Sustainable Production Methods Research Articles

Concentrated C2+ Alcohol Production Enabled by Post-Intermediate Modulation and Augmented CO Adsorption in CO Electrolysis.

The electrocatalytic synthesis of multicarbon products from CO2/CO feedstock represents a sustainable method for chemical production with a reduced carbon footprint. Traditional copper catalysts predominantly produce alkenes, but generating valuable and versatile C2+ alcohols, especially high-energy-density C3 alcohols, has been challenging due to issues with selectivity, activity, and stability. Here, we present the construction of Ru-doped Cu nanowires that enhance the selectivity of n-PrOH and C2+ alcohols. In situ Raman spectroscopy shows that our approach promotes both *CO binding and availability, particularly facilitating the formation of high-frequency-bound *CO (*COHFB) and maintaining multiple *CO adsorption modes on Ru-modified and bare low-coordinated Cu nanowires. Density-functional theory (DFT) simulations illustrate that introducing Ru species onto a low-coordinated Cu step surface simultaneously stabilizes CO and alcohol-related intermediates, shifting the dominant reaction pathway toward alcohols and facilitating CO-C2 coupling at the expense of ethylene selectivity. In an alkaline gas-diffusion electrolyzer, we attained a maximum Faradaic efficiency (FE) of 35.9% for n-PrOH and 62.4% for the total C2+ alcohols. Optimizing parameters in the membrane electrode assembly (MEA) system enabled the one-pot generation and separation of C2+ alcohols, achieving a record concentration of 18.8 wt % (4.2 wt % n-PrOH and 14.6 wt % EtOH) with nearly 100% purity at 200 mA/cm2 over 100 h. This work not only provides new insights and guidance for the development of future catalysts from the perspectives of surface science and mechanisms but also highlights the importance of coupling material engineering with reactor engineering to optimize the production process of high-value alcohol products.

Synergistic N/F Dual-Doped MoC/C Catalyst Synthesized via Liquid Phase Plasma for Sustainable Ammonia Production.

NH3 is a versatile solution for the storage and distribution of sustainable energy, offering high energy density and promising applications as a renewable hydrogen carrier. However, electrochemical NH3 synthesis under ambient conditions remains challenging, such as low selectivity and efficiency, owing to the inertness of N≡N and competing reactions. In this study, a catalyst (MoC/NFC) comprising molybdenum carbide evenly dispersed on carbon doped with N and F heteroatoms was successfully synthesized using liquid-phase plasma. The MoC/NFC catalyst exhibited a maximum NH3 yield of 115 μg h-1 mg-1cat. with a faradaic efficiency of 1.15% at -0.7 V vs reversible hydrogen electrode in 0.1 M KOH electrolyte. Pyridinic- and pyrrolic-N atoms adjacent to the carbon pores served as active sites for N2 adsorption and enabled N2 triple bond cleavage. In addition, F doping contributed to N2 activation owing to the high electronegativity of 3.98, resulting in the attraction of more electrons. These findings demonstrate a significant advancement in the development of efficient catalysts for electrochemical ammonia synthesis, potentially paving the way for scalable and sustainable NH3 production methods that can support the growing demand for renewable energy storage solutions.

PH-sensitive polymeric hydrogels coated with cobalt ferrite nanoparticles for combined drug delivery as controlled release carriers: fabrication and in-vitro estimation

In this investigation, we produced pH-responsive hydrogels for the controlled release of drugs by graft copolymerizing Gum ghatti and acrylic acid (AA) in an aqueous medium. N, N′-methylene-bis-acrylamide (MBA) and ammonium persulphate (APS) served as cross-linkers during the synthesis process. Our research explores the integration of cobalt ferrite (CoFe2O4) magnetic nanoparticles (CFMNPs) in delivering a combination drug comprising metformin hydrochloride and sodium diclofenac. The diverse applications of CoFe2O4 nanoparticles have driven the exploration of innovative and environmentally sustainable production methods. The development of novel materials for nanoparticle synthesis adheres to the principles of “Green Chemistry” through a co-precipitation technique. Characterization of the cross-linked hydrogels involved Fourier transform infrared spectroscopy (FT-IR) and X-ray diffraction (XRD) analyses. In vitro drug release kinetics were observed under physiological conditions using Ultraviolet–Visible Spectroscopy. The drug-loaded Gg-cl-poly(AA)/CoFe2O4 hydrogels exhibited a sustained drug release profile over 24 h, with significant release occurring at a pH of 4. To comprehend the drug release mechanism, we employed kinetic modeling, encompassing Zero order, First order, Higuchi model, Hixson-Crowell model, and Korsmeyer-Peppas model, for all developed hydrogels. The findings indicated that the drug release mechanism from the hydrogels followed the Korsmeyer-Peppas model. The study concludes that the developed hydrogel offers a promising solution for the controlled administration of metformin hydrochloride and diclofenac sodium.Graphical

Sustainability assessment of denim fabric made of PET fiber and recycled fiber from postconsumer PET bottles using LCA and LCC approach with the EDAS method.

The textile industry is under pressure to adopt sustainable production methods because its contribution to global warming is expected to rise by 50% by 2030. One solution is to increase the use of recycled raw material. The use of recycled raw material must be considered holistically, including its environmental and economic impacts. This study examined eight scenarios for sustainable denim fabric made from recycled polyethylene terephthalate (PET) fiber, conventional PET fiber, and cotton fiber. The evaluation based on the distance from average solution (EDAS) multicriteria decision-making method was used to rank scenarios according to their environmental and economic impacts, which are assessed using life cycle assessment and life cycle costing. Allocation, a crucial part of evaluating the environmental impact of recycled products, was done using cut-off and waste value. Life cycle assessments reveal that recycled PET fiber has lower freshwater ecotoxicity and fewer eutrophication and acidification impacts. Cotton outperformed PET fibers in human toxicity. Only the cut-off method reduces potential global warming with recycled PET. These findings indicated that recycled raw-material life cycle assessment requires allocation. Life cycle cost analysis revealed that conventional PET is less economically damaging than cotton and recycled PET. The scenarios were ranked by environmental and economic impacts using EDAS. This ranking demonstrated that sustainable denim fabric production must consider both economic and environmental impacts. Integr Environ Assess Manag 2024;20:2347-2365. © 2024 The Author(s). Integrated Environmental Assessment and Management published by Wiley Periodicals LLC on behalf of Society of Environmental Toxicology & Chemistry (SETAC).

Leguminous Green Manure Intercropping Promotes Soil Health in a Citrus (Citrus reticulata) Orchard

The intercropping of green manure is an important and sustainable production method in citrus orchards (Citrus reticulata). However, few studies focus on the impact of annual and perennial green manure on soil health, particularly soil microbiome and properties in acid soil. Our research objective was to explore the potential effects on soil health by intercropping with annual and perennial leguminous green manures in acid soil citrus orchards of southwestern China. The leguminous green manures used were alfalfa (Medicago sativa) and hairy vetch (Vicia villosa). The results showed that intercropping with green manure increased the total nitrogen, nitrate nitrogen, and available phosphorous in the soil by 48.67~74.67%, 50.00~96.67%, and 44.48~45.04%, respectively. Intercropping with alfalfa significantly increased the activity of soil sucrase 63.75%, and intercropping with hairy vetch increased the activity of β-1,4-glucosidase 44.38% in the soil compared to the monoculture treatment. Intercropping hairy vetch and alfalfa altered the diversity and composition of the soil microbial community and enriched the soil with beneficial fungi and bacteria, including Mortierella and Streptomyces. The richness increased by 58.72% and 17.90% in alfalfa intercropping treatment. In conclusion, intercropping leguminous green manure improved the nutrients and activity of the enzymes in the soil and enriched the antagonistic microbiome in the soil, promoting soil health in the citrus orchard.

Reshaping the substrate-binding pocket of acyl-ACP reductase to enhance the production of sustainable aviation fuel in Escherichia coli.

To reduce carbon emissions and address environmental concerns, the aviation industry is exploring the use of sustainable aviation fuel (SAF) as an alternative to traditional fossil fuels. In this context, bio-alkane is considered a potentially high-value solution. The present study focuses on the enzymes acyl-acyl carrier protein [ACP] reductase (AAR) and aldehyde-deformylating oxygenase (ADO), which are crucial enzymes for alka(e)ne biosynthesis. By using protein engineering techniques, including semi-rational design and site-directed mutagenesis, we aimed to enhance the substrate specificity of AAR and improve alkane production efficiency. The co-expression of a modified AAR (Y26G/Q40M mutant) with wild-type ADO in Escherichia coli significantly increased alka(e)ne production from 28.92 mg/L to 167.30 mg/L, thus notably demonstrating a 36-fold increase in alkane yield. This research highlights the potential of protein engineering in optimizing SAF production, thereby contributing to the development of more sustainable and efficient SAF production methods and promoting greener air travel.

Evaluation of methyl jasmonate as elicitor in the production of cycloartane saponins in Astragalus aitosensis in vitro root cultures

Methyl jasmonate (MeJA) treatment is known to increase the levels of plant secondary metabolites. The significant medicinal benefits of cycloartane type saponins, including immune modulation, antiviral properties, and antitumor activity, drive high global demand, making sustainable production methods economically, medically, and ecologically important. In this study the effect of MeJA as an elicitor for promoting higher accumulation of cycloartane saponins – astragaloside I, II and IV was evaluated. The experiment was conducted using biotechnological approaches for sustainable production using in vitro root cultures of the endemic plant species Astragalus aitosensis, which is known to produce rare cycloartane saponins. LC-HRESI-MS analysis was used to identify and quantify compounds. The content of astragaloside I increased significantly by 68% (118 ng/mg DW) compared to control group (70 ng/mg DW). Astragaloside II was found with 1.5 points increased amount (473 ng/mg DW), compared to control (331 ng/mg DW) and astragaloside IV production was also improved. The highest cost-efficacy concentration of the elicitor for all tested astragalosides was observed at 50 µL MeJA.

Environmental Impact of the Hungarian Swine Sector during the PRRS Eradication Program with Full Herd Replacement (2014-2022).

The Porcine Reproductive and Respiratory Syndrome (PRRS) eradication program in Hungary, implemented between 2014 and 2022, utilized complete herd replacement and the introduction of high-performance breeds to enhance production efficiency and environmental sustainability in the swine sector. As a result, the sow population was reduced by 26.2% while maintaining nearly the same number of slaughter pigs. This led to significant reductions in ammonia emissions (-145,857 kg), slurry production (-153,879 m3), nitrogen emissions (-1,409,951 kg), and overall greenhouse gas emissions (91,768,362 kg CO2eq). Additionally, the feed and water consumption were substantially decreased by 53,237,805 kg and 292,978,094 L, respectively, further lowering the sector's environmental footprint. The study demonstrates the effectiveness of customized eradication strategies and advanced breeding practices in reducing the environmental impact of animal husbandry. These findings underscore the necessity for ongoing collaboration among scientists, policymakers, and industry stakeholders to develop and implement sustainable livestock production methods. The Hungarian experience provides valuable insights into how targeted interventions can simultaneously improve production outcomes and reduce the environmental burden in the swine industry.

Enhancing production efficiency through optimizing plant density in maize-soybean strip intercropping.

Due to limited arable land resources, intercropping has emerged as an efficient and sustainable production method for increasing total grain yield per unit land area. Maize-soybean strip intercropping (MSSI) technology is being widely promoted and applied across China. However, the combination of optimal density for achieving higher production efficiency of both soybean and maize remains unclear. The objective of this study was to evaluate the differences in yield, economic benefits, land, and nitrogen (N) efficiency in MSSI systems under different densities. Five maize/soybean density combinations (67,500/97,500 plants ha-1, D1; 67,500/120,000 plants ha-1, D2; 67,500/142,500 plants ha-1, D3; 60,000/142,500 plants ha-1, D4; 52,500/142,500 plants ha-1, D5) were set under the same N input in the field experiment. The results demonstrated that optimizing the density in the intercropping system could enhance production efficiency. Increasing the density of soybean and maize significantly increased the total grain yield (D3 > D2 > D1 > D4 > D5). The D3 treatment, exhibiting the best comprehensive performance, also promoted increases in leaf area index, dry matter accumulation, and N absorption and utilization. Path analysis indicated that density had the most substantial impact on maize yield, while grain number had the greatest influence on soybean yield, with contribution rates of 49.7% and 61.0%, respectively. These results provide valuable insights into optimal field density for summer planting in MSSI, facilitating its wider adoption.

Cr-doped tri-metallic nano prism catalyst for efficient alkaline and seawater splitting

Electrochemical water splitting is one of the most promising methods for sustainable production of green hydrogen. The oxygen evolution reaction (OER) is a crucial step in the process of water splitting. However, it exhibits sluggish kinetics and requires a significant overpotential for functioning at reasonable reactionrates. The efficiency of the reaction can be enhanced by reducing the overpotential, lowering the energy barrier, and using an effective electrocatalyst. Transition metal-basedcatalysts are well studied for this purpose. Specially, nickel–cobalt (Ni-Co) based catalysts have been regarded as the best OER electrocatalysts. Therefore, several studies have been carried out to enhance the electrocatalytic efficiency of Ni-Co catalysts. While mixing other transition metals with Ni-Co is a straightforward and reliable method to improve the OER activity of Ni-Co catalysts, there is still a need for a thorough examination of the design of Ni-Co catalysts with various additional elements. Seawater electrolysis, which utilizes abundant water resources that constitute over 97% of the world’s water, is highly appealing for sustainable energy production. To achieve commercial feasibility, scientists are striving to solve challenges, such as corrosion resistance, highoverpotential, and the need for efficient and durable electrocatalysts.In this study, we fabricated a transition metal-based trimetallic catalyst (CNF), consisting of cobalt (Co), nickel (Ni), and iron (Fe). Furthermore, CNF was doped with chromium (Cr-doped CNF) and tested for the OER in alkaline freshwater and alkaline seawater. Our Cr-doped trimetallic CNF catalyst demonstrates exceptional performance in both seawater and freshwater, with overpotential of 320 mV and 280 mV at 10 mA cm−2 current density, making it a promising candidate for large-scale, sustainable hydrogen production.

Development of biocatalysts for high-value-added compounds.

High-value-added compounds, such as monoterpenoids, are an important industrial targets because they are an essential group of compounds for pharmaceutical and industrial applications. Meanwhile, the depletion of natural resources and climate change demands sustainable production methods. In recent years, biocatalysis, which allows microbial bioproduction by regio- and stereo-selective reaction under mild conditions, has been attracted researchers' attention as a possible alternative to conventional methods. In this mini-review, we focus on the identification of biotransformation pathways in the non-model microorganism Acinetobacter sp. Tol 5 using geraniol, a representative monoterpenoid, and on the construction of an unconventional bioproduction method for high-value-added monoterpenoid (E)-geranic acid, which has great potential for industrial applications. This method offers a more environmentally friendly approach and insights contribute to optimizing biotransformation and bioproduction strategies for high-value-added compounds.

Evaluation of a Sustainable Production of Encapsulated Chili Pepper Powder (Capsicum pubescens) through Convective and Vacuum Drying

Throughout the world, chili and chili powders are spices of considerable economic importance. Rocoto (Capsicum pubescens R. & P.) is a chili pepper used in Andean cuisine. Fresh chili is perishable and therefore it is convenient to protect the capsaicin, color and other bioactive compounds through preservation methods such as encapsulation. The present study systematically evaluates the technical and environmental aspects of producing encapsulated Rocoto red chili powder using three different wall materials—maltodextrin, rice protein and rice flour—in conjunction with two drying methods, namely convection drying and vacuum drying. Our technical objectives focused on developing an encapsulated product with high heat and vibrant red color, key attributes that significantly influence consumer purchasing behavior. In addition, the study aimed to mitigate the loss of polyphenols, flavonoids and antioxidant activity. After identifying the optimal conditions for each wall material and drying process, a comprehensive environmental assessment was conducted to identify the most efficient and sustainable production methods. The results demonstrate that rice flour encapsulation (20%) in conjunction with hot air drying (40 °C) represents the most efficacious method for the preservation of chili powder’s pungency. This approach resulted in a mere 24% reduction in Scoville units while maintaining the powder’s vibrant red coloration. This method not only preserved key bioactive compounds, including capsaicin, polyphenols and flavonoids, but also significantly enhanced the antioxidant capacity of the product. From an environmental perspective, this approach offers significant sustainability benefits, reducing the overall environmental impact by approximately 72% compared to vacuum drying of unencapsulated chili. The use of rice flour as an encapsulant aligns with sustainability goals, making it the most efficient option for balancing product quality and environmental performance.

An Overview of Different Water Electrolyzer Types for Hydrogen Production

While fossil fuels continue to be used and to increase air pollution across the world, hydrogen gas has been proposed as an alternative energy source and a carrier for the future by scientists. Water electrolysis is a renewable and sustainable chemical energy production method among other hydrogen production methods. Hydrogen production via water electrolysis is a popular and expensive method that meets the high energy requirements of most industrial electrolyzers. Scientists are investigating how to reduce the price of water electrolytes with different methods and materials. The electrolysis structure, equations and thermodynamics are first explored in this paper. Water electrolysis systems are mainly classified as high- and low-temperature electrolysis systems. Alkaline, PEM-type and solid oxide electrolyzers are well known today. These electrolyzer materials for electrode types, electrolyte solutions and membrane systems are investigated in this research. This research aims to shed light on the water electrolysis process and materials developments.

Improving Iron Content in Sustainable Mycoprotein Production through Seawater Fermentation

The growing global population and rising protein demand are straining freshwater resources. Fusarium venenatum (Fv) mycoprotein offers a sustainable protein alternative, with environmental efficiency and potential health benefits. However, its low iron content remains a concern, especially for vegetarians and vegans. This study introduces a sustainable approach, employing seawater as a fermentation medium for Fv production. Our analysis reveals that mycoprotein derived from SEA Fv exhibits elevated levels of sodium and calcium, with a notably high iron content (2.2 mg/100g wet weight). The sodium content, while 3.31 times higher than in non-seawater fermentation, remains within recommended daily intake parameters. No plasticizers or heavy metals were detected in the SEA Fv cell body, minimizing long-term toxicity risks from seawater use. A unique metabolite, dihydroorotic acid, was identified from an in-house library of 774 metabolites, serving as an internal biomarker for seawater-based production methods. An acute safety study condensing 600g of SEA Fv to simulate high mycoprotein digestion showed no effects on key physical behaviors or major organs, including the heart and lungs. This positions the product as a viable protein alternative with enhanced iron content, highlighting seawater-based fermentation as a sustainable method for future food production and industry progress.

Catalytic oxidation of 5-hydroxymethylfurfural to 2,5-furandicarboxylic acid using Co-N/C catalysts with stepwise base addition approach

The production of 2,5-furandicarboxylic acid (FDCA) through green reaction routes is of crucial scientific value for the production of sustainable polymers. This study explores the active centers in cobalt-nitrogen-doped carbon (Co-N/C) for FDCA production. It was established that Co-Nx synergistically along with the nitrogen-doped carbon acted as centers for 5-hydroxymethylfurfural (HMF) oxidation. This study demonstrates a sustainable method for FDCA production from HMF without using precious metals, organic solvents, and harsh basic environments. Co-N/C catalyst displayed a high FDCA yield of ∼90% in an aqueous medium under mildly basic conditions in 34 h with 100% HMF conversion. An innovative strategy of stepwise base addition has been proposed to effectively accelerate the generation reaction of FDCA. The detrimental effects of high heating rate and calcination temperature on the active centers were also thoroughly investigated. Through DFT simulations it was established that Co-Nx aided in the activation of oxygen for HMF oxidation.

Impacts of Humic Acid on Growth and Yield of Wheat: A Review

Wheat (Triticum aestivum L.) is a crucial crop, providing 20% of caloric intake for many populations worldwide. Soil organic matter, an essential component of soil, directly influences soil fertility and texture. Humic substances, derived from biomolecules' physical, chemical, and microbiological transformation, are integral to soil humus. Humic acid has become a standard method for enhancing crop growth, yield, and soil fertility. While the effects of humic acid on wheat have been extensively studied, the optimal type and application method for wheat cultivation remain undetermined. This review investigates sustainable wheat production methods using humic acid to mitigate the negative impacts of chemical fertilizers and climate change factors. Research indicates that humic acid significantly increases wheat plant growth parameters: shoot length (18%), root length (29%), shoot dry weight (76%), root dry weight (100%), and chlorophyll content (96%). Moreover, humic acid substantially improves wheat yield and yield components, including spike length (14.66%), number of spikes per square meter (28.73%), number of spikelets per spike (23.52%), and 1000-grain weight (23.90%). As a sustainable organic substance, humic acid application offers a promising approach to improving wheat production. This method could help meet the food demands of the growing global population, particularly in countries like Afghanistan, where food security is a pressing concern.

Postharvest Quality of Arugula (Eruca sativa) Microgreens Determined by Microbiological, Physico-Chemical, and Sensory Parameters.

(1) Background: Cultivating microgreens is emerging as an excellent market opportunity. Their easy, short, and sustainable production methods are the main reasons they are approved by growers. However, a feature that still prevents its further spread is the microbiological risk and their rapid senescence. The present study was conducted to evaluate the post-harvest storage and shelf life of arugula microgreens in different packaging through microbiological, physico-chemical, and sensory parameters; (2) Methods: Plants were stored at 5 °C in open air, vacuum sealed, and under modified atmosphere bags and tested at 0, 3, 5, 7, and 10 days; (3) Results: Microgreens stored in all packaging were safe for consumption within ten days. Regarding physical and chemical parameters, open packaging proved to be promising, with less weight loss and slower chlorophyll degradation. The sensory analysis demonstrated that the microgreens stored in the vacuum-sealed packaging showed a decrease in quality from the fifth day onwards for all attributes. However, the MAP presented good scores with a better visual quality, similar to the fresh microgreens.

Preparation and motion-sensing properties of ion/electron mixed conductive hydrogels fabricated by carbon-coated sepiolite nanofibers

Hydrogels have experienced significant advancements owing to their versatile applications in biomedicine, wound care, food packaging, and smart devices. The pursuit of environmentally sustainable and scalable hydrogel production methods remains a primary research objective. This study introduces an innovative hydrogel fabrication technique involving the integration of surface-modified sepiolite nanofibers with polyacrylamide (PAM), resulting in the formation of sepiolite-based composite hydrogels (PASSC). These hydrogels exhibit both ionic and electronic conductivity, along with improved mechanical properties and rheological behavior. PASSC hydrogels demonstrate remarkable fatigue resistance, maintaining mechanical integrity over 10,000 stress cycles, thereby indicating their potential for long-term applications. Additionally, these hydrogels exhibit distinctive mixed conductivity, which enhances their strain sensitivity and efficacy in strain sensing. The ability of PASSC hydrogels to accurately detect a range of movements underscores their versatility and reliability in monitoring strain changes across diverse applications.

Genome-guided bioprospecting for industrially important enzymes from a thermophilic Bacillus subtilis strain SR-7, an isolate from hot spring of Madhya Pradesh, India

The study focused on isolating thermophilic bacteria from the hot springs of Madhya Pradesh, India, with the aim of identifying strains capable of producing industrially valuable enzymes. Among the 15 isolated strains, SR-7 identified as Bacillus subtilis exhibited significant enzyme activity, leading to its selection for further investigation. Genomic analysis revealed key characteristics of SR-7, including a 3,593,163 base pair chromosome with a GC content of 44.14 %. The genome was found to contain 55 tRNA genes, four rRNA clusters, and 3744 protein-coding genes. These genes encompass essential metabolic pathways and genes responsible for thermophilic adaptation, highlighting the potential for industrial applications. Further experimentation demonstrated SR-7 have the ability to produce various enzymes of industrial significance, such as amylase, lipase, cellulase, protease, lecithinase, gelatinase, and pectinase. Importantly, enzyme production was observed across a broad pH range (6.5 to 10) and temperature spectrum, indicating the versatility and adaptability of SR-7 to different environmental conditions. The findings suggest that SR-7 holds promise as a valuable resource for the pharmaceutical and industrial sectors. Its capacity to produce thermostable enzymes suitable for a range of applications underscores its potential contribution to biotechnological processes. By harnessing the enzymatic capabilities of thermophilic bacteria like SR-7, industries can pursue more sustainable and efficient production methods, reducing reliance on traditional chemical processes and enhancing overall productivity. Further research into the enzymatic properties and genetic mechanisms of SR-7 may unveil additional avenues for its utilization in various industrial processes.

Pilot-Scale Aluminothermic Production of Silicon Alloy and Alumina-Rich Slag.

As global demand for silicon (Si) and alumina continues to surge, the significance of developing more sustainable production methods has intensified. The SisAl process represents a path-breaking approach to producing Si and alumina by utilizing side streams from the silicon and aluminum industries. In the present work, a comprehensive series of pilot-scale trials was conducted to assess the scalability and validity of the SisAl process. The influences of reductant raw materials, charging methods, input material ratios, and other processing parameters were also investigated. On coupling between thermodynamic calculations and experimental results, it was demonstrated that the SisAl process is stable and controllable at a pilot scale. The typical composition of the produced Si alloy ranges from 70 to 75 wt % Si, 15-18 wt % Ca, and 8-10 wt % Al. The produced CaO-Al2O3-based slag has a composition of 48-57 wt % Al2O3, 40-45 wt % CaO, and 3-13 wt % SiO2. Furthermore, various reductants, including Al blocks, dross, and scraps, were evaluated in the pilot trials, yielding comparable outcomes, with alloy composition differences only within approximately 3 wt % under the same parameter conditions, demonstrating the versatility of raw materials selection in the SisAl process. Moreover, it was found that acidic slag exhibited better features for future upscaling than the neutral slags, with a 5 wt % higher Si content in the alloy and a 4 wt % increase in Al2O3 content in the slag phase. Additionally, the chemical composition of the products was shown to be controllable by adjusting the stoichiometry of the input materials (Al/SiO2 ratio). As the charged stoichiometry increases from 1 to 1.2, the Si content in the alloy significantly decreases from 73 to 63 wt %, while the Al content correspondingly increases from 9 to 18 wt %. Further investigation into processing parameters, such as charging method, slag prefusion, and stirring methods, has also revealed valuable insights toward the continued upscaling of the SisAl process to a potentially innovative, sustainable, low-carbon industrial process.