and Ni concentration, it is more susceptible to irradiation-induced nucleation of Mn-Ni-Si-P (MNSP) nanoprecipitates and dislocation loops, which both contribute to hardening. Conversely, the forged material nucleates fewer MNSPs, causing dislocation loops to control irradiation hardening. These results show promise for the irradiation performance of PM-HIP SA508 and can motivate future nuclear code qualification of PM-HIP fabrication for RPVs.

Fabrication of pH-Responsive PDPAEMA Thin Film Using a One-Step Environmentally Friendly Plasma Enhanced Chemical Vapor Deposition

In recent years, there has been growing interest in pH-responsive polymers. Polymers with ionizable tertiary amine groups, which have the potential to be used in many critical application areas due to their pKa values, have an important place in pH-responsive polymers. In this study, poly(2-Diisopropyl aminoethyl methacrylate) (PDPAEMA) thin films were coated on various substrates such as glass, fabric, and silicon wafer using a one-step environmentally friendly plasma enhanced chemical vapor deposition (PECVD) method. The effects of typical PECVD plasma processing parameters such as substrate temperature, plasma power, and reactor pressure on the deposition rate were studied. The highest deposition rate was obtained at a substrate temperature of 40 °C, a reactor pressure of 300 mtorr, and a plasma power of 60 W. The apparent activation energy was found to be 17.56 kJ/mol. Based on the results of this study, uniform film thickness and surface roughness were observed in a large area. The PDPAEMA thin film was exposed to successive acid/base cycles. The results showed that the pH sensitivity of the thin film produced by the PECVD method is permanent and reversible.

Effect of non-clustering element C and Mo on irradiation-induced clustering in reactor pressure vessel steels

Commercial reactor pressure vessel steels in nuclear power plant applications contain C and other minor non-clustering elements in addition to the clustering elements of Mn, Ni and Si. However, the effect of such non-clustering elements on irradiation-induced solute clustering in ferritic steels has seldom been addressed. Herein, we reveal that a commercial RPV steel and its Fe-Mn-Ni-Si model alloy with coarse/fine grains subjected to ion irradiation exhibits different irradiation-induced clustering, particularly in chemistry, mean size, and number density of irradiation-induced MnNiSi-clusters. The different chemical compositions of the clusters indicate different thermodynamics in driving solute clustering in RPV steel and its model alloy. The different number density and size evolutions of the clusters indicate different kinetics in governing irradiation-induced clustering. The presence of C and Mo, as non-clustering elements, is primarily responsible for the different clustering behaviors of Ni, Mn and Si in the two materials exposed to ion irradiation. The research finding is of significant implication for modelling and fundamental understanding irradiation-induced clustering in commercial RPV steels.

A multiscale study on the microstructure and hardening models of the irradiation defects on reactor pressure vessel steels: Modelling and experiment

Irradiation defects are known to impede the dislocation motion in irradiated reactor pressure vessel (RPV) steels. However, consistent experimental studies of the respective irradiation defects and relevant theoretical studies of the interaction mechanism and hardening model are still lacking. In this study, the microstructure and irradiation-induced hardening of RPV steels are investigated using transmission electron microscopy (TEM)/energy-dispersive X-ray spectrometry (EDS) and molecular dynamics (MD) simulations. In A508-Ⅲ steel, 9R, twinned fcc, and other typical Cu-rich cluster structures are observed using TEM after the irradiation experiment. Based on the experimental results, MD simulations are performed to study the interactions between the dislocations and Cu clusters or voids. A mechanism diagram of the interaction mechanism coupling the effects of temperature and defect size is shown for both the Cu clusters and voids. A relevant hardening model is proposed based on the MD data, which is further discussed in relation to the macroscopic mechanical properties. Furthermore, the irradiation-induced hardening of the RPV steel is successfully predicted, which further demonstrates the reliability of the proposed unified hardening model.

Study on the Re-Aging Behavior of Cu-Rich Precipitates in a FeCu Alloy under Electropulsing.

The nanoscale Cu-rich precipitates (CRPs) are one of the most critical microstructural features responsible for degrading the mechanical properties of reactor pressure vessel (RPV) steels. The prospect of the rapid regeneration of the service performance of degraded materials through electropulsing is attractive, and electropulsing has been proven to have the application potential to eliminate the CRPs and recover the mechanical properties of RPV materials. However, few studies have investigated the secondary service issue of electropulsing. This paper provides experimental findings from microstructural investigations and property evaluations of a FeCu RPV model alloy subjected to re-aging following recovery electropulsing and annealing treatments. The evolution behavior of CRPs and the changes in the hardness of the alloy during the re-aging process after electropulsing treatment were consistent with the initial aging process, while the re-aging process of the annealing treatment group was quite different from the initial aging. The difference between the electropulsing and annealing treatment groups was that the annealing treatment failed to eliminate the precipitates completely, leaving behind some large precipitates. This work demonstrates the potential application of EPT in this field.

Numerical analysis on ammonia decomposition for hydrogen production in a membrane reactor assisted by a parabolic trough solar collector

Ammonia (NH3) has emerged as a promising hydrogen storage carrier due to its considerable hydrogen storage density, storage and transportation convenience, and zero carbon emissions during endothermic decomposition. By utilizing a parabolic trough solar collector to provide heat and integrating NH3 decomposition with a membrane reactor, a clean and sustainable method of hydrogen production can be achieved. This paper establishes a comprehensive numerical model for NH3 decomposition within a parabolic trough solar receiver/membrane reactor (PTSMR). The model incorporates heat and mass transfer in porous catalyst beds, membrane permeation, and reaction dynamics to accurately capture the intricate phenomena under actual operating conditions. Special attention is paid to the influences of inlet temperature, flow rate, flow pattern, and reaction pressure on NH3 conversion and hydrogen recovery. The results demonstrate that the temperature distribution within the PTSMR exhibits non-uniformity, and the temperature at the bottom is always higher than that at the top, especially at the outlet, where the temperature difference is more than 100K. The NH3 conversion rate in counterflow is higher than that in parallel flow, while the hydrogen recovery rate in parallel flow is higher due to the reverse permeation of hydrogen in counterflow. For a 2-mm-thickness catalyst bed, the addition of membranes increases NH3 conversion rate by 9% at a reaction pressure of 5 bar, compared to a 3% increase for an 8-mm-thickness catalyst bed. The PTSMR with a 2-mm-thickness catalyst bed obtains the optimum hydrogen yield rate.

Irradiation microstructures and hardening in commercial nuclear reactor pressure vessel steels at high extended life fluence

Nuclear reactor lifetimes up to and beyond 80 years may be limited by nano-scale Cu-Mn-Ni-Si precipitates (CRPs and MNSPs) that form under neutron irradiation in pressure vessel (RPV) steels, resulting in hardening and ductile to brittle transition temperature increases, or embrittlement. Here, Atom Probe Tomography (APT) is used to characterize precipitation in nine actual RPV steels, irradiated in the ATR-2 test reactor, to a high fluence 1.38 × 1020 n/cm2 at 292 °C and 3.68 × 1012 n/cm2 s. APT quantifies the relation between a wide range surveillance alloy Cu, Ni, Mn, and Si contents and the corresponding precipitate volume fractions, number densities, sizes, and compositions. The precipitate volume fraction (fp) is dominated by the dissolved steel Cu and Ni contents. Irradiation hardening shows the expected dependence on the √fp. The APT results also provide an opportunity to evaluate flux effects by direct comparisons with corresponding archival data from low flux surveillance irradiations. Most notably, this work establishes a strong microstructural and mechanistic foundation for the new data-driven Odette, Wells, Almirall, and Yamamoto (OWAY) model to predict high fluence RPV steel embrittlement.

Analysis of heat-loss mechanisms with various gases associated with the surface emissivity of a metal containment vessel in a water-cooled small modular reactor

In various small modular reactor (SMR) designs currently under development, the conventional concrete containment building has been replaced by a metal containment vessel (MCV). In these systems, the gap between the MCV and the reactor pressure vessel is filled with gas or vacuumed weakly, effectively suppressing conduction and convection heat transfer. However, thermal radiation remains the major mode of heat transfer during normal operation. The objective of this study was to investigate the heat-transfer mechanisms in integral pressurized water reactor (IPWR)-type SMRs under various gas-filled conditions using computational fluid dynamics. The use of thermal radiation shielding (TRS) with a much lower emissivity material than the MCV surface was also evaluated. The results showed that thermal radiation was always the dominant contributor to heat loss (48–97%), while the conjugated effects of the gas candidates on natural convection and thermal radiation varied depending on their thermal and radiative properties, including absorption coefficient. The TRS showed an excellent insulation performance, with a reduction in the total heat loss of 56–70% under the relatively low temperatures of the IPWR system, except for carbon dioxide (13%). Consequently, TRS can be utilized to enhance the thermal efficiency of SMR designs by suppressing the heat loss through the MCV.

On the reactivity and selectivity trends in the tandem Diels-Alder cycloaddition and dehydrative aromatization between dimethylfuran and ethene over solid acids

Tandem Diels-Alder (DA) cycloaddition and dehydration reactions between bio-derived furans and dienophiles offer a sustainable route potentially able to meet the growing demands of aromatic chemicals worldwide. In particular, efforts to maximize the production of p-xylene from dimethylfuran (DMF) and ethene have led to an expanding list of solid acids with, reportedly, outstanding catalytic performances. In this work, we have revisited the kinetic complexities of this reaction that are characterized by a distinct shift in the rate-limiting step depending sensitively on catalyst mass, and addressed the possible origins of reactivity and selectivity trends across a range of solid acids that hold promise for the target reaction, including aluminosilicates and a series of mesoporous metal phosphate catalysts (MOPOx; M = Sn, Ti, Zr, Hf, Nb and Ta), in both dehydration- and cycloaddition-limiting regimes. In contrast to initial p-xylene formation rates in the dehydration-limiting regime, which benefit from an increased acid strength of Brønsted acid sites, p-xylene formation rates within the cycloaddition-limiting regime are essentially unaffected by variations in acid site densities, Lewis and Brønsted acid strength, and pore confinement. Such weak dependences of DA reactivity on a multitude of acid properties provide strong hints that DA cycloaddition between DMF and ethene follows an inverse-electron-demand [4 + 2] route, most likely as a consequence of a more favorable adsorption of DMF than that of ethene on the acid sites enhancing so the electrophilicity of DMF, but not that of ethene as required by the normal-electron-demand cycloaddition. Product selectivities and carbon balances were tracked as functions of reaction time, conversion and reactant pressure or concentration to identify the side reactions and acid properties responsible for p-xylene selectivity losses and the ultimate formation of carbonaceous deposits. These findings deepen our understanding of the roles of Lewis acid sites and Brønsted acid sites for the chemical reactivities toward the DA cycloaddition, the consecutive cycloadduct dehydrative aromatization and undesired acid-catalyzed side reactions, and inform strategies to enhance DA reactivities and suppress deleterious side reactions from the standpoint of both materials and process design.

Ultrafast annihilation of irradiation-induced defects using pulsed electric current for damage performance regeneration

As the most important irradiation-induced defects, dislocation loop and copper-rich nanocluster are the major contributors to the embrittlement of the neutron-irradiated reactor pressure vessel steels. In this study, such nano-defects were introduced into the material by 3 MeV Fe ions up to the dose of 1 dpa at high temperature (290 °C) to simulate neutron irradiation. It was found that pulsed electric current can effectively reduce 95 % of irradiation-induced hardening. Correspondingly, the characterization results showed that almost all the dislocation loops disappeared and the quantity of copper-rich nanoclusters also reduced greatly at relatively low temperature (450 °C), and the process took only 20 min. Meanwhile, it was qualitatively proved by positron annihilation spectroscopy that the number of irradiation-induced vacancy-type defects and solute-enriched clusters was significantly decreased after electropulsing. Furthermore, under the pulsed electric field, the rapid annihilation of the dislocation loops due to their accelerated collision with vacancies can remove the nucleation sites of the copper-rich nanoclusters and make them become dispersed, further promoting the nanoclusters that lack nucleation sites dissolving faster. Therefore, this electropulsing treatment provides a practical ‘‘in-situ” performance repair technology to extend the service life of reactor pressure vessel steels by regulating the interaction between vacancies, interstitial atoms and irradiation-induced defects.

Novel method for recovering valuable metals from Sn ash: Vacuum carbothermal reduction-directional condensation

Sn ash recycling is an industry with positive development prospects, as it provides better-protected resources, promotes sustainable development, and lays a solid foundation for future development. In this study, an innovative vacuum carbothermal reduction-directional condensation process was developed. The thermodynamic analysis results indicated that the initial reaction pressure and temperature for the carbothermal reduction of the system was 1–10 Pa and 998–1063 K, respectively. The saturation vapor pressure, separation coefficient, and condensation temperature of Sn, Pb, and Zn in the reduced products differed significantly, and their separation could be achieved by controlling the volatilization and condensation temperatures. A single-factor experiment investigated the effects of carbon ratio, temperature, and time on the reduction efficiency, direct yield, and recovery rate. The optimal experimental conditions were the ratio of MeO to C of 4:1, temperature of 1373 K, and time of 120 min. Sn, Pb, and Zn products were obtained at different positions. This process shortens the traditional process, reduces the reduction cost of Sn, and enables the implementation of the process, making it environmentally friendly.