Particuology最新文献_第3页

Modelling of dry manufacturing of LFP cathode filaments with twin-screw extruder using the Discrete Element Method 用离散元法对双螺杆挤出LFP阴极灯丝干式加工进行建模

IF 4.3 2区材料科学 Q2 ENGINEERING, CHEMICAL

Particuology

Pub Date : 2025-12-11 DOI: 10.1016/j.partic.2025.11.020

Kaize Shi , Ali Hassanpour , Meisam Babaie , Masoud Jabbari

Material extrusion is a key step in the solvent-free fabrication of lithium-ion battery (LIB) electrodes, offering reduced costs and environmental impact compared to slurry-based methods. While discrete element method (DEM) based mesoscopic models have been used to study twin-screw extrusion, the microstructural characterisation of extrudates immediately after nozzle exit remains unexplored. In this study, a series of DEM simulations were conducted to perform a sensitivity analysis of the microstructure and electrochemical performance-related parameters of extruded electrode filaments by varying the feeding rate and feeding mode, screw rotational speed, and particle cohesion. Furthermore, this work addresses the previously unexamined phenomenon of filament expansion during extrusion. By introducing the Augmented Dickey-Fuller (ADF) method, the study also provides the first analysis of the temporal dynamic stability of filament quality during the dry electrode manufacturing extrusion process. The results show that increasing the screw speed from 100 to 500 RPM reduces porosity by 10 % and limits expansion, while lower speeds improve consistency in electrode quality. A novel approach to quantifying dynamic behaviour is proposed, offering insights for optimising solvent-free electrode manufacturing.

材料挤压是无溶剂制造锂离子电池（LIB）电极的关键步骤，与基于浆料的方法相比，可以降低成本和对环境的影响。虽然基于离散元方法（DEM）的细观模型已被用于研究双螺杆挤压，但挤出物在喷嘴出口后的微观结构特征仍未被探索。在本研究中，通过一系列DEM模拟，通过改变进料速率和进料方式、螺杆转速和颗粒内聚力，对挤压电极细丝的微观结构和电化学性能相关参数进行敏感性分析。此外，这项工作解决了以前未检查的现象，长丝膨胀期间挤压。通过引入ADF （Augmented Dickey-Fuller）方法，首次分析了干电极制造挤压过程中长丝质量的时间动态稳定性。结果表明，将螺杆转速从100转/分提高到500转/分，气孔率降低了10%，并限制了膨胀，而较低的转速提高了电极质量的一致性。提出了一种量化动态行为的新方法，为优化无溶剂电极制造提供了见解。

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引用次数: 0

Multi-objective optimisation of dual inlet cyclone separator using response surface methodology 基于响应面法的双入口旋风分离器多目标优化

IF 4.3 2区材料科学 Q2 ENGINEERING, CHEMICAL

Particuology

Pub Date : 2025-12-10 DOI: 10.1016/j.partic.2025.12.004

Saikat Barua , Mohammad Zulafif Bin Rahim , Qingqing Liu

Given the growing emphasis on sustainable industrial practices and regulatory constraints on particulate emissions, enhancing cyclone separator performance remains a critical area of research for ensuring the high-efficient solid-gas separation with minimal energy penalties. This study presents a comprehensive numerical investigation and multi-objective optimisation of a dual-inlet cyclone separator to enhance the particle collection efficiency while minimizing the pressure drop. The Eulerian-Lagrangian approach is employed using the RNG

k - ε

turbulence modelling, coupled with the Discrete Phase Model for particle tracking. Key geometric parameters, including the inlet height to width, vortex finder angle, vortex finder diameter, barrel height, cone height, and bin diameter, are systematically varied to analyse their effects on the cyclone performance. Two optimal factors are tested among the three most significant factors at once to evaluate their combined effects on the collection efficiency and the pressure drop. Results indicate that the optimised cyclone design improves average collection efficiency by 11.5 % across particle sizes, reduces the Euler number by 50.96 %, and lowers the particle cut-off diameter by 16.15 %, while maintaining a balanced trade-off with the pressure drop. The prediction errors for the pressure drop and the collection efficiency are within acceptable limits at 11 % and 3.5 %, respectively. The improved geometry strengthens the tangential flow and moderates the peak axial velocity, resulting in a more effective centrifugal separation for fine particles.

鉴于对可持续工业实践的日益重视和对颗粒排放的监管限制，提高旋风分离器的性能仍然是确保以最小的能源损失实现高效固气分离的关键研究领域。本文对双入口旋风分离器进行了全面的数值研究和多目标优化，以提高颗粒收集效率，同时最小化压降。欧拉-拉格朗日方法采用RNG k-ε湍流模型，并结合离散相位模型进行粒子跟踪。系统地改变了主要几何参数，包括入口高度与宽度、涡流探测仪角度、涡流探测仪直径、桶高、锥高和料仓直径，以分析它们对旋风分离器性能的影响。在三个最重要的因素中同时测试两个最优因素，以评估它们对收集效率和压降的综合影响。结果表明，优化后的旋风分离器设计使不同粒径的平均收集效率提高了11.5%，欧拉数降低了50.96%，颗粒截止直径降低了16.15%，同时保持了与压降的平衡权衡。对压降和收集效率的预测误差分别为11%和3.5%，均在可接受范围内。改进的几何形状加强了切向流动，缓和了轴向速度峰值，从而更有效地对细颗粒进行离心分离。

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引用次数: 0

Preparation of cold-bonded ceramsite based on particle packing theory and high-efficiency utilization of granite powder 基于颗粒充填理论及花岗岩粉体高效利用的冷粘陶粒制备

IF 4.3 2区材料科学 Q2 ENGINEERING, CHEMICAL

Particuology

Pub Date : 2025-12-09 DOI: 10.1016/j.partic.2025.12.002

Hongqiang Li, Hui Li, Yueyao Zhao, Hongbo Cui, Wukui Zheng

The utilization of granite powder (GP) is substantially limited by its low pozzolanic activity and inert structure, posing a significant challenge for its high-volume incorporation. This study conducts experimental research on cold-bonded ceramsite based on the GP–fly ash–cement system, adopting the modified Andreasen–Andersen (MAA) particle packing model as a tool for mix ratio design and evaluation. By designing multiple groups of different particle size combinations, the raw material particle gradation is made to produce controllable deviations from the MAA target curve within a certain range. RSS is used to quantitatively characterize the degree of deviation of the particle gradation from the MAA target curve, and the influence mechanism of this deviation on the physical properties and pore structure of ceramsite is systematically analyzed. The results indicated that an RSS value of 6736 yielded the most compact ceramsite structure, which exhibited a cylinder compressive strength of 5.76 MPa, a bulk density of 1041 kg/m³, and a water absorption as low as 12.65 %. Further particle size fractionation experiments revealed that single-size raw material systems performed significantly worse than full-range particle distributions. The latter facilitated the formation of a skeleton–filler collaborative structure, thereby enhancing compactness and mechanical stability. Compared with existing utilization pathways of GP, the proposed structure-regulated preparation strategy for cold-bonded ceramsite enables up to 85 % incorporation of GP and delivers comprehensive performance improvement without reliance on high-temperature sintering or alkali activation. This approach demonstrates considerable engineering feasibility and application potential, providing a novel perspective and theoretical foundation for the high-efficiency valorization of low-activity solid wastes.

花岗岩粉（GP）的利用受到其低火山灰活性和惰性结构的极大限制，对其大量掺入提出了重大挑战。本研究采用改进的MAA （Andreasen-Andersen）颗粒充填模型作为配合比设计与评价工具，对gp -粉煤灰-水泥体系的冷粘陶粒进行了试验研究。通过设计多组不同粒度的组合，使原料粒度级配在一定范围内与MAA目标曲线产生可控偏差。采用RSS定量表征了颗粒级配与MAA目标曲线的偏离程度，系统分析了这种偏离对陶粒物理性质和孔隙结构的影响机理。结果表明，当相对过饱和度为6736时，陶粒结构最致密，筒体抗压强度为5.76 MPa，容重为1041 kg/m3，吸水率低至12.65%。进一步的粒度分馏实验表明，单一粒度的原料系统的性能明显差于全范围的颗粒分布。后者促进了骨架-填料协同结构的形成，从而提高了密实度和机械稳定性。与现有的GP利用途径相比，本文提出的结构调节冷粘合陶粒制备策略使GP的加入率高达85%，并且在不依赖高温烧结或碱活化的情况下实现了全面的性能改善。该方法具有相当的工程可行性和应用潜力，为低活性固体废物的高效增值提供了新的视角和理论基础。

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引用次数: 0

Separation dynamic model of air dense medium fluidized bed for coal beneficiation and control 煤选风密介质流化床分离动力学模型及控制

IF 4.3 2区材料科学 Q2 ENGINEERING, CHEMICAL

Particuology

Pub Date : 2025-12-06 DOI: 10.1016/j.partic.2025.11.019

Gansu Zhang , Tianxin Li , Hongyang Li , Zhiqiang Li , Shuxian Su , Xuan Xu , Wei Dai , Liang Dong

This study presents a comprehensive framework for the separation dynamic model of Air Dense Medium Fluidized Bed (ADMFB) to promote the intelligentization of coal preparation. The framework is a double-layer composite structure. In the outer layer, the static model of partition was extended from Dense Medium Cyclones to ADMFB. In the inner layer, the dynamic model of bed density was developed from the coupling model to the decoupling model with self-balancing characteristics. The model predicts product yield and ash content, which is validated against industrial separation data. The baseline performance is good but unstable, with maximum relative error 38.43 % and minimum relative error 4.48 % for coal ash content. To address this, an ash correction algorithm was innovatively put forward by introducing organic efficiency θ. The performance improvement is significant that coal ash content has maximum relative error 5.97 % and minimum relative error 0.48 %. Finally, Model Predictive Control (MPC) was implemented following the global linearization of the nonlinear bed density model, whose convergence speed to reach the tracking value is 46 % faster than constant control. Overall, this work provides a pathway for coal preparation plants to achieve more stable and intelligent production.

为促进选煤过程的智能化，提出了空气致密介质流化床（ADMFB）分选动力学模型的综合框架。框架为双层复合结构。在外层，将划分的静态模型从稠密介质旋风扩展到ADMFB。在内层，床层密度动态模型由耦合模型发展为具有自平衡特性的解耦模型。该模型预测了产品收率和灰分含量，并与工业分离数据进行了验证。基准性能良好，但不稳定，煤灰含量的最大相对误差为38.43%，最小相对误差为4.48%。针对这一问题，创新性地引入有机效率θ，提出了一种灰分校正算法。粉煤灰含量的最大相对误差为5.97%，最小相对误差为0.48%。最后，对非线性床层密度模型进行全局线性化，实现模型预测控制（MPC），达到跟踪值的收敛速度比恒定控制快46%。总的来说，这项工作为选煤厂实现更稳定、更智能的生产提供了一条途径。

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引用次数: 0

Numerical investigation on reactive crystallization of Li-ion batteries precursor Ni(OH)2 in a stirred tank: Effect of structural factors on particle size and distribution 锂离子电池前驱体Ni(OH)2在搅拌槽中反应结晶的数值研究：结构因素对颗粒大小和分布的影响

IF 4.3 2区材料科学 Q2 ENGINEERING, CHEMICAL

Particuology

Pub Date : 2025-12-05 DOI: 10.1016/j.partic.2025.12.001

Junhai Deng , Jiuhua Chen , Shuyao Feng , Yunyun Tian , Yingqi Liao , Bi Luo , Luchang Han , Yefeng Zhou

The stirred tank reactor is widely used for preparing Li-ion batteries precursors, and the high-performance materials are utilized in various fields such as electronic devices. However, controlling the particle characteristics remains a significant challenge due to the complex interaction between fluid dynamics and crystallization kinetics. Therefore, this work proposes the computational fluid dynamics-population balance model coupled model to simulate Ni(OH)₂ reactive crystallization. By altering the structure and operation, this work analyzes effects of turbulence parameters on particle characteristics. Results show that increasing the height, baffle number and rotational speed enhances turbulence parameters, which reduces the Sauter mean diameter about 1.08–2.14 times and decreases the span from 1.6 to 1.17. Axial-flow impellers generate lower turbulent dissipation and shear force compared to radial-flow impellers, causing less particle breakage and better suitability for reactive crystallization. The wave bottom enhances turbulent dissipation about 1.19–1.38 times compared to flat and round bottom, improving flow circulation and reducing dead zones. Moreover, experiment and simulation demonstrate consistent trend in particle size and distribution under different baffle numbers, with morphology becoming better. This work provides important theoretical support for optimizing reactor design and enhancing reactive crystallization, facilitating the production of high-performance materials.

搅拌槽反应器广泛用于制备锂离子电池前驱体，高性能材料应用于电子器件等各个领域。然而，由于流体动力学和结晶动力学之间复杂的相互作用，控制颗粒特性仍然是一个重大的挑战。因此，本文提出了计算流体动力学-种群平衡模型耦合模型来模拟Ni(OH)2反应结晶。通过改变结构和操作，分析了湍流参数对颗粒特性的影响。结果表明，增加挡板高度、挡板数和转速可提高湍流参数，使Sauter平均直径减小1.08 ~ 2.14倍，跨度从1.6减小到1.17；与径向叶轮相比，轴流叶轮产生的湍流耗散和剪切力更小，颗粒破碎更少，更适合反应结晶。波底比平底和圆底增强了1.19-1.38倍的湍流耗散，改善了流动循环，减少了死区。实验和模拟结果表明，不同挡板数下，颗粒大小和分布趋势一致，形貌越好。该工作为优化反应器设计，提高反应结晶性能，促进高性能材料的生产提供了重要的理论支持。

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引用次数: 0

Allowing optical measurements in a 3D packed bed with gas flow: A novel reactor concept 允许在具有气流的三维填充床中进行光学测量：一种新的反应器概念

IF 4.3 2区材料科学 Q2 ENGINEERING, CHEMICAL

Particuology

Pub Date : 2025-12-04 DOI: 10.1016/j.partic.2025.11.018

Christin Velten, Kerstin Hülz, Katharina Zähringer

Industrial processes based on packed beds with gaseous flow come with high energy and resource consumption. To gain a better understanding of these phenomena, it is essential to investigate flow properties inside such systems. This study presents a novel reactor concept that allows for direct optical measurements inside the voids of the packing. It is based on polyhedral parallel arranged particles in a modular way. Through the modularity different regular and irregular configurations can be generated allowing for direct optical access avoiding major distortion. Particle Image Velocimetry (PIV) is applied to obtain spatially and temporally highly resolved 2D flow fields of the ambient temperature gas flow through the packing. Two different particle Reynolds numbers (100 and 1000) are investigated to validate the concept of the novel reactor model. The successful application of PIV to the inner pores of the bed, delivering reliable snapshot based data, mean velocity and turbulent kinetic energy of the gas flow, shows the potential of this reactor concept also for other optical measurement techniques that allow for the validation of numerical models and simulations of packed bed reactors.

基于气体流动填充床的工业过程具有高能耗和资源消耗。为了更好地理解这些现象，有必要研究这些系统内部的流动特性。本研究提出了一种新的反应器概念，允许在填料的空隙内进行直接光学测量。它是基于多面体平行排列的粒子以模块化的方式排列的。通过模块化，可以产生不同的规则和不规则配置，从而允许直接光学访问，避免重大失真。采用粒子图像测速技术（PIV）获得了环境温度下气体通过填料的二维流场的空间和时间高分辨率。研究了两种不同的粒子雷诺数（100和1000）来验证新反应器模型的概念。PIV在床层内部孔隙的成功应用，提供了可靠的基于快照的数据，平均速度和气体流动的湍流动能，显示了该反应器概念的潜力，也可以用于其他光学测量技术，允许验证数值模型和填充床反应器的模拟。

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引用次数: 0

Evaluation of effects of particle parameters on the particle bed in supercritical CO2 fractures using coupled CFD-DEM approach 利用耦合CFD-DEM方法评价超临界CO2裂缝中颗粒参数对颗粒床的影响

IF 4.3 2区材料科学 Q2 ENGINEERING, CHEMICAL

Particuology

Pub Date : 2025-12-04 DOI: 10.1016/j.partic.2025.11.017

Bin Li, Lele Yang, Xiaodong Chen, Chengyu Huang, Yue Wu

In this study, a coupled CFD–DEM framework incorporating heat transfer was established to elucidate the transport and deposition behavior of proppant particles in supercritical CO₂ (SC-CO₂) fracturing. A three-dimensional fracture-scale physical model was developed to investigate the effects of particle concentration, density, diameter, and non-sphericity on the evolution of the proppant bed. The simulations reveal that both the equilibrium height and length of the granular bed increase with particle concentration, exhibiting a near-linear dependence on the injected mass flux. As particle density rises, the bed height increases while the deposition front advances upstream, facilitating earlier bed formation. Increasing particle diameter from 0.4 mm to 1 mm produces pronounced morphological changes—larger particles form thicker, shorter beds, whereas smaller particles are more easily transported to distal fracture regions. Enhanced particle non-sphericity promotes the development of higher and wider beds due to increased mechanical interlocking and larger inter-particle voids, which strengthen flow-channel connectivity and potentially improve hydrocarbon recovery. The integrated thermal–hydrodynamic–granular analysis demonstrates that SC-CO₂'s temperature-dependent viscosity and density variations significantly modulate drag, lift, and buoyancy forces, jointly governing the self-organization and stability of proppant beds within fractures.

在这项研究中，建立了一个包含传热的耦合CFD-DEM框架，以阐明支撑剂颗粒在超临界CO2 （SC-CO2）压裂中的运移和沉积行为。建立了三维裂缝尺度物理模型，研究了颗粒浓度、密度、直径和非球形度对支撑剂层演化的影响。模拟结果表明，颗粒床的平衡高度和平衡长度随颗粒浓度的增加而增加，与注入的质量通量呈近似线性关系。随着颗粒密度的增加，层高增加，沉积锋面向上游推进，有利于较早地层形成。将颗粒直径从0.4 mm增加到1 mm会产生明显的形态变化——较大的颗粒形成更厚、更短的层，而较小的颗粒更容易运输到远端断裂区域。由于机械联锁作用的增强和颗粒间空隙的增大，颗粒非球形度的增强促进了更高更宽层的发育，从而加强了流道连通性，并有可能提高油气采收率。综合热流体动力颗粒分析表明，SC-CO2的温度依赖性粘度和密度变化显著调节了阻力、升力和浮力，共同控制着裂缝内支撑剂层的自组织和稳定性。

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引用次数: 0

Preface to special issue: Advances in spouted beds – The 8th International Symposium on Spouted Beds in honour of Norman Epstein 特刊前言：喷水床的进展-第八届喷水床国际研讨会，以纪念诺曼·爱泼斯坦

IF 4.3 2区材料科学 Q2 ENGINEERING, CHEMICAL

Particuology

Pub Date : 2025-12-01 DOI: 10.1016/j.partic.2025.10.013

Martin Olazar , Gartzen Lopez , Xiaotao Bi , Xiaojun Bao , Choon Jim Lim

引用次数: 0

Influence of fluidization dynamics and liquid evaporation on particle growth in a top-spray fluidized bed 流态化动力学和液体蒸发对顶喷流化床颗粒生长的影响

IF 4.3 2区材料科学 Q2 ENGINEERING, CHEMICAL

Particuology

Pub Date : 2025-11-29 DOI: 10.1016/j.partic.2025.11.013

Han Pu, Jiliang Ma, Jialiang Cai, Yi Wang, Xiaoping Chen, Cai Liang, Daoyin Liu, Meng Liu

The phenomenon of particle agglomeration in a liquid-containing fluidized bed is closely associated with the interactions between gas and solid phases, as well as the evaporation of the liquid component. This study performs an experimental investigation to examine the interactions among particle growth, fluidization behavior, and droplet evaporation within a continuous top-spray fluidized bed system. The research indicates that increased drying air temperatures generate severe drying conditions that promote the conversion of liquid bridges to solid bridges between particles. This conversion significantly decreases the nucleation time and encourages a more consistent distribution of agglomerate sizes. Additionally, a rise in the spraying rate and binder viscosity, strengthen the cohesive forces among particles, resulting in the development of larger agglomerates. The evaporation of the liquid binder exhibits a substantial correlation with the behavior of bubbles within the bed, which in turn affects particle growth and the chaotic dynamics of the fluidized bed system. The process of particle growth is delineated into two separate phases: nucleation growth and shell growth. Notably, the duration of nucleation growth phase exceeds that of the shell growth phase. Ultimately, a regime map has been developed to evaluate the feasibility of the spray granulation process concerning fluidization and drying parameters. The findings suggest that excessively low fluidization numbers, coupled with inadequate drying conditions, could lead to the failure of the liquid-containing fluidization process.

含液流化床中的颗粒团聚现象与气固两相的相互作用以及液体组分的蒸发密切相关。本研究对连续顶喷流化床系统中颗粒生长、流化行为和液滴蒸发之间的相互作用进行了实验研究。研究表明，干燥空气温度的升高会产生严重的干燥条件，促进颗粒之间的液体桥转化为固体桥。这种转化显著地缩短了成核时间，并促使团聚体尺寸的分布更加一致。此外，喷射速率和粘结剂粘度的增加，增强了颗粒之间的凝聚力，导致更大的团聚体的发展。液体粘结剂的蒸发与床内气泡的行为有很大的相关性，而气泡的行为反过来又影响颗粒的生长和流化床系统的混沌动力学。粒子的生长过程分为两个阶段：成核生长和壳生长。值得注意的是，成核生长阶段的持续时间超过了壳生长阶段。最后，开发了一个状态图来评估有关流化和干燥参数的喷雾造粒工艺的可行性。研究结果表明，过低的流化数，加上不适当的干燥条件，可能导致含液流化过程的失败。

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引用次数: 0

Morphology controlled synthesis of ZSM-5 and enhanced catalytic activity in polypropylene hydrocracking 形貌控制了ZSM-5的合成，增强了聚丙烯加氢裂化的催化活性

IF 4.3 2区材料科学 Q2 ENGINEERING, CHEMICAL

Particuology

Pub Date : 2025-11-28 DOI: 10.1016/j.partic.2025.11.016

Ziru Wang , Li Gao , Ying Zhang , Xia Zhang , Bingsen Zhang

ZSM-5 zeolite has emerged as an outstanding catalyst in converting waste plastics into high-value chemicals. Constructing hierarchical micro-mesoporous ZSM-5 can significantly enhance diffusion characteristics and consequently improve catalytic cracking performance. The morphology of ZSM-5 plays a crucial role in altering its catalytic hydrocracking efficiency in plastic degradation, but the reasons behind this is not clear. Herein, by precisely adjusting the structure-directing agent (SDA) ratio to control nucleation dynamics, we have developed a morphology-controlled synthesis strategy for ZSM-5 zeolites. Two distinct hierarchical ZSM-5 catalysts were successfully fabricated: plate-shaped n-ZSM-5 and quasi-spherical s-ZSM-5. And, increasing the SDA content was worked in promoting nucleation kinetics, facilitating the incorporation of active components into the zeolite framework, and increasing surface acid site density. The plate-shaped n-ZSM-5 exhibited exceptional catalytic performance in polypropylene hydrocracking with a liquid yield of 57.3 %, and proved to maintain effective activity for the actual conversion of plastic waste. The catalytic mechanism reveals that the morphology engineering can effectively regulate mass transport within catalyst pores, provide a novel approach for tailoring zeolite catalyst properties. This work offers fundamental insights into structure-performance relationships for advanced plastic upcycling catalysts.

ZSM-5沸石已成为将废塑料转化为高价值化学品的杰出催化剂。构建分级微介孔ZSM-5可以显著提高扩散特性，从而提高催化裂化性能。ZSM-5的形貌对其在塑料降解中催化加氢裂化效率的改变起着至关重要的作用，但其背后的原因尚不清楚。本文通过精确调节结构导向剂（SDA）的比例来控制成核动力学，建立了一种形态控制的ZSM-5分子筛合成策略。成功制备了两种不同层次的ZSM-5催化剂：片状n-ZSM-5和准球形s-ZSM-5。同时，增加SDA的含量可以促进分子筛成核动力学，促进活性组分进入分子筛骨架，增加表面酸位密度。板状n-ZSM-5在聚丙烯加氢裂化中表现出优异的催化性能，产液率为57.3%，对塑料废弃物的实际转化具有良好的催化活性。分子筛的催化机理表明，形貌工程可以有效地调节催化剂孔内的质量传递，为调整沸石催化剂的性能提供了一种新的途径。这项工作为先进的塑料升级回收催化剂的结构-性能关系提供了基本的见解。

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引用次数: 0