Engineering Commons^™

Techno-Enviro-Economic Analysis Of Precipitated Calcium Carbonate Production From Carbon Dioxide In Cement Industry Flue Gas And Calcium Hydroxide, Natalia Debora Panggabean, Widodo Wahyu Purwanto

Journal of Materials Exploration and Findings

CCUS is a technological solution to reduce emissions from the cement industry, which is the second largest CO2-intensive industry. This study aims to analyze technical, economic, and environmental performance of Precipitated Calcium Carbonate (PCC) synthesis in cement industry flue gas. The process simulation includes the CO2 capture system from cement plant, CO2 captured used as feedstock for PCC synthesis process through its reaction with calcium hydroxide. The simulation was carried out using ASPEN Plus software. Technical analysis was performed to determine the CO2 capture efficiency and PCC synthesis efficiency. Economic analysis was conducted to calculate CO2 capture cost and production …

Feasibility Analysis Of Thermal Oxidizer To Determine Remaining Life Using Fitness- For-Service Level 3 Method, Yudhi Yudistirawan, Donanta Dhaneswara, Wahyuaji Narottama Putra, Gama Widyaputra, Dewi Kurnia Suci, Agung Putra Mahardhika

Journal of Materials Exploration and Findings

An aged thermal oxidizer (TOX) in the oil and gas industry necessitates a comprehensive evaluation to ensure its continued safe operation. This study presents a Remaining Life Assessment (RLA) and a Fitness for Service (FFS) evaluation for the four main components of the TOX, in accordance with API 510, API 579/ASME FFS-1, and ASME BPVC Section VIII Div-1 standards. The investigation includes the determination of maximum stress and maximum temperature required to assess the operational viability of the reactor. The four components are radiant, convection, transition, and stack sections—were modeled using the finite element method (FEM). Following the geometric modeling, …

Assessing Passenger Electric Vehicle Growth Strategies And Their Impacts On Electricity Demand Load And Co2 Emissions In Aceh Province To Achieve Net Zero Emission Target By 2060, Taufik Hidayat, Widodo Wahyu Purwanto

Journal of Materials Exploration and Findings

The electrification of the transport sector is a crucial pathway for achieving Indonesia’s Net Zero Emissions (NZE) target by 2060. This study assesses the potential impact of passenger electric vehicle (EV) penetration on electricity demand and CO2 emissions in Aceh Province through a scenario-based modelling approach. Two policy-aligned scenarios are assessed: a low-penetration (LP) scenario and a high-penetration (HP) scenario. Using the Gompertz model and the ASIF framework, total CO2 emissions were projected from 2020 to 2060. Results show that although higher EV penetration reduces direct emissions from internal combustion engine (ICE) vehicles, total CO2 emissions increase more significantly under …

Revitalising Tanzania’S Textile Industry Through The Uk Textile System’S Role, Charles M. Kahabi

Tanzania Journal of Engineering and Technology (TJET)

Currently, there is the environmental and social challenges emerging from the global clothing and textile industry, specifically on textile waste management.  Additionally, the flow of second-hand clothing (SHC) between European countries especially the UK and Tanzania is increasing. In the UK, rapid growth of second-hand clothing (mitumba) driven by fast fashion results in vast quantities of discarded garments, of which only a fraction is recycled, leaving the remainder in landfills. Conversely, Tanzania has long depended on imported SHC a practice that, while affordable, has undermined local textile industries and contributed to waste accumulation. By examining Tanzania’s textile landscape, the research …

Harnessing Phase Engineered Porous Mxene-Tio2 In Polyamide Reverse Osmosis Membranes For Enhanced Short- And Long Chain Pfas Removal From Water, Roham Ghanbari, Javad Farahbakhsh, Ahmad Najafidoust, Ratish Permala, Stefan Iglauer, Shervin Kabiri, Masoumeh Zargar

Research outputs 2022 to 2026

MXenes (2D transition metal nitrides, oxycarbides, carbonitrides, and carbides) hold promise in water treatment due to tunable surface chemistry and hydrophilic nature but restacking in aqueous environments and susceptibility to oxidation remain challenging. Here, we deliberately exploit partial oxidation of Ti3C2Tx MXene to in situ grow TiO2 nanoparticles on its surface, creating a porous, phase-engineered MXene-TiO2 composite. The anatase:rutile ratio was adjusted through different hydrothermal process time (12, 18, and 24 h), after 18 h composition yielding the best balance of surface charge and structural stability. This composite was incorporated into the polyamide (PA) layer of a thin-film composite reverse …

Effects Of Solvent Type, Storage Time, And Storage Temperature On Free Radical Stability And Concentration In Model Radical Systems And Complex Vegetable Oil Matrices, Rachid Ismail Daboussi

Thesis/ Dissertation Defenses

Free radicals are reactive species with unpaired electrons that occur and form within a range of biological, physical, and chemical systems. These highly reactive entities can interact with each other and/or with other molecules present in a mixture, often leading to significant changes in the system. Control over free radical concentration and free radical reactions is necessary in various fields depending on the aim of the process. For instance, free radical addition reactions play an essential role in the synthesis of polymers, where controlled radical behavior is necessary. However, in the thermal cracking of oil, free radical addition reactions are …

Utilization Of Commercial Phosphonium And Ammonium Ionic Liquids In Enhanced Oil Recovery Of Carbonate Reservoirs, Nada Berrandjia

Thesis/ Dissertation Defenses

Despite advancements in renewable energy, oil and gas still dominate global energy supply, while a substantial portion of original oil in place (OOIP) remains unrecovered through conventional recovery methods. One of the most effective approaches used to mobilize residual oil is chemical enhanced oil recovery (CEOR) through mechanisms such as reduction of interfacial tension (IFT), alteration of wettability, emulsification, and improved displacement efficiency. Recently, ionic liquids (ILs) have gained interest as alternative CEOR agents due to their tunable structure and superior stability under harsh reservoir conditions. This thesis experimentally investigates the potential of low-cost and commercially available ILs for enhanced …

Comparative Performance Of Polymeric Membrane-Catalytic Combined Module Systems For Efficient Co2 Capture, Yamna Saif Alshamsi

Thesis/ Dissertation Defenses

Effective carbon dioxide (CO2) capture is crucial for mitigating climate change. Membrane-based gas absorption systems, particularly those utilizing monoethanolamine (MEA), offer a modular, scalable, and energy-efficient alternative to conventional methods. However, challenges such as membrane wetting, solvent degradation, and mass-transfer limitations hinder their performance.This research investigated the efficiency of polyvinylidene fluoride (PVDF) and polyethersulfone (PES) polymeric membrane contactors for CO2 absorption using MEA under simulated flue gas conditions. A novel approach involved incorporating nanocatalytic material into the absorbent solution to enhance CO2 absorption. Characterization included SEM, FTIR, XRD, permeability, tensile strength, and contact angle measurements, alongside CO2 absorption performance evaluation. …

Mathematical Modelling And Optimisation Of The Reactor For The Esterification Process Of Safflower Oil With N-Butyl Alcohol, Sadritdin Makhamatdinovich Turabdjanov Academician, Hasan Sadriddin Ugli Fozilov, Ozoda Bakhronovna Axmedova, Sadriddin Fayzullayevich Fozilov

Technical science and innovation

This study addresses the mathematical modelling and optimisation of a reactor for the esterification of safflower oil with n-butyl alcohol. To improve process controllability and reduce the need for numerous pilot-scale trials, an ideal-mixing continuous stirred-tank reactor (CSTR) model was adopted. Incorporating reaction kinetics, the effect of contact time on the relative viscosity of the product mixture was analysed. The modelling results indicate that achieving an acceptable degree of feedstock conversion is difficult when a single ideal-mixing reactor is used. Therefore, a CSTR cascade was proposed, and the configuration with N = 2 reactors was selected as the most appropriate …

Analysis Of Soda Production Processes In Ammonia-Soda Production, Nadirbek Rustambekovich Yusupbekov Professor, Djalolitdin Paxritdinovich Mukhitdinov Professor, Fatima Faxritdinovna Iskhakova

Technical science and innovation

This paper provides a comprehensive analysis of the fundamental principles of the classical Solvay process, a key component in the industrial production of soda ash. It is noted that despite its widespread use and technological maturity, the process has a number of significant technological, energy, and environmental limitations associated with high raw material and energy consumption, the generation of significant industrial waste, and CO₂ emissions. The need to modernize the traditional production process to improve efficiency, resource conservation, and environmental sustainability is substantiated. The review systematically summarizes current approaches to process improvement, including modified versions of the Solvay process, the …

Relationships Between The Parameters Of The Vegetable Oil Refining Process And Energy Consumption, Umidjon Abdimajitovich Ruziev, Marufjon Kobuljonovich Shodiev

Technical science and innovation

Vegetable oil refining is a multi-stage thermochemical process that is closely related to energy consumption, process parameters, product quality, and food safety requirements. Despite the extensive scientific literature on oil quality and pollutant formation, the quantitative relationship between purification parameters and relative energy consumption has not been sufficiently studied. In this work, a systematic analysis and engineering synthesis were carried out based on existing studies. According to the analysis results, the deodorization process accounts for 52–56% of the total thermal energy consumption, with a relative value ranging from 160 to 380 kJ/kg, depending on the enterprise's capacity and heat utilization …

Iron Ore Tailings Reprocessing By Electrostatic Separation Plus Two-Stage Froth Flotation, Vincent Bailey Arohunmolase, Akintunde Stephen Samakinde, Palas Kamlakar Borkar, Daniel Amponsah-Berko, Timothy Eisele

Michigan Tech Publications

The reprocessing of tailings is crucial for recovering valuable iron and reducing the environmental impact associated with tailings disposal. The raw iron ore tailings used in this study had an initial iron oxide content of 24.05 wt% Fe2O3, as determined by ICP-OES analysis. This study investigates the practicality of tailings reprocessing to enhance iron oxide content by integrating electrostatic separation with a two-stage froth flotation process consisting of direct anionic flotation using oleic acid followed by reverse cationic flotation using amine collectors. The primary goal is to efficiently recover valuable iron from tailings, thereby reducing waste and promoting sustainable resource …

Understanding The Binding Of Nickel(Ii) Bromide To A Zirconium Metal-Organic Cage For Heterogeneous Catalysis, Luci Green

Caroliniana Undergraduate Research Journal

Heterogeneous catalysts offer inherent advantages in improving the sustainability of industrial chemical processes. Their high ease of separation and recyclability has the potential to reduce the cost, waste, and energy consumption of processes that currently rely on homogeneous catalysts. Metal–organic cages (MOCs) are an attractive material for heterogeneous catalysis due to their discrete and highly tunable structures, which can be functionalized by binding these complexes with catalytically active metals. The specific objective of this study is to provide preliminary insight into the binding of nickel(II) bromide (NiBr₂) to zirconium MOCs, which was done by studying the binding of …

Sustainable Cellulose Aerogels And Biofaoms From Date Palm Waste For Thermal Insulation Application, Hyder Ali Al Abdallah

Thesis/ Dissertation Defenses

This dissertation is concerned with the use of date palm waste for the preparation of green lightweight aerogels and foams. Cellulose extracted from date palm wood waste is utilized to fabricate cellulose aerogels. Moreover, wood foams are prepared from whole biomass wood waste, without any prior treatment or extraction processes. The aim of this research is to produce sustainable, green, environmentally friendly heat insulation materials the construction, to replace commercial and fossil-fuel derived heat insulators. In this research, cellulose is extracted from date palm trees waste using both traditional and green environmentally friendly solvents. After extraction, cellulose aerogels are prepared …

Biomass Demineralization: A Critical Need For Future Biorefineries, Leoncio Santiago-Martínez, Styliani Avraamidou, Alejandro Ayala-Cortés, Ruth Azike, Santanu Bakshi, Chumki Banik, Ezra Bar Ziv, Fei Long, Rebecca Ong, Et Al.

Michigan Tech Publications

Biomass contains up to 14 essential elements that serve as nutrients for plant growth and development, including photosynthesis and enzyme functionalities. These elements in different chemical forms (e.g., minerals) constitute the inorganic fraction of biomass and can cause operational issues in thermal and biochemical biomass conversion technologies. In biomass gasification and pyrolysis processes, for instance, inorganics can cause fouling, tar formation, and corrosion. In catalytic and biochemical processes, inorganics can poison catalysts, alter biochemical pathways, and modify product yields and selectivity. This review provides an overview of the inorganic content in biomass feedstocks, the critical role inorganics play in plant …

Self-Assembly Interactions In Magnetite-Coated Cellulose Nanocrystals: Implications For Magnetic Hyperthermia Applications, Mohammad J. Hasan, Erin L. Mcneill, Kishore Chand, Juganta Roy, Monishita Deb, Katherine Schlaak, Sydney Herzog, Yvonne Sun, Sarah Watzman, Esteban E. Ureña-Benavides, Erick S. Vasquez-Guardado

Chemical and Materials Engineering Faculty Publications

Magnetic cellulose nanocrystal (MCNC) nanocomposites are promising sustainable and biocompatible platforms for magnetic hyperthermia; however, the molecular mechanisms governing Fe3O4 adsorption and deposition onto CNCs remain poorly understood. Here, sulfated (S-CNC) and TEMPO-oxidized CNCs (T-CNC) were used to prepare nanocomposites at 1:2 and 1:4 CNC:Fe3O4 mass ratios, enabling a systematic evaluation of how surface chemistry and nanoparticle loading dictate interfacial interactions and magneto-colloidal behavior. Bare magnetite nanoparticles were 21 ± 5 nm by TEM but grew to 144 ± 18 in the DLS measurement at pH 7. The S-CNC nanocomposites had hydrodynamic sizes between 144 and 210 nm, not much …

Gas Lift Valve Operation Under Elevated Pressure And Temperature Conditions, Pedro O. De Melo Flores

LSU Master's Theses

Gas lift valves are critical components in artificial lift systems, and their performance directly influences well unloading efficiency and long-term production. Current industry models used to correct valve opening and closing pressure for temperature rely on assumptions that have not been extensively validated against experimental data. This study experimentally investigates the opening and closing behavior of injection pressure-operated (IPO) gas lift valves under controlled elevated-temperature conditions. A load rate test bench was modified to include a heating system capable of maintaining valve temperatures up to 220°F. Five gas lift valve designs from multiple manufacturers were tested over a range of …

Spray Drying Of Cromolyn Sodium For Pulmonary Delivery, Waasif Karuthedath Wahab

Thesis/ Dissertation Defenses

Cromolyn sodium (CS) is an anti-inflammatory drug that can be used for the effective treatment of respiratory diseases such as asthma. Spray drying techniques are widely used in the pharmaceutical industry to produce fine drug powders for pulmonary delivery. The study aimed to develop a new dry powder formulation of CS in combination with leucine and mannitol by spray drying. The target of this study was to develop an inhalable formulation with improved fine particle fraction and less ethanol percentage in the feed solution. To obtain respirable CS: Leucine: Mannitol microparticles, process variables such as total solid concentration, leucine weight …

Evaluating Square Gradient Theory For Correlation And Prediction Of Surface Tension, J. Richard Elliot

University Research

The ESD EOS [Elliott, Suresh, and Dohohue, IECR 1990, 29, 1476] is incorporated into the open-source Square Gradient Theory (SGT) library published by Mejia et al. [Mejia, Müller, and Chaparro-Maldonado, J. Chem. Inf. Model. 2021, 61, 1244]. The combined formalism is evaluated for accuracy compared to experimental measurements and empirical correlation methods. Earlier evaluations of the ESD EOS have shown it to provide accuracy like other EOSs for vapor pressure, vapor–liquid, liquid–liquid, and solid–liquid equilibria where the databases covered roughly 500 compounds and 100–200 mixtures each. For surface tension, a database of measured values for roughly 1000 compounds has been …

Controlled Gelation Of Co₂-Resistant Polymer Systems For Improved Conformance In Co₂-Eor, Maryam Sharifi Paroushi

Miners Solving for Tomorrow Research Conference

This presentation introduces a CO₂-resistant hydrogel developed to control fluid movement and improve CO₂ injection performance in subsurface reservoirs for Enhanced Oil Recovery (EOR) and Carbon Capture and Storage (CCS). Conventional polymer gels often lose strength in CO₂-rich environments, resulting in weak plugging, early breakdown, and ineffective flow control. To address this limitation, a sulfonated HPAM-based gel system crosslinked with chromium was developed. The effects of polymer concentration, molecular weight, crosslinker ratio, ionic strength, and pH were investigated to better understand gelation behavior and performance. The formulation exhibited controlled gelation, strong resistance to temperature and CO₂, and minimal shrinkage over …

Biosensors For Biomedicine, Drake O'Leary

Miners Solving for Tomorrow Research Conference

This project investigated the use of engineered bacterial reporter systems to detect cellular stress responses associated with antibiotic activity. While constructs were successfully introduced and tested against known antibiotics, the reporter consistently produced a blue signal across conditions, limiting the ability to distinguish specific stress responses. This suggests issues such as leaky expression, insufficient regulatory control, or lack of specificity in the reporter design. Although results were inconclusive, this work highlights key challenges in developing reliable biosensors and provides a foundation for future optimization. Improving signal specificity and reducing background expression will be critical for enabling accurate characterization of antibiotic …

Zwitterionic And Anionic Ultrafiltration Membrane Modification For Efficient, Fouling-Resistant Microalgae Harvesting, Victor Okorie Mkpuma, Mohadeseh Najafi, Javad Farahbakhsh, Masoumeh Zargar, Navid Reza Moheimani, Houda Ennaceri

Research outputs 2022 to 2026

Membrane surface modification is a promising strategy for fouling mitigation in membrane-based microalgae filtration, primarily by limiting the interactions between the membrane surface and the foulant particles. This study investigated the effectiveness of modified membranes in filtering Chlorella sp. MUR 269. First, three polyethersulfone membranes with varying pore sizes were evaluated to determine the influence of pore size on filtration performance and fouling behavior. The ultrafiltration membrane that exhibited the best performance was subsequently modified using two functional monomers: the zwitterionic [2-(methacryloyloxy)ethyl]dimethyl (3-sulfopropyl) ammonium hydroxide and the negatively charged mono-2-(methacryloyloxy)ethyl succinate (MMS). The filtration performance and fouling resistance of the …

Liquid Membranes For The Selective Extraction Of Lithium Ions From Brine: A Review, Maryam Gonbadi, Shayan Abrishami, Yasaman Boroumand, Ana Vafadar, Magdalena Wajrak, Amir Razmjou

Research outputs 2022 to 2026

The surging global demand for lithium, driven by its essential role in batteries for electric vehicles, portable electronics, and energy storage systems, underscores the need for efficient and sustainable extraction technologies. This review provides a comprehensive analysis of liquid-based membrane technologies (bulk liquid membranes (BLMs), supported liquid membranes (SLMs), and polymer inclusion membranes (PIMs)) for selective lithium extraction from brine sources. These membranes employ carrier molecules such as crown ethers, organophosphorus compounds, and ionic liquids to achieve high selectivity over competing ions through facilitated transport mechanisms. BLMs, primarily used in laboratory settings, utilize various configurations enabling selective complexation and diffusion …

Graphene Synthesis: A Reactor-Oriented Review Of Conventional And Emerging Production Methods, Paul C. Ani, Zeyad Zeitoun, Hasan J. Al-Abedi, Joseph D. Smith

Chemical and Biochemical Engineering Faculty Research & Creative Works

Graphene's unparalleled electrical, mechanical, and thermal properties have positioned it as a transformative material across diverse sectors, including electronics, energy storage, biomedicine, and environmental remediation. However, scalable, cost-effective, and high-quality production remains a critical challenge. This review presents a comprehensive, reactor-oriented analysis of both conventional and emerging graphene synthesis methods, categorized into top-down and bottom-up approaches. Special emphasis is placed on the role of reactor configurations in determining product quality, layer control, scalability, and economic viability. Key synthesis techniques explored include chemical vapor deposition (CVD), epitaxial growth, electrochemical exfoliation, ultrasonic-assisted methods, microwave reactors, combustion synthesis, and plasma-enhanced processes. By evaluating …

Biocrude From Organic Waste And Its Conversion To Hard Carbon: Experimental And Modeling Study, Isamu Umeda

Civil & Environmental Engineering Theses & Dissertations

This study establishes a technical and theoretical foundation for the efficient conversion of organic waste into biocrude and high-value carbon materials, aiming to facilitate the industrialization of hydrothermal and solvothermal liquefaction. The dissertation research is structured as follows:

Chapter 2 developed a novel chemical kinetic model for the HTL of corn stover based on elemental balances (C, H, N, and O). By incorporating temperature, residence time, solid loading as an independent variable, the model successfully predicted product yields and properties, revealing that there was non-pseudo-first-order reaction pathways in the conversion of water soluble organics in aqueous phase (AP) to hydrochar. …

Dendrimer Nanogels With Built-In Free Radical Scavenging Enable Efficient Topical Delivery Of A Hydrophilic Antioxidant To Restore Lens Redox Balance For Cataract Treatment, Lin Qi, Huari Kou, Anna Chernatynskaya, Da Huang, Vimalin Jeyalatha Mani, Humeyra Karacal, Nuran Ercal, Hu Yang

Chemistry Faculty Research & Creative Works

Cataract is a leading cause of vision impairment worldwide and are primarily caused by oxidative stress that damages and aggregates lens proteins, leading to lens opacification. However, the eye's anatomical barriers limit the penetration and bioavailability of antioxidant therapies. To address this challenge, a dendrimer-based nanogel with a built-in reactive oxygen species (ROS)-scavenging capability developed by us was employed to deliver the antioxidant N-acetylcysteine (NAC) to the lens. NAC was loaded into a generation-5 PEGylated poly(amidoamine) dendrimer (G5-PEG-TK, termed the GPT) nanogel. The resulting NAC-GPT was characterized for its ROS-scavenging activity, bioavailability, and corneal permeability. The efficacy of NAC-GPT was …

Numerical Study Of Nutrient Mixing In Trabecular Bone In Microgravity, Disuse And Normogravity, Sagar Gharti

Doctoral Dissertations and Master's Theses

Mechanical loading is known to regulate bone remodeling by driving interstitial fluid flow which stimulates cells and drives nutrient transport within the trabecular network. In microgravity, the absence of mechanical stimulation or loading suppresses convective flow processes, causing diffusion-driven nutrient mixing and renewal, and accelerated bone loss. This thesis investigates how oscillation frequency and trabecular bone density jointly control nutrient mixing and wall shear stress within trabecular cavities.

A computational fluid dynamics (CFD) framework is developed in STAR-CCM+ using a soft-cap oscillation model that mimics cyclic compression. Three idealized trabecular morphologies are simulated across different frequencies to represent microgravity or …

Near-Wall Void Distribution Characterization In Pebble Bed Reactor Using Gamma-Ray Ct And Dem Simulation, Ahmed Jasim, Mauricio Maestri, Abdullah Al Zubaidi, Omar Farid, Muthanna Al-Dahhan

Chemical and Biochemical Engineering Faculty Research & Creative Works

Accurate characterization of void-fraction distributions in pebble-bed reactors (PBRs) is essential for predicting flow, heat transfer, and neutronic behavior. High-fidelity experimental benchmark data for validating such predictions remain scarce, largely due to the challenges of non-invasive measurements. In this study, gamma-ray computed tomography (CT) was employed to measure radial and cross-sectional porosity in a laboratory-scale pebble bed containing 6cm graphite pebbles. A Discrete Element Method (DEM) simulation was implemented and validated against these measurements, then applied to the full-scale geometry of the Xe-100 high-temperature gas-cooled pebble-bed reactor. Analyses included radial and axial void-fraction profiles in the cylindrical section and conical …

Enhancing Co2 Adsorption And Co2/N2 Separation Performance By Incorporating Calcium In Mil-53 (Al), Hussein Rasool Abid, Hussein Znad, Nabil Majd Alawi, Farhan Lafta Rashid, Anmar Dulaimi, Amer Alanazi, Alireza Keshavarz, Stefan Iglauer, Shaobin Wang

Research outputs 2022 to 2026

Global warming is primarily driven by the rapid accumulation of carbon dioxide (CO₂) in the atmosphere. Metal–organic frameworks (MOFs) have emerged as promising materials for mitigating CO₂ emissions due to their tunable porosity, large surface area, and structural flexibility. Among them, MIL-53(Al) has attracted widespread interest owing to its excellent thermal and chemical stability. Recent studies show that modifying MOFs with secondary metals can significantly enhance their CO₂ adsorption performance. In this work, a one-pot synthesis method was employed to incorporate calcium (Ca), functioning as a Lewis basic metal, into the MIL-53(Al) framework to produce a series of bimetallic materials: …

Engineering Zinc Anodes Through Advanced Manufacturing Strategies For Next-Generation Zinc–Air Batteries, Yasir Arafat, Kareem Bakhsh, Muhammad Rizwan Azhar

Research outputs 2022 to 2026

Rechargeable zinc–air batteries (ZABs) are promising next-generation energy storage systems due to their high energy density, intrinsic safety, and low cost. Nevertheless, commercial deployment of Zn anodes is hampered by persistent challenges like dendrite formation, deformation, passivation, corrosion, and the hydrogen evolution reaction. This review systematically highlights the critical relationship between anode morphology and electrochemical performance and discusses recent advances in advanced manufacturing strategies for Zn anodes. Additive manufacturing approaches, such as 3D printing, enable the fabrication of porous and tunable Zn electrodes with enhanced surface area and uniform ion flux distribution. Furthermore, advanced materials processing techniques like alloying, coatings, …