The combustion of metal fuels as energy carriers in a closed-cycle carbon-free process is a promising approach for reducing CO₂ emissions in the energy sector. For a possible large-scale implementation, the influence of process conditions on particle properties and vice versa has to be well understood. In this study, the influence of different fuel–air equivalence ratios on particle morphology, size and degree of oxidation in an iron–air model burner is investigated by means of small- and wide-angle X-ray scattering, laser diffraction analysis and electron microscopy. The results show a decrease in median particle size and an increase in the degree of oxidation for leaner combustion conditions. The difference of 1.94 μm in median particle size between lean and rich conditions is twentyfold greater than the expected amount and can be connected to an increased intensity of microexplosions and nanoparticle formation for oxygen-rich atmospheres. Furthermore, the influence of the process conditions on the fuel usage efficiency is investigated, yielding efficiencies of up to 0.93. Furthermore, by choosing a suitable particle size range of 1 to 10 μm, the amount of residual iron content can be minimized. The results emphasize that particle size plays a key role in optimizing this process for the future.

The increasing demand for lithium-ion batteries requires constant improvements in the areas of production and recycling to reduce their environmental impact. In this context, this work presents a method for structuring carbon black aggregates by adding colloidal silica via a spray flame with the goal of opening up more choices for polymeric binders. The main focus of this research lies in the multiscale characterization of the aggregate properties via small-angle X-ray scattering, analytical disc centrifugation and electron microscopy. The results show successful formation of sinter-bridges between silica and carbon black leading to an increase in hydrodynamic aggregate diameter from 201 nm to up to 357 nm, with no significant changes in primary particle properties. However, segregation and coalescence of silica particles was identified for higher mass ratios of silica to carbon black, resulting in a reduction in the homogeneity of the hetero-aggregates. This effect was particularly evident for silica particles with larger diameters of 60 nm. Consequently, optimal conditions for hetero-aggregation were identified at mass ratios below 1 and particle sizes around 10 nm, at which homogenous distributions of silica within the carbon black structure were achieved. The results emphasise the general applicability of hetero-aggregation via spray flames with possible applications as battery materials.

Solar cells, liquid crystal displays (LCDs) and light-emitting diodes (LEDs) have become more and more important in recent decades. Crucial components of such electronic devices include rare metals (e.g., indium and gallium), which are only available in limited quantities. In order to meet their rising demand in the coming years, recycling processes, especially those that enable selective recovery of the individual components, are steadily gaining in importance. One conceivable method is particle-loaded solvent extraction followed by mechanical processing. Therefore, we first investigated the possibility of recovering individual particle fractions from a multicomponent mixture on the basis of the surface properties. Both UV–Vis spectroscopy and small-angle X-ray scattering (WAXS) were used for evaluation. The conducted experiments showed, among other things, that the indium oxide content increased from 50% to 99% in a binary system and from 33% to 94% in a ternary compound. In addition, the purification of the separated particles was examined in detail. Using UV–Vis spectrometry, it was found that permeation washing of filter cakes is suitable for removing impurities and retrieving most of the solvent used. Based on the results of the conducted laboratory tests, we finally developed a concept for the continuous and selective recovery of rare metals.

The hetero‐aggregation of carbon black and colloidal silica in a spray flame is a promising approach to improve dispersibility and stability of carbon black. The mixing quality, i.e., homogeneity of the materials within the hetero‐aggregate, is important for both properties, yet challenging to quantify. For this purpose, multiple STEM‐EDX (Scanning Transmission Electron Microscopy with Energy Dispersive X‐Ray Spectroscopy) elemental maps are conducted on two distinct process conditions, leading to hetero‐aggregates two different mixing qualities. By sampling cutouts of the images at randomized locations and applying principles adapted from classical mixing theory, hetero‐aggregates are characterized with respect to mixing quality, irrespective of composition and primary particle size. Furthermore, correlation coefficient functions give insight to the length scale of primary particle clusters in the hetero‐aggregates. In addition, on the basis of the intra‐aggregate mixing state and the distribution of hetero‐aggregate composition, a suitable description of the inter‐aggregate mixing state is achieved. The developed methods present a generally valid, precise characterization of the mixing quality of hetero‐aggregates.