Chemical Engineering Research & Design最新文献

{"title":"Research on FCC slurry centrifugal de-solidification assisted by agricultural solid waste biomass: Coupling centrifugal parameters with wheat straw properties","authors":"Xiaohan Dong ,&nbsp;Ziyu Huang ,&nbsp;Libo Zhang ,&nbsp;Jiachen Zuo ,&nbsp;Hui Wang ,&nbsp;Yinjie Liu ,&nbsp;Fan Qinzhen ,&nbsp;Hong Chen","doi":"10.1016/j.cherd.2025.12.042","DOIUrl":"10.1016/j.cherd.2025.12.042","url":null,"abstract":"<div><div>Effective ash removal from catalytic oil slurries (FCC) is important to improve the economic utilization of FCC slurries. Developing biomass in the refining industry can maximise the value of wood fibre biomass and is expected to encourage refining to become more environmentally friendly and sustainable. Based on this background, FCC slurry was used in this study, and the effects of centrifugal parameters, diesel addition, and the assistance of lignocellulosic biomass (wheat straw) on the de-solidation of FCC slurry were systematically investigated. Under the optimal centrifugal conditions (75 % diesel addition, 11,000 rpm centrifugal speed, 40 min centrifugal time, 10 % straw addition, 5 mm wheat straw), the ash content of FCC slurry was reduced from 4800 ppm to 79.73 ppm. Considering the need to balance separation efficiency and operational costs in actual industrial applications, subsequent system experiments selected a 50 % diesel addition ratio for in-depth mechanism studies. The mechanisms of centrifugal parameters, diesel fuel addition and wheat straw addition on the de-consolidation of FCC slurries were investigated by XRD, XPS and SEM characterization of FCC slurries before and after de-consolidation, as well as calcined ash. The research results indicate that diesel can effectively dissolve macromolecular colloids and asphaltenes in low-quality oil, promoting contact between macromolecular substances and wheat straw adsorbents, thereby improving the removal efficiency of metal compounds under centrifugal conditions and enhancing the centrifugal solid removal efficiency of FCC slurry. The addition of wheat straw, with its rich cellulose and lignin content, forms a multi-level pore structure that can physically adsorb mineral particles in ash. The lignin and cellulose components can also form hydrogen bonds and π-π interactions with gum and asphalt molecules, promoting flocculation and thereby enhancing the centrifugal solid separation efficiency of FCC slurry. This study demonstrates the feasibility of utilizing agricultural solid waste wheat straw in the refining industry. It provides important reference value for the development of biomass applications in the refining industry and the promotion of clean development in the oil refining industry.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"226 ","pages":"Pages 159-176"},"PeriodicalIF":3.9,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145881977","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Ammonia adsorption by oxyacid-modified woodchip gasification residues for urea pelleting system: Performances and mechanisms","authors":"Zixuan Zhang ,&nbsp;Bingtao Zhao ,&nbsp;Mengqi Wang ,&nbsp;Tong Lou","doi":"10.1016/j.cherd.2025.12.038","DOIUrl":"10.1016/j.cherd.2025.12.038","url":null,"abstract":"<div><div>Ammonia is a significant atmospheric pollutant, posing a significant risk to the environment and human health. Inadequate ammonia adsorption during industrial urea pelleting often leads to ammonia escape. To address this issue, this study prepared activated carbon derived from woodchip gasification residues and modified it by loading it with varying concentrations of citric acid, phosphoric acid, nitric acid, and sulfuric acid. The ammonia adsorption performance of the modified activated carbon was evaluated using a fixed-bed reactor. SEM, XRD, FTIR, and BET analysis characterized its physicochemical properties. Furthermore, pseudo-first-order and pseudo-second-order kinetic models were used to describe the adsorption behavior, and an economic evaluation factor was proposed to assess the economic performance of the material. Results showed that at 25 °C, the adsorption capacity of the activated carbon loaded with 30 % phosphoric acid was 35.12 mg/g, 57 times that of the unmodified activated carbon. Analysis of the adsorption mechanism suggests that ammonia reacts with oxygen-containing acids to produce NH₄⁺ . Pseudo-first-order, pseudo-second-order and Thomas models effectively describe the adsorption process, with correlation coefficients (R²) exceeding 0.990 and economic evaluation factors down to 0.995, demonstrating significant application potential. Furthermore, a dry ammonia adsorption process for urea pelleting was proposed, and the adsorbed product can be mixed with urea to produce compound fertilizer. These findings provide valuable insights for achieving efficient and economical ammonia adsorption in engineering applications.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"226 ","pages":"Pages 134-145"},"PeriodicalIF":3.9,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145881975","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A new strategy for sulfide recovery through synergistic pyrolysis of sodium sulfate and sodium thiocyanate","authors":"Xiaoge Wang ,&nbsp;Binchuan Li ,&nbsp;Daxue Fu ,&nbsp;Jianshe Chen ,&nbsp;Shuang Cui ,&nbsp;Kuiren Liu ,&nbsp;Yina Li ,&nbsp;Yongfeng Chang ,&nbsp;Qing Han","doi":"10.1016/j.cherd.2026.01.027","DOIUrl":"10.1016/j.cherd.2026.01.027","url":null,"abstract":"<div><div>Cyanide-containing wastewater from the gold industry often contains high concentrations of sodium sulfate (Na₂SO₄) and sodium thiocyanate (NaSCN), resulting in large amounts of waste salts. This study presents, for the first time, the utilization of the reducing property of NaSCN to convert Na₂SO₄ waste salts into value-added products such as sodium disulfide (Na₂S₂), sodium sulfide (Na₂S), and calcium sulfide (CaS), achieving the synergistic resource recovery of both salts. The pyrolysis of NaSCN alone, the co-pyrolysis of NaSCN and Na₂SO₄, and the effect of calcium oxide (CaO) on the pyrolysis process were investigated. Thermogravimetric analysis results indicate that, compared to carbothermal reduction, using NaSCN as a reducing agent can lower the theoretical reduction temperature of Na₂SO₄ by 267.3 K. The products from the pyrolysis of NaSCN alone are Na₂S₂, C, and N₂(g). The solid products from the co-pyrolysis of Na₂SO₄ and NaSCN are Na₂S₂ and Na₂S. In the Na₂SO₄-NaSCN-CaO system, the solid pyrolysis products are Na₂S and CaS. The intermediate gaseous products CO(g) and CO₂₍g) generated during the pyrolysis of NaSCN significantly influence the reaction kinetics. At 973 K for 30 min, Na₂SO₄ can be completely reduced by NaSCN. In the Na₂SO₄-NaSCN-CaO system, however, the absorption of CO₂(g) by CaO to form calcium carbonate (CaCO₃) inhibits rapid pyrolysis at lower temperatures, requiring 60 min at 973 K to achieve complete conversion of SCN^- ions. The reduction of Na₂SO₄ by NaSCN involves complex reactions among solid, liquid, and gas phases. Through in-depth analysis of the reaction process and thermodynamic equation fitting, it is confirmed that the rate-controlling step is the gas-solid interfacial reaction. The apparent activation energies for the Na₂SO₄-NaSCN and Na₂SO₄-NaSCN-CaO systems are 154.56 kJ·mol⁻¹ and 141.23 kJ·mol⁻¹, respectively.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"226 ","pages":"Pages 667-675"},"PeriodicalIF":3.9,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146034748","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Research on drag reduction and permeability enhancement of micro nano bubbles in gas displacement","authors":"Zhonghao Liu ,&nbsp;Shilin Li ,&nbsp;Pengfei Wang ,&nbsp;Yong Chen ,&nbsp;Yafei Luo ,&nbsp;Fei Huang","doi":"10.1016/j.cherd.2026.01.007","DOIUrl":"10.1016/j.cherd.2026.01.007","url":null,"abstract":"<div><div>To improve the problems of cost, environment and efficiency faced by traditional coal seam water injection technology, this paper proposes to use micro-nano bubble (MNB) water as a new water injection medium, and studies its performance through experimental systems such as wettability, drag reduction, microstructure and gas displacement. The results showed that MNB water significantly improved the wettability of coal, with the surface tension being instantaneously reduced by 12.6 mN/m and the contact angle decreasing by approximately 11.17°. A notable drag reduction effect was observed during the water injection process, where the maximum drag reduction rate reached 28.05 %. Microscopically, it promoted the secondary development of pores in coal, resulting in increases in porosity and permeability by 22.73 % and 27.61 %, respectively, compared to raw coal. In the gas displacement experiment, the instantaneous flow rate and gas permeability increased by up to 44.21 % and 42.81 %, respectively. This study confirms that MNB water has great potential in enhancing water injection effects, improving the wettability of coal bodies and strengthening gas displacement, providing an economical and environmentally friendly new approach for the prevention and control of coal mine disasters. However, its universality needs to be further verified through experiments on coal samples of different coal grades in the future.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"226 ","pages":"Pages 349-357"},"PeriodicalIF":3.9,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145973889","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Multi-objective optimization for sustainable dimethyl oxalate synthesis: A plant-wide framework balancing economic benefits and carbon emissions","authors":"Shida Gao ,&nbsp;Cuimei Bo ,&nbsp;Guo Yu ,&nbsp;Quanling Zhang ,&nbsp;Furong Gao ,&nbsp;Genke Yang ,&nbsp;Jian Chu","doi":"10.1016/j.cherd.2026.01.035","DOIUrl":"10.1016/j.cherd.2026.01.035","url":null,"abstract":"<div><div>Ethylene glycol (EG) serves as a primary raw material in the polyester industry, with syngas-to-dimethyl oxalate (DMO) conversion representing an advanced EG production method. However, this process encounters conflicting objectives between maximization of economic benefits and minimization of carbon emissions, particularly exacerbated by constraints and market prices. To address this challenge, we developed a multi-objective optimization framework for various working conditions: First, we establish a steady-state simulation system incorporating reaction kinetics and mechanisms to model the DMO synthesis process. Then, an innovative economy-carbon emission multi-objective optimization problem is formulated, where the ranges of pivotal operating parameters are determined by sensitivity analysis, and the response surface method is used to obtain the reference points under different conditions. Finally, the optimization problem is solved by the Pareto frontier (PF) estimation algorithm to solve the irregular PF problem, which arises from the complex nonlinear interactions between process variables under various working and price conditions. Under regular working conditions, we compare the knee point among the obtained Pareto solution set with the reference point, and the framework reduces carbon emissions by 19.63% (129.5 kmol/h) while increasing economic benefits by 1.38% (1253.1 yuan/h). Considering three typical conditions of sharp increase of DMC prices, limited production capacity and short-term negative profits, our framework identifies solutions that dominate the reference points and the original turning points in the obtained PF. The results have verified that this study is able to support the decision-making in providing solutions with a good balance between economy and carbon emissions under various working and price conditions.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"226 ","pages":"Pages 536-549"},"PeriodicalIF":3.9,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146034239","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Modelling and optimization of vacuum pressure swing adsorption CO2 capture pilot using MIL-160(Al)","authors":"A. Henrotin,&nbsp;N. Heymans,&nbsp;M.-E. Duprez,&nbsp;G. De Weireld","doi":"10.1016/j.cherd.2025.12.030","DOIUrl":"10.1016/j.cherd.2025.12.030","url":null,"abstract":"<div><div>Global warming, driven by increasing CO₂ emissions from fossil fuel combustion, necessitates the development of effective carbon capture technologies. Among various approaches, Vacuum Pressure Swing Adsorption (VPSA) offers an energy-efficient solution for post-combustion CO₂ capture, especially in power plants and energy-intensive industries. This work focuses on validating a simulation model using a laboratory VPSA pilot with the Aluminum Metal-Organic Framework (Al-MOF) MIL-160(Al) and optimizing both lab-scale and industrial-scale VPSA pilots through simulation. Process modeling in Aspen Adsorption software simulated a 3-bed 6-step cycle using parameters from experimental adsorption isotherms and breakthrough curves. The simulation model was compared to previous lab-scale VPSA pilot experiments treating a synthetic 15/85 CO₂/N₂ mixture at 1 Nm³ /h, showing mean absolute errors of 1.47 % for purity and 3.19 % for recovery. Surrogate models, including kriging and artificial neural networks (ANN), were used to optimize recovery and purity of the lab-scale pilot using the Non-dominated Sorting Genetic Algorithm-II (NSGA-II). The ANN model proved more accurate, especially in determining pareto fronts. The model was extended to an industrial VPSA pilot as part of the MOF4AIR project, designed to treat flue gas of 50–100 Nm³ /h with three 41 L adsorption columns. Simulations showed that the pilot could achieve 95 % purity and recovery for CO₂ concentrations ranging from 5 % to 15 %. The estimated energy consumption and productivity for 15 % CO₂ gas were 413.19 kWh/tCO₂ and 3.03 tCO₂/(m³ads.day) at a gas flow rate of 55.62 Nm³ /h, demonstrating the technology's potential and competitiveness on a larger scale.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"226 ","pages":"Pages 14-30"},"PeriodicalIF":3.9,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145801949","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Energy-efficient separation of benzene/isopropanol/water by introducing a tailor-made ionic liquid solvent","authors":"Ting Chen ,&nbsp;Heng Liu ,&nbsp;Xiaoyong Bao ,&nbsp;Jiaqi Feng ,&nbsp;Yuqiu Chen ,&nbsp;Guohua Liu","doi":"10.1016/j.cherd.2025.12.041","DOIUrl":"10.1016/j.cherd.2025.12.041","url":null,"abstract":"<div><div>In the industrial production of chloramphenicol, large volumes of waste liquids containing benzene, isopropanol, and water are generated. Conventional treatment methods often discharge these waste streams as wastewater, leading to severe environmental pollution and significant resource losses. To address this challenge, this study proposes a novel ionic liquid (IL)-assisted distillation process for efficient separation and recovery of benzene and isopropanol from mixed waste streams. A computer-aided ionic liquid design (CAILD) framework is developed, integrating innovative design objectives with a mixed-integer nonlinear programming (MINLP) model to systematically screen and select high-performance ILs. This approach identifies imidazolium methylsulfate ([IM][MeSO₄]) as the optimal solvent, offering superior separation capability compared with conventional entrainers. Results demonstrate that, compared to conventional distillation without extractants, the [IM][MeSO₄]-based process achieved 66.64 % energy savings, 19.72 % total annual cost (TAC) savings, and a 66.73 % reduction in carbon emissions. Even when compared to the ethylene glycol (EG)-based process, the [IM][MeSO₄]-based process delivered additional improvements of 4.88 % in energy savings and 5.05 % in carbon emissions, without requiring extra economic investment. This work introduces a systematic, model-driven approach for IL selection and process design, showcasing the potential of IL-based distillation technology to enable more energy-efficient and environmentally sustainable recovery of valuable solvents from industrial waste streams.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"226 ","pages":"Pages 146-158"},"PeriodicalIF":3.9,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145881978","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Multiphasic simulation and thermal stress evaluation of an industrial methane reformer in the DRI hydrogen production process","authors":"Mahmoud Makki Abadi ,&nbsp;Mostafa Ghasemi ,&nbsp;Hadi Karim Ghasmi ,&nbsp;Mohammad Zare ,&nbsp;Udayabhaskararao Thumu ,&nbsp;Aliakbar Taghipour ,&nbsp;Mohammad Saleh Haj Mohammadi","doi":"10.1016/j.cherd.2025.12.033","DOIUrl":"10.1016/j.cherd.2025.12.033","url":null,"abstract":"<div><div>In this study, a comprehensive numerical simulation of an industrial methane-based reformer used in the Direct Reduction of Iron (DRI) process was conducted based on the MIDREX method. The objective was to assess the reformer's thermal, kinetic, and thermodynamic behavior and to investigate flow characteristics, heat transfer, and thermal stress distribution within the catalytic tubes. The reformer contains tubes packed with three catalyst zones—active, semi-active, and inert—through which a feed mixture of natural gas (primarily CH₄), steam (H₂O), and carbon dioxide (CO₂) flows. These species undergo highly endothermic steam and dry reforming reactions, generating a hydrogen-rich reducing gas. The simulation was developed using real industrial data from the Goharzamin DRI plant in Sirjan, Iran, and employed a multiphysics modeling approach coupling chemical kinetics, mass and heat transfer, and solid mechanics. Results revealed that increasing the external wall temperature from 1300 K to 1500 K led to a 12.24 % increase in H₂ and a 5.71 % increase in CO production. Furthermore, increasing the CO₂/CH₄ ratio from 0.80 to 1.25 resulted in an approximate 2.74 % rise in CO output, highlighting the sensitivity of reforming efficiency to feed composition. Increasing the wall temperature was found to intensify these stresses, with stress at the inlet rising from 9 MPa at 1300 K to 12 MPa at 1500 K, and at 2.6 m increasing from 12.5 MPa to 13 MPa. At the critical 5.2 m location, stress grew from 38 MPa at 1300 K to nearly 42 MPa at 1500 K. Also, results indicate that the actual gas composition is well beyond the thermodynamic limit for carbon deposition, confirming that solid carbon (coke) formation is highly unfavorable under these operating conditions.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"226 ","pages":"Pages 114-133"},"PeriodicalIF":3.9,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145881976","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Realisation of mathematical conditions ensuring smooth transition of heat and mass transfer at the boundaries of solids and liquids","authors":"J.E. Safarov ,&nbsp;Sh.A. Sultanova ,&nbsp;D.I. Samandarov ,&nbsp;Gurbuz Gunes ,&nbsp;M.R. Najafli ,&nbsp;A.A. Mambetsheripova ,&nbsp;M.M. Pulatov ,&nbsp;Gunel Imanova","doi":"10.1016/j.cherd.2026.01.032","DOIUrl":"10.1016/j.cherd.2026.01.032","url":null,"abstract":"<div><div>The drying process involving heat and mass transfer at solid-liquid interfaces is fundamental in various industries such as food, pharmaceuticals and textiles. One of the most challenging aspects of this phenomenon is to ensure smooth heat and mass transfer at solid-liquid interfaces, as discontinuities in boundary conditions can lead to inaccurate results and complicate process control. This study is devoted to the formulation of mathematical conditions that ensure a smooth transition at solid-liquid interfaces in a combined drying process. A transition state model based on Fourier and Fick equations is proposed to describe heat exchange and moisture diffusion in a food product. The modelling takes into account the thermophysical properties of the material, the heat transfer coefficient and the operating conditions of the system. Fundamental theories and mathematical methods required for effective modelling to improve the understanding and control of drying processes are also discussed.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"226 ","pages":"Pages 476-484"},"PeriodicalIF":3.9,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145973738","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Physical simulation study on the gas-liquid two-phase flow mixing time in bottom-blown lead smelting process utilizing RGB color model and dimensional analysis","authors":"Yanxin Wu ,&nbsp;Jing Li ,&nbsp;Jindi Huang ,&nbsp;Fupeng Liu","doi":"10.1016/j.cherd.2026.01.012","DOIUrl":"10.1016/j.cherd.2026.01.012","url":null,"abstract":"<div><div>In the process of bottom-blown lead smelting, the mixing time acts as a crucial indicator for assessing the homogenization effectiveness in the bottom-blown furnace. This research established a water model scaled down at a ratio of 1:10.3 of an industrial furnace prototype based on the similarity principle. Subsequently, a physical simulation approach was adopted to conduct an in-depth exploration of the gas-liquid two-phase flow mixing time in the bottom-blown lead smelting operation. Precise quantification of the mixing time was achieved using the RGB color model. In conjunction with dimensional analysis, which helps to identify the key dimensionless groups governing the mixing process, a comprehensive investigation was carried out to determine how key variables—including liquid level height (<em>H</em>), gas flow rate (<em>Q</em>), lance angle (<em>θ</em>), and feed inlet position (<em>P</em>)—affect the mixing time. Furthermore, through nonlinear regression fitting of the experimental values, a dimensionless correlation equation for the mixing time <span><math><mrow><mi>t</mi><msup><mrow><mo>(</mo><mrow><mi>g</mi><mo>/</mo><mi>D</mi></mrow><mo>)</mo></mrow><mrow><mn>0.5</mn></mrow></msup><mo>=</mo><mn>2.24</mn><mo>×</mo><msup><mrow><mn>10</mn></mrow><mn>7</mn></msup><msup><mrow><mo>(</mo><mrow><mi>H</mi><mo>/</mo><mi>D</mi></mrow><mo>)</mo></mrow><mrow><mo>-</mo><mn>2.83</mn></mrow></msup><msup><mrow><mo>(</mo><mi>F</mi><msup><mrow><mi>r</mi></mrow><mo>′</mo></msup><mo>)</mo></mrow><mrow><mo>-</mo><mn>0.46</mn></mrow></msup><msup><mrow><mo>(</mo><mrow><mi>P</mi><mo>/</mo><mi>D</mi></mrow><mo>)</mo></mrow><mrow><mn>0.32</mn></mrow></msup><msup><mrow><mo>(</mo><mn>90</mn><mo>−</mo><mi>θ</mi><mo>)</mo></mrow><mrow><mo>-</mo><mn>2.23</mn></mrow></msup></mrow></math></span> was obtained. The research findings can provide scientific and theoretical guidance for optimizing the process and furnace structure in the bottom-blown lead smelting process, thereby contributing to the low-carbon and efficient development of China's lead smelting industry.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"226 ","pages":"Pages 326-335"},"PeriodicalIF":3.9,"publicationDate":"2026-02-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145973741","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}