The rapid advancement of industrialization has directly correlated with a significant increase in the severity of atmospheric pollutant emissions. According to the International Energy Agency (IEA) “2024 Coal Report – Analysis and forecast to 2027,” global coal consumption remains significant in high-temperature industrial processes, especially coal-fired power generation, metal smelting, and coal chemical engineering. The dust-laden gases produced in these industrial processes not only contain a large number of particulate matter but are also accompanied by harmful gases such as SOx and NOx, posing dual threats to the environment and process systems. Achieving efficient gas–solid separation under high-temperature conditions (>600 °C) has become a key technological bottleneck to improve resource utilization and meet increasingly stringent environmental protection standards. The development of high-performance filtration materials is critical for the implementation of efficient and stable high-temperature gas–solid separation processes. These materials must possess good mechanical strength and exhibit excellent high-temperature thermal stability, thermal shock resistance, and corrosion resistance, ensuring long-term stable operation under extreme working conditions. Conventional filtration media often present challenges associated with limited filtration efficiency, compromised corrosion resistance, and inadequate mechanical strength, thereby restricting their applicability in industrial processes. Therefore, developing efficient high-temperature filtration materials, enabling the direct filtration and purification of high-temperature flue gases, is important for reducing carbon emissions and promoting green industrial transformation.

In this study, Co-Al-Cr (39.79 %) IMCs with interconnected channels and high porosity were rapidly synthesized using a low-energy exothermic reaction. The effective heat of formation (EHF) was employed to predict the phase formation sequence of the reaction system, and the impact of adding different amounts of Cr on the TE reaction process, pore structure, and mechanical properties of the Co-Al system was studied in detail. Furthermore, the relationship between the microstructure and the corrosion behavior of the product was established through non-destructive internal structure reconstruction. The synthesized porous IMCs demonstrate significant potential as alternative materials for applications requiring resistance to corrosive media and high pressures, thereby offering new material selections for the replacement of conventional filters in industrial high-temperature gas filtration systems.

Fig. 1. (a) Ternary phase diagram of Co-Al-Cr and (b) the schematic depiction of the synthesis process of the porous Co-Al-Cr IMCs.

Fig. 2. Lattice boltzmann method simulation of pore structure and velocity field analysis.

Fig. 3. (a) Open-circuit potential, (b) potentiodynamic polarization curves and (c) Nyquist diagram (insert displays the equivalent circuit) of the sample; (d) schematic diagram of the proposed processes occurring during the corrosion of the samples examined in 3.5 wt% NaCl.

Title: 3D microstructure and corrosion behavior of porous Co-Al-Cr intermetallic fabricated via rapid low-energy self-exothermic reaction for advanced filtration applications

Authors: Zhichao Shang, Sanjith Udayakumar, Hao Wang, Xiangming Li, Jianzhong Wang, Xiang Ji, Xianghong Wang*, Baojing Zhang, Xuanru Ren, Farshid Pahlevani*, Baojing Zhang, Peizhong Feng*

Link: https://www.sciencedirect.com/science/article/pii/S138358662503117X#f0085

DOI: https://doi.org/10.1016/j.seppur.2025.134520

If you want to get the PDF version, please contact the E-mail: shangzhichao1996@163.com，shangzc1996@cumt.edu.cn