Graphene nanoplatelets (GNPs) can be produced by exfoliating graphite in solvents via high-power tip sonication. In order to understand the influence of tip sonication parameters on graphite exfoliation to form GNPs, three typical flaked graphite samples were exfoliated into GNPs via tip sonication at power of 60, 100, 200, or 300 W for 10, 30, 60, 90, 120, or 180 min. The concentration of GNP dispersions, the size and defect density of the produced GNPs, and the sedimentation behavior of GNP dispersions produced under various tip sonication parameters were determined. The results indicated that the concentration of the GNP dispersions was proportional to the square root of sonication energy input (the product of sonication power and time). The size and I_D/I_G values (determined by Raman spectrum) of GNPs produced under various tip sonication powers and times ranged from ~ 1 to ~ 3 μm and ~ 0.1 to ~ 0.3, respectively, which indicated that all the produced GNPs were of high quality. The sedimentation behavior of GNP dispersions showed that the dispersions were favorably stable, and the concentration of each GNP dispersion was ~ 70% of its initial concentration after sedimentation for 96 h. Moreover, the TEM images and electron diffraction patterns were used to confirm that the produced GNPs were few-layer. This study has important implications for selecting the suitable tip sonicating parameters in exfoliating graphite into GNPs.

The ironmaking process is the most significant source of CO₂ emission in the iron and steel industry, which generates large quantities of greenhouse gases. Recently, oxygen blast and top gas recycling have been applied to the blast furnace to improve the energy efficiency and reduce the pollution from the ironmaking process. However, as a new ironmaking technology, the oxygen blast furnace with top gas recycling (TGR-OBF) is still under development. This paper focuses on the investigation of the energy consumption and carbon emission for the TGR-OBF process by modeling the stack, the bosh, the combustion zone, and the gas recycling system. Effects of the key parameters in the TGR-OBF process on the carbon consumption of reactions and the energy consumption of the system are investigated by orthogonal experiments. Our results indicate that the TGR-OBF process has the advantages of reducing energy consumption and CO₂ emission. The low temperature and high reducing environment in the new furnace is favorable to lower the coke gasification and increase the reaction rate of iron oxide. The recycling of the top gas can significantly reduce CO₂ emission, and the main advantage comes when the stripped CO₂ is stored.

High CO₂ emissions and energy consumption have greatly restricted the development of China’s iron and steel industry. Two alternative ironmaking processes, top gas recycling-oxygen blast furnace (TGR-OBF) and COREX^®, can reduce CO₂ emissions and coking coal consumption in the steel industry when compared with a conventional blast furnace (BF). To obtain parameters on the material flow of these processes, two static process models for TGR-OBF and COREX were established. Combining the operating data from the Jingtang steel plant with established static process models, this research presents a detailed analysis of the material flows, metallurgical gas generation and consumption, electricity consumption and generation, comprehensive energy consumption, and CO₂ emissions of three integrated steel plants (ISP) equipped with the BF, TGR-OBF, and COREX, respectively. The results indicated that the energy consumption of an ISP with the TGR-OBF was 16% and 16.5% lower than that of a conventional ISP and an ISP with the COREX. Compared with a conventional ISP, the coking coal consumption in an ISP with the TGR-OBF and an ISP with the COREX were reduced by 39.7% and 100% respectively. With the International Energy Agency factor, the ISP with the TGR-OBF had the lowest net CO₂ emissions, which were 10.8% and 35.0% lower than that of a conventional ISP and an ISP with the COREX. With the China Grid factor, the conventional ISP had the lowest net CO₂ emissions—2.8% and 24.1% lower than that of an ISP with the TGR-OBF and an ISP with the COREX, respectively.