Modelling the direct reduction of iron is challenging

 #Modelling the direct reduction of #iron is challenging – it involves complex, multi-scale processes like phase transformations and gas transport in porous pellets. Conventional models often rely on fitting to experimental conversion data, which can leave critical mechanisms underexplored.

Ömer Kerim Büyükuslu and his colleagues developed a thermodynamically grounded pellet-scale model for H₂/CO atmospheres that captures key reaction mechanisms with fewer fitting parameters, while strictly enforcing thermodynamic limits. By adding spatially resolved microstructural data into model calibration, they reveal how reduction progresses inside the pellet.

This approach provides a tool for understanding and optimising hydrogen-based ironmaking – a key step towards greener #steel production.

#openaccess paper: https://lnkd.in/d4D89bvk

source : Max Planck Institute for Sustainable saterials

Coolbrook Achieves Breakthrough in Circular Materials: Large-Scale Pilot Successfully Cracks Plastic Waste Pyrolysis Oil

Coolbrook, a transformational technology and engineering company, has achieved a major breakthrough in circular plastics and materials by successfully cracking 100% plastic-waste-derived pyrolysis oil (py-oil) at its large-scale pilot facility using the RotoDynamic Reactor™ (RDR) technology.

As the first company globally, Coolbrook has demonstrated that 100% pyrolysis oil from plastic waste can be cracked directly in the RotoDynamic Reactor (RDR), while still delivering high yields of ethylene and propylene and maintaining stable operations. This achievement underscores the robustness and unique capabilities of Coolbrook’s electrified cracking technology in processing alternative, circular feedstocks.

#Pyrolysisoil derived from waste is an essential building block in closing the loop for plastics recycling. By proving that the RDR can handle this challenging feedstock effectively, #Coolbrook is paving the way for sustainable olefin production from end-of-life plastics.

This breakthrough builds on Coolbrook’s earlier pilot plant success at Brightlands in the Netherlands, where we demonstrated the ability to heat a range of gases, including air, steam, nitrogen, and methane to over 1000 °C using renewable electricity. Coolbrook has also successfully cracked naphtha at the pilot plant, achieving significantly increased yields compared to traditional furnaces and further proving the versatility of its technology. With the new py-oil cracking results, Coolbrook has demonstrated that its electrified turbomachinery-based process can be extended to the cracking of real-world #circularfeedstocks.

Dr. Tuomas Ouni, Head of Process Development, said, “Cracking 100% pyrolysis oil directly without the need for dilution with conventional #fossilfeedstock simplifies operations and enhances traceability of circular materials. Using Coolbrook’s RDR also delivers benefits in terms of ethylene and propylene yields compared to conventional furnaces, without any noticeable increase in coking. These results confirm the potential of Coolbrook’s RDR to play a central role in both decarbonisation and circularity in the #petrochemical industry.

The tests were conducted as part of the eLECTRO project, funded under the EU Horizon Europe programme, which aims to develop an electrified pathway for converting mixed plastic waste into light olefins. It combines advanced waste pre-treatment, electrified pyrolysis, and electrified cracking via Coolbrook’s RDR. The project aims to demonstrate sustainable, circular, and scalable solutions for the future of #plastics and petrochemicals.

source : Coolbrook

Today's KNOWLEDGE Share : Minimizing Warpage

Today's KNOWLEDGE Share

I read a recent post that was a bit misleading about minimizing warpage in the molding of unfilled polymers, like simple PP.

The post was advocating for uniform packing pressure to be the key of lower part warpage. And it was supported by pictures from simulation.

I just want to be a bit more specific and more technically correct here :

Lowest warpage in these materials will come when volumetric shrinkage is as uniform as possible, not always corresponding to the most uniform packing pressure.

In complex parts, or very variable thickness part distribution, you might have to produce occasionally somewhat non uniform packing pressure to achieve the most uniform shrinkage.

That is because shrinkage is a combination of pressure and flow-time.
When flow ceases quickly you need more pressure to achieve a certain shrinkage. When packing flow lasts longer, you will need less pressure to reach the same shrinkage.

So make sure, when looking at your Flow Analysis results, to concentrate on volumetric shrinkage results.

Also, do not forget that higher viscosity unfilled crystalline polymers (HDPE typical example) can still warp because of anisotropic shrinkage despite a uniform volumetric shrinkage.

Arkema and Catalyxx accelerate the transition to lower-carbon footprint acrylic monomers and acrylic resins

Arkema, a global leader in specialty materials, and Catalyxx, an innovator in bio-based chemicals, announce a strategic partnership. This collaboration aims to develop a new value chain for low-carbon, bio-based acrylic resins by leveraging breakthrough proprietary technology.

#Catalyxx is planning to build a first-of-its-kind industrial facility to produce #bioalcohols, including bio n-butanol, from bioethanol. These bio-alcohols, based on a patented technology validated at a demonstration plant in Seville, Spain, offer a significantly lower carbon footprint compared to fossil-based alternatives.

#Arkema is evaluating the use of these bio-alcohols as feedstocks for the commercial-scale production of #biobasedacrylicresins with lower carbon footprint. These resins will serve high-performance applications in coatings, adhesives for new energy solutions, e-mobility, living comfort, and sustainable infrastructure markets.

This project marks a key milestone in the transition toward more responsible materials and reinforces Arkema’s commitment to replacing fossil-based raw materials with #renewable alternatives—without compromising on performance.

source : Arkema

Today's KNOWLEDGE Share : How to Spot a High-Quality HDPE Container

Today's KNOWLEDGE Share

How to Spot a High-Quality HDPE Container

Not all HDPE containers are created equal. And when you're storing chemicals or running high-volume production, cutting corners on packaging isn't worth the risk.

Here’s what you should look for when choosing a quality plastic container:

🔹 Even wall thickness.

If the walls of the container are too thin in some areas, you’ll start seeing weak spots under pressure especially during transport or stacking. Our containers are moulded with uniform thickness for durability and balance.

🔹 Clean moulding with no flashing or rough edges.

Rough seams, flashing, or excess plastic around the handle or base are signs of low-quality manufacturing. These flaws can cause discomfort during handling, make stacking uneven, or even create structural weaknesses over time. You want smooth, precise lines every time.

🔹 A tight, reliable cap fit.

A loose or poorly threaded cap can mean leaks, contamination, or spills. We test every container for a secure screw fit that seals tightly and stays that way, even after multiple uses.

🔹 Proper HDPE material.

Cheap blends of recycled plastic with unknown additives can behave unpredictably in real-world conditions. We use high-grade HDPE to ensure every batch meets industry standards.

If you’ve had a container fail mid-job, you know how costly it can be. What do you look for when ordering packaging?

source : Dave Leyshon-UPack

https://u-pack.co.za/

Dave Leyshon

Today's KNOWLEDGE Share : 3D-printable transparent block copolymer resin via photopolymerization-induced microphase separation

Today's KNOWLEDGE Share

Impact-resistant, haze-free, 3D-printable transparent block copolymer resin via photopolymerization-induced microphase separation

Incorporating rubbery domains into glassy polymers is an effective route to improve toughness and impact strength. However, retaining the transparency of the composite material over a wide temperature range with enhanced mechanical attributes is challenging because of a mismatch in refractive indices with changing temperatures, limiting their applications as optical materials.

Here, we report photopolymerization-induced microphase separation as a strategy for the fabrication of transparent, temperature-resistant nanostructured polymeric materials. Taking poly(methyl methacrylate) (PMMA) as the glassy component for its renowned high transparency, we perform controlled radical polymerization upon light exposure to transform the whole polymerization mixture into a cross-linked block polymer material, where a bicontinuous nanostructure consisting of PMMA and cross-linked rubbery microdomains spontaneously arises during polymerization in situ. The facile formation of the rubbery domains, smaller than 50 nm yet 3D continuous and cross-linked, is the key to retaining transparency above 120 °C in the visible light wavelength with dimensional stability and allowing efficient stress dissipation through the large interfacial area. We further demonstrate the 3D printability of the nanostructured materials into custom shapes via direct ink writing.

DOI: https://doi.org/10.1038/s41427-025-00618-3

source : Nature

Today's KNOWLEDGE Share : How composites helped launch France’s first zero-emission cargo vessel

Today's KNOWLEDGE Share

How composites helped launch France’s first zero-emission cargo vessel

Late 2024, Paris witnessed a milestone in the history of sustainable transport: the baptism of the Zulu 06, a 55-meter-long river cargo vessel capable of carrying 400 tonnes of goods while operating entirely on hydrogen fuel cells. Developed by Sogestran Group under the European Flagships program, the Zulu 06 is more than just a ship; it is a demonstrator of what zero-emission inland transport can achieve.

Pascal Girardet, Chairman and CEO of Sogestran, emphasized the importance of this step: “If the hydrogen sector is still under construction, every stone in the building plays a role in its democratization and will ultimately allow a complete value chain to be structured. With the Zulu 06, we are taking a key step for river transport. This vessel embodies not only technological excellence but also Sogestran’s commitment to sustainable and efficient mobility.

Equipped with two 200 kW PEM fuel cells, the vessel runs on 300 kg of compressed green hydrogen at 300 bar, granting it an operational autonomy of about 500 kilometers—perfectly suited for urban distribution between Gennevilliers and Bonneuil-sur-Marne on the Seine. By drastically reducing emissions, noise, and particulate pollution, the Zulu 06 offers a vision of a cleaner logistics network embedded in metropolitan centers.

From road to river, composites at the core

Hydrogen is notoriously difficult to store and transport due to its low density and high-pressure requirements. This is where the expertise of Hexagon Purus came into play. In 2021, Sogestran selected Hexagon Purus as supplier of a 20ft Multiple-Element Gas Container (MEGC) with Type 4 composite cylinders. The choice was no coincidence. Hexagon Purus had decades of experience in hydrogen storage for road transport. As Stefan Wedowski, Product Manager Hexagon Purus, explains “in 2021, Sogestran chose Hexagon Purus as supplier for a 20ft MEGC with Type 4 composite cylinders. due to its long experience in manufacturing Multiple-Element Gas Container (MEGC) for hydrogen transportation and storage.

Meeting safety and regulatory challenges

Introducing hydrogen to inland waterways meant meeting stringent safety requirements. The collaboration between Sogestran, shipbuilders, and classification societies led to design modifications. As Wedowski recalls, “already during pre-order discussions between customer and technical sales department, the first Piping and Instrumentation Diagram (P&ID) was agreed on. During the course of the project, the design was discussed by the shipbuilder with the classification society of the vessel. In comparison to the original, additional pressure relief devices, which are no standard safety features for MEGC, were introduced.

Why composites matter

At the heart of the Zulu 06’s hydrogen storage system are Type 4 high-pressure cylinders. “The cylinders are so-called Type 4 high-pressure cylinders. They consist of an inner plastic liner, which is fully wrapped with carbon fibre. The advantages of the composite design are the low weight to payload ratio of this type of cylinders, and corrosion- and fatigue-resistant properties of the material combination,” describes Wedowski.

The composite wrapping-carbon fiber wound around the liner provides the structural resilience needed to withstand pressures up to 950 bar, while accommodating geometric changes in the liner under varying load conditions. In this respect, the Zulu 06 benefits from more than four decades of R&D in composite cylinder manufacturing, making hydrogen storage lighter, safer, and longer lasting compared to steel alternatives.

While the materials were proven, certification remained a hurdle. “As mentioned, the cylinders itself were not developed specifically for Zulu. However, the approval for the vessel included a thorough discussion of cylinder specifications and tests which were carried out during development of the cylinders,

source :JEC Composites/ Sogestran @MIGNOT Gauthier / Hexagon Purus