Pub Date : 2026-01-09DOI: 10.1016/j.cherd.2026.01.015
E. Kofanova , M. Deminsky , A. Lebedev , B. Potapkin
Methane pyrolysis in a liquid metal bubble column reactor is a non-oxidative perspective technology of hydrogen production. The present work examines the gas phase distribution gas holdup dependence upon gas jet parameters and injection method. A 3D model approach combining liquid metal and bubbles hydrodynamics with chemical kinetics was used for analysis methane conversion. The 3D two-phase hydrodynamic model shows good agreement with recent gas holdup estimates from studies on large-scale hydrogen production under optimal conditions. The obtained results demonstrate how reactor performance quantitatively depends on the gas injection method. Non-uniform gas distribution, resulting from inefficient injection, degrades methane conversion and can reduce reactor performance by up to 50 %.
{"title":"Numerical investigation of the influence of the gas injection method upon holdup and melt reactor productivity in the process of the methane pyrolysis","authors":"E. Kofanova , M. Deminsky , A. Lebedev , B. Potapkin","doi":"10.1016/j.cherd.2026.01.015","DOIUrl":"10.1016/j.cherd.2026.01.015","url":null,"abstract":"<div><div>Methane pyrolysis in a liquid metal bubble column reactor is a non-oxidative perspective technology of hydrogen production. The present work examines the gas phase distribution gas holdup dependence upon gas jet parameters and injection method. A 3D model approach combining liquid metal and bubbles hydrodynamics with chemical kinetics was used for analysis methane conversion. The 3D two-phase hydrodynamic model shows good agreement with recent gas holdup estimates from studies on large-scale hydrogen production under optimal conditions. The obtained results demonstrate how reactor performance quantitatively depends on the gas injection method. Non-uniform gas distribution, resulting from inefficient injection, degrades methane conversion and can reduce reactor performance by up to 50 %.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"226 ","pages":"Pages 485-498"},"PeriodicalIF":3.9,"publicationDate":"2026-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145973742","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}
Pub Date : 2026-01-08DOI: 10.1016/j.cherd.2026.01.004
Qingsong Hu , Linjun Wang , Xiaolu Xu, Yi Liu, Yunjie Xie, Bowen Xu, Chaoyang Jiang, Jing Li, Guiyun Liu, Feng Zeng
The catalytic hydrogenation of CO2 into value-added alcohols presents a viable pathway for carbon recycling and sustainable fuel production. However, the complex interplay of components in multi-metallic catalysts makes rational design challenging. In this study, we employed a three-level, full-factorial (33) experimental design to systematically investigate the compositional effects of CoAlPtMo catalysts on CO2 hydrogenation. The impacts of the Co/(Co+Al) molar ratio, Mo mass fraction, and Pt mass fraction on methanol productivity (PMeOH), higher-alcohol productivity (PHA), CO-free methane selectivity (SCH4(CO-free)), and CO selectivity (SCO) were quantified using polynomial regression and analysis of variance (ANOVA). The resulting statistical models accurately described the catalytic performance (R2 > 0.87) and revealed significant interactions between the metallic components. The Co/(Co+Al) ratio was identified as the most dominant factor, with a high ratio strongly promoting higher-alcohol formation but also increasing undesirable methanation. Conversely, a low Co/(Co+Al) ratio favored methanol production, reducing SCH4(CO-free). Molybdenum incorporation effectively suppressed methanation but hindered alcohol productivity, while platinum promotion enhanced hydrogenation activity promoting both the production of alcohols and methane. The quadratic and interaction terms capture the factors’ nonlinear effects on performance, improving the model’s explanatory power. The optimized Co0.1Al0.9-Mo3Pt7 catalyst exhibited a high methanol productivity of 2720.5 μmol gPt+Co+Mo−1 h−1 and a CO-free selectivity of 79.1 %. For the optimized Co0.9Al0.1-Mo3Pt10.5, higher-alcohol productivity reached 602.7 μmol gPt+Co+Mo−1 h−1 with a CO-free selectivity of 8.5 %. The structure–performance correlation highlights the pivotal role of adsorption strength (tailored by catalyst composition) in modulating the hydrogenation capability of the catalysts and, consequently, the product distribution. This statistical method guides catalyst design by elucidating factor effects and enabling rational optimization of product distribution and selectivity in CO2 hydrogenation.
{"title":"Systematic optimization of quaternary CoAlPtMo catalysts for alcohol synthesis from CO2 hydrogenation using a full-factorial design approach","authors":"Qingsong Hu , Linjun Wang , Xiaolu Xu, Yi Liu, Yunjie Xie, Bowen Xu, Chaoyang Jiang, Jing Li, Guiyun Liu, Feng Zeng","doi":"10.1016/j.cherd.2026.01.004","DOIUrl":"10.1016/j.cherd.2026.01.004","url":null,"abstract":"<div><div>The catalytic hydrogenation of CO<sub>2</sub> into value-added alcohols presents a viable pathway for carbon recycling and sustainable fuel production. However, the complex interplay of components in multi-metallic catalysts makes rational design challenging. In this study, we employed a three-level, full-factorial (3<sup>3</sup>) experimental design to systematically investigate the compositional effects of CoAlPtMo catalysts on CO<sub>2</sub> hydrogenation. The impacts of the Co/(Co+Al) molar ratio, Mo mass fraction, and Pt mass fraction on methanol productivity (<em>P</em><sub>MeOH</sub>), higher-alcohol productivity (<em>P</em><sub>HA</sub>), CO-free methane selectivity (<em>S</em><sub>CH4(CO-free)</sub>), and CO selectivity (<em>S</em><sub>CO</sub>) were quantified using polynomial regression and analysis of variance (ANOVA). The resulting statistical models accurately described the catalytic performance (R<sup>2</sup> > 0.87) and revealed significant interactions between the metallic components. The Co/(Co+Al) ratio was identified as the most dominant factor, with a high ratio strongly promoting higher-alcohol formation but also increasing undesirable methanation. Conversely, a low Co/(Co+Al) ratio favored methanol production, reducing <em>S</em><sub>CH4(CO-free)</sub>. Molybdenum incorporation effectively suppressed methanation but hindered alcohol productivity, while platinum promotion enhanced hydrogenation activity promoting both the production of alcohols and methane. The quadratic and interaction terms capture the factors’ nonlinear effects on performance, improving the model’s explanatory power. The optimized Co<sub>0.1</sub>Al<sub>0.9</sub>-Mo<sub>3</sub>Pt<sub>7</sub> catalyst exhibited a high methanol productivity of 2720.5 μmol g<sub>Pt+Co+Mo</sub><sup>−1</sup> h<sup>−1</sup> and a CO-free selectivity of 79.1 %. For the optimized Co<sub>0.9</sub>Al<sub>0.1</sub>-Mo<sub>3</sub>Pt<sub>10.5</sub>, higher-alcohol productivity reached 602.7 μmol g<sub>Pt+Co+Mo</sub><sup>−1</sup> h<sup>−1</sup> with a CO-free selectivity of 8.5 %. The structure–performance correlation highlights the pivotal role of adsorption strength (tailored by catalyst composition) in modulating the hydrogenation capability of the catalysts and, consequently, the product distribution. This statistical method guides catalyst design by elucidating factor effects and enabling rational optimization of product distribution and selectivity in CO<sub>2</sub> hydrogenation.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"226 ","pages":"Pages 336-348"},"PeriodicalIF":3.9,"publicationDate":"2026-01-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145973745","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}
Pub Date : 2026-01-07DOI: 10.1016/j.cherd.2026.01.012
Yanxin Wu , Jing Li , Jindi Huang , Fupeng Liu
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 (H), gas flow rate (Q), lance angle (θ), and feed inlet position (P)—affect the mixing time. Furthermore, through nonlinear regression fitting of the experimental values, a dimensionless correlation equation for the mixing time 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.
{"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 , Jing Li , Jindi Huang , 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":"2026-01-07","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}
Pub Date : 2026-01-07DOI: 10.1016/j.cherd.2026.01.008
Mahmood Mousavi , Caleb Caldwell , Jacob Baltes , Forough A. Parizad , Muteb Aljasem , Bok Jik Lee , Nader Karimi
Achieving clean combustion systems is crucial for addressing environmental impacts, decarbonization needs, and sustainability challenges. Traditional combustion modeling techniques via computational fluid dynamics with accurate chemical kinetics face obstacles in computational cost and accurate representation of turbulence-chemistry interactions. Physics-Informed Neural Networks (PINNs), as a novel framework merging physical laws with data-driven learning, demonstrate great potential as an alternative methodology. By directly integrating conservation equations into their training process, PINNs achieve accurate mesh-free modeling of complex combustion phenomena despite having limited datasets.
This review examines state-of-the-art PINNs applications in clean combustion systems, focusing on their impact in aerospace propulsion. We systematically analyze implementations across flame dynamics and propagation (achieving computational speedups of 2.3-4.9 times), turbulent combustion modeling including thermoacoustic instabilities, emissions prediction for NOx, soot, and CO, stiff reaction systems (with speedups of 6.0-14.6 times for chemical source terms), and optimization and control strategies. The review provides detailed comparisons with traditional CFD methods, highlighting PINNs advantages in computational efficiency, mesh-free operation, and native inverse problem capability, while acknowledging challenges in training stability, uncertainty quantification, and industrial validation.
We present a research roadmap spanning short-term priorities (2025–2027) for algorithm development and uncertainty quantification, medium-term goals (2027–2030) for industrial deployment and multi-physics integration, and long-term vision (2030+) encompassing quantum-enhanced PINNs and self-learning systems. Cross-cutting themes include evolution toward physics-discovering frameworks, integrated experimental-computational workflows, and transferable knowledge across scales. Critical analysis reveals that while PINNs have progressed rapidly from fundamental demonstrations to industrial applications within four years, significant challenges remain in real-time control, safety certification, and industrial deployment.
Next-generation aerospace engines rely on PINNs to reduce computational costs while increasing predictive performance and enabling real-time control methods. This review demonstrates how PINNs can revolutionize sustainable and efficient combustion technologies in aerospace propulsion systems, contributing to climate change mitigation while maintaining performance requirements of modern propulsion systems.
{"title":"Physics-informed neural networks in clean combustion: A pathway to sustainable aerospace propulsion","authors":"Mahmood Mousavi , Caleb Caldwell , Jacob Baltes , Forough A. Parizad , Muteb Aljasem , Bok Jik Lee , Nader Karimi","doi":"10.1016/j.cherd.2026.01.008","DOIUrl":"10.1016/j.cherd.2026.01.008","url":null,"abstract":"<div><div>Achieving clean combustion systems is crucial for addressing environmental impacts, decarbonization needs, and sustainability challenges. Traditional combustion modeling techniques via computational fluid dynamics with accurate chemical kinetics face obstacles in computational cost and accurate representation of turbulence-chemistry interactions. Physics-Informed Neural Networks (PINNs), as a novel framework merging physical laws with data-driven learning, demonstrate great potential as an alternative methodology. By directly integrating conservation equations into their training process, PINNs achieve accurate mesh-free modeling of complex combustion phenomena despite having limited datasets.</div><div>This review examines state-of-the-art PINNs applications in clean combustion systems, focusing on their impact in aerospace propulsion. We systematically analyze implementations across flame dynamics and propagation (achieving computational speedups of 2.3-4.9 times), turbulent combustion modeling including thermoacoustic instabilities, emissions prediction for NO<sub>x</sub>, soot, and CO, stiff reaction systems (with speedups of 6.0-14.6 times for chemical source terms), and optimization and control strategies. The review provides detailed comparisons with traditional CFD methods, highlighting PINNs advantages in computational efficiency, mesh-free operation, and native inverse problem capability, while acknowledging challenges in training stability, uncertainty quantification, and industrial validation.</div><div>We present a research roadmap spanning short-term priorities (2025–2027) for algorithm development and uncertainty quantification, medium-term goals (2027–2030) for industrial deployment and multi-physics integration, and long-term vision (2030+) encompassing quantum-enhanced PINNs and self-learning systems. Cross-cutting themes include evolution toward physics-discovering frameworks, integrated experimental-computational workflows, and transferable knowledge across scales. Critical analysis reveals that while PINNs have progressed rapidly from fundamental demonstrations to industrial applications within four years, significant challenges remain in real-time control, safety certification, and industrial deployment.</div><div>Next-generation aerospace engines rely on PINNs to reduce computational costs while increasing predictive performance and enabling real-time control methods. This review demonstrates how PINNs can revolutionize sustainable and efficient combustion technologies in aerospace propulsion systems, contributing to climate change mitigation while maintaining performance requirements of modern propulsion systems.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"226 ","pages":"Pages 258-281"},"PeriodicalIF":3.9,"publicationDate":"2026-01-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145922444","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}
Pub Date : 2026-01-06DOI: 10.1016/j.cherd.2026.01.011
Shebly Akter , Nazia Rahman , Umme Salma , Md. Ferdous Alam , Md Minhajul Islam , Zeenath Fardous , M. Ahasanur Rabbi , Md. Nabul Sardar
Environmental pollution resulting from heavy metal effluents is a significant concern, and it becomes necessary to treat these effluents before they are released into the ecosystem. In this study, the adsorption of Cr (VI) and Co (II) ions was analyzed from aqueous solution by using grafted amidoximated grafted fabrics. The radiation-induced (γ-ray) grafting method (a 50 kGy radiation dose) was used to graft non-woven Polyethylene (PE) with Acrylonitrile (AN) and Sodium Styrene Sulfonate (SSS) co-monomers. The grafted fabrics were amidoximated. FTIR, SEM, TGA, and DMA were used to characterize the adsorbent. The maximum capacity of adsorption was obtained at a contact time of 24 h, an initial metal ion concentration of 600 ppm, pH 1.43, and temperature of 60 °C for Cr (VI), and a contact time of 6 h, an initial metal ion concentration of 400 ppm, pH 8.05 and temperature of 70 °C for Co (II) during the dynamic adsorption phenomena. The findings demonstrated how well the Langmuir isotherm model fit the data, with the highest adsorption capacity of 138.95 mg/g for Cr (VI) and 97.86 mg/g for Co (II). According to kinetic observations, the batch experimental results were found to be consistent with the pseudo-second-order model. The values of ΔH°, ΔS°, and ΔG° in the thermodynamic study suggest that the process of removal was endothermic, spontaneous, and favorable, as demonstrated in the thermodynamic observation. Furthermore, investigating the adsorbent's ability to desorb metal ions and its reusability indicates that it is a novel and efficient alternative material for removing Cr (VI) and Co (II) ions from the aqueous environment.
{"title":"Fabricating nitrile and sulfonate functionalized nonwoven polyethylene (PE) adsorbent by using radiation-induced grafting for efficient capture of Cr (VI) and Co (II)","authors":"Shebly Akter , Nazia Rahman , Umme Salma , Md. Ferdous Alam , Md Minhajul Islam , Zeenath Fardous , M. Ahasanur Rabbi , Md. Nabul Sardar","doi":"10.1016/j.cherd.2026.01.011","DOIUrl":"10.1016/j.cherd.2026.01.011","url":null,"abstract":"<div><div>Environmental pollution resulting from heavy metal effluents is a significant concern, and it becomes necessary to treat these effluents before they are released into the ecosystem. In this study, the adsorption of Cr (VI) and Co (II) ions was analyzed from aqueous solution by using grafted amidoximated grafted fabrics. The radiation-induced (γ-ray) grafting method (a 50 kGy radiation dose) was used to graft non-woven Polyethylene (PE) with Acrylonitrile (AN) and Sodium Styrene Sulfonate (SSS) co-monomers. The grafted fabrics were amidoximated. FTIR, SEM, TGA, and DMA were used to characterize the adsorbent. The maximum capacity of adsorption was obtained at a contact time of 24 h, an initial metal ion concentration of 600 ppm, pH 1.43, and temperature of 60 °C for Cr (VI), and a contact time of 6 h, an initial metal ion concentration of 400 ppm, pH 8.05 and temperature of 70 °C for Co (II) during the dynamic adsorption phenomena. The findings demonstrated how well the Langmuir isotherm model fit the data, with the highest adsorption capacity of 138.95 mg/g for Cr (VI) and 97.86 mg/g for Co (II). According to kinetic observations, the batch experimental results were found to be consistent with the pseudo-second-order model. The values of ΔH°, ΔS°, and ΔG° in the thermodynamic study suggest that the process of removal was endothermic, spontaneous, and favorable, as demonstrated in the thermodynamic observation. Furthermore, investigating the adsorbent's ability to desorb metal ions and its reusability indicates that it is a novel and efficient alternative material for removing Cr (VI) and Co (II) ions from the aqueous environment.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"226 ","pages":"Pages 310-325"},"PeriodicalIF":3.9,"publicationDate":"2026-01-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145973744","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}
Pub Date : 2026-01-06DOI: 10.1016/j.cherd.2026.01.007
Zhonghao Liu , Shilin Li , Pengfei Wang , Yong Chen , Yafei Luo , Fei Huang
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.
{"title":"Research on drag reduction and permeability enhancement of micro nano bubbles in gas displacement","authors":"Zhonghao Liu , Shilin Li , Pengfei Wang , Yong Chen , Yafei Luo , 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":"2026-01-06","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}
Pub Date : 2026-01-06DOI: 10.1016/j.cherd.2026.01.010
Muhammad Arslan Jameel Malik , Muhammad Athar , Muhammad Aashan Jabbar , Azmi Mohd Shariff , Asim Umer
The lifecycle process comprises various stages, with process design being a critical stage divided into multiple steps. Economic evaluation has a substantial role in shaping the final design. In addition to economic factors, the principle of inherent safety significantly influences the development of sustainable process designs. Traditionally, inherent safety considerations have been applied separately to the characteristics of individual equipment. However, a comprehensive approach that simultaneously addresses inherent safety, equipment-specific factors, and economic considerations has been lacking. To bridge this gap, a novel methodology named as inherently safer economical heat exchanger network (ISEHEN) has been introduced. This approach integrates inherent safety and economic aspects into a unified framework. ISEHEN employs an index, namely the inherent safety cost index for heat exchanger network (ISCIHEN), to pinpoint critical heat exchanger, which are then subjected to explosion risk assessments. If the risk level is deemed unacceptable, inherent safety guidewords are utilized to propose design modification, which are subsequently evaluated for economic feasibility. In this work, risk consequences are expressed in economic terms, and hence, the proposed method appears to be a valuable tool for process designers to make decisions regarding process designs at earlier stages, considering safety and economics simultaneously.
{"title":"Sustainable process design approach of heat exchanger network engaging inherent safety and economics at preliminary design stage","authors":"Muhammad Arslan Jameel Malik , Muhammad Athar , Muhammad Aashan Jabbar , Azmi Mohd Shariff , Asim Umer","doi":"10.1016/j.cherd.2026.01.010","DOIUrl":"10.1016/j.cherd.2026.01.010","url":null,"abstract":"<div><div>The lifecycle process comprises various stages, with process design being a critical stage divided into multiple steps. Economic evaluation has a substantial role in shaping the final design. In addition to economic factors, the principle of inherent safety significantly influences the development of sustainable process designs. Traditionally, inherent safety considerations have been applied separately to the characteristics of individual equipment. However, a comprehensive approach that simultaneously addresses inherent safety, equipment-specific factors, and economic considerations has been lacking. To bridge this gap, a novel methodology named as inherently safer economical heat exchanger network (ISEHEN) has been introduced. This approach integrates inherent safety and economic aspects into a unified framework. ISEHEN employs an index, namely the inherent safety cost index for heat exchanger network (ISCIHEN), to pinpoint critical heat exchanger, which are then subjected to explosion risk assessments. If the risk level is deemed unacceptable, inherent safety guidewords are utilized to propose design modification, which are subsequently evaluated for economic feasibility. In this work, risk consequences are expressed in economic terms, and hence, the proposed method appears to be a valuable tool for process designers to make decisions regarding process designs at earlier stages, considering safety and economics simultaneously.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"226 ","pages":"Pages 296-309"},"PeriodicalIF":3.9,"publicationDate":"2026-01-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145922443","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}
Pub Date : 2026-01-05DOI: 10.1016/j.cherd.2026.01.006
Ao Chen , Baozong Zhang , Hongkun Huo , Weiye Chen , Xuechao Gao
The multi-objective optimization of gas fractionation unit with other novel techniques is a critical and complex challenge in the propylene industry, where the significant application potential of new techniques could be concealed due to the presence of local minimum. To solve this issue, this work proposed a multi-objective optimization approach by integrating the NSGA-III algorithm to explore the application potential of membrane separation technology, where the gas fractionation unit was used as a representative case. Through the multi-objective algorithm optimization of NSGA-III, the total annual cost and CO2 emissions were reduced by 3.6 % and 1.6 %, respectively. To further optimize the total annual cost and CO₂ emissions, a membrane unit was deliberately employed to sequentially replace three distillation columns, respectively, where the membrane area and compressing power were balanced. The minimum total annual cost was achieved when the propylene distillation column was replaced by a membrane unit operated under a compression ratio of 8, resulting in a 52.4 % reduction in total annual cost and a 64.7 % decrease in CO₂ emissions. These discoveries could provide valuable references to the optimization and modification of chemical engineering processes with new techniques.
{"title":"Exploring the application potential of membrane separation in the gas fractionation unit for propylene production by NSGA-III algorithm","authors":"Ao Chen , Baozong Zhang , Hongkun Huo , Weiye Chen , Xuechao Gao","doi":"10.1016/j.cherd.2026.01.006","DOIUrl":"10.1016/j.cherd.2026.01.006","url":null,"abstract":"<div><div>The multi-objective optimization of gas fractionation unit with other novel techniques is a critical and complex challenge in the propylene industry, where the significant application potential of new techniques could be concealed due to the presence of local minimum. To solve this issue, this work proposed a multi-objective optimization approach by integrating the NSGA-III algorithm to explore the application potential of membrane separation technology, where the gas fractionation unit was used as a representative case. Through the multi-objective algorithm optimization of NSGA-III, the total annual cost and CO<sub>2</sub> emissions were reduced by 3.6 % and 1.6 %, respectively. To further optimize the total annual cost and CO₂ emissions, a membrane unit was deliberately employed to sequentially replace three distillation columns, respectively, where the membrane area and compressing power were balanced. The minimum total annual cost was achieved when the propylene distillation column was replaced by a membrane unit operated under a compression ratio of 8, resulting in a 52.4 % reduction in total annual cost and a 64.7 % decrease in CO₂ emissions. These discoveries could provide valuable references to the optimization and modification of chemical engineering processes with new techniques.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"226 ","pages":"Pages 238-257"},"PeriodicalIF":3.9,"publicationDate":"2026-01-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145922438","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}
Biodiesel derived from waste cooking oil (WCO) represents a promising strategy for meeting energy demands, mitigating environmental impact, and supporting carbon neutrality goals in countries such as Japan and India. However, conventional alkaline transesterification faces challenges, including soap formation from free fatty acids (FFAs) in WCO and poor miscibility of oil and alcohol phases, both of which limit efficiency. Although one-step acidic esterification and traditional organic cosolvents have been explored to overcome these drawbacks, such approaches raise economic and environmental concerns. Thus, this study investigated a two-step acid-base catalysis process employing the low-toxicity cyclopentyl methyl ether (CPME) cosolvent for the production of biodiesel from WCO, which was collected from local restaurants in Tokyo, Japan. The process was carried out through initial acidic esterification to convert FFAs to esters, followed by alkaline transesterification optimized at a 1:6 oil-to-cosolvent molar ratio. CPME, characterized by its low toxicity, intermediate polarity and excellent miscibility, facilitated a high biodiesel yield of 97.5 %, outperforming n-hexane (96 %) and reactions conducted without a cosolvent (89 %). Gas chromatography-mass spectrometry (GC-MS) analysis confirmed that the synthesized biodiesel met the EN 14214 European quality standard (≥96.5 % FAME content). The process operated at a mild temperature of 40°C, enhancing yield with lower energy input. Overall, the CPME-assisted two-step process offers an efficient and viable route for biodiesel production from waste feedstocks.
{"title":"Optimization of a two-step biodiesel production from waste cooking oil: Comparative evaluation of n-hexane and CPME as transesterification cosolvents","authors":"Md. Rubel , Cheng Shuo , Sasipa Boonyubol , M.M. Harussani , Surendra Singh Kachhwaha , Jeffrey S. Cross","doi":"10.1016/j.cherd.2026.01.005","DOIUrl":"10.1016/j.cherd.2026.01.005","url":null,"abstract":"<div><div>Biodiesel derived from waste cooking oil (WCO) represents a promising strategy for meeting energy demands, mitigating environmental impact, and supporting carbon neutrality goals in countries such as Japan and India. However, conventional alkaline transesterification faces challenges, including soap formation from free fatty acids (FFAs) in WCO and poor miscibility of oil and alcohol phases, both of which limit efficiency. Although one-step acidic esterification and traditional organic cosolvents have been explored to overcome these drawbacks, such approaches raise economic and environmental concerns. Thus, this study investigated a two-step acid-base catalysis process employing the low-toxicity cyclopentyl methyl ether (CPME) cosolvent for the production of biodiesel from WCO, which was collected from local restaurants in Tokyo, Japan. The process was carried out through initial acidic esterification to convert FFAs to esters, followed by alkaline transesterification optimized at a 1:6 oil-to-cosolvent molar ratio. CPME, characterized by its low toxicity, intermediate polarity and excellent miscibility, facilitated a high biodiesel yield of 97.5 %, outperforming n-hexane (96 %) and reactions conducted without a cosolvent (89 %). Gas chromatography-mass spectrometry (GC-MS) analysis confirmed that the synthesized biodiesel met the EN 14214 European quality standard (≥96.5 % FAME content). The process operated at a mild temperature of 40°C, enhancing yield with lower energy input. Overall, the CPME-assisted two-step process offers an efficient and viable route for biodiesel production from waste feedstocks.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"226 ","pages":"Pages 282-295"},"PeriodicalIF":3.9,"publicationDate":"2026-01-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145922442","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}
Pub Date : 2026-01-03DOI: 10.1016/j.cherd.2026.01.002
Xiang Liu, Yingchun Zhang, Xiao Xu
Hollow droplets, characterized by their large specific surface areas, thin liquid films, and interfacial oscillations, have attracted significant interest owing to their unique physicochemical properties and broad applicability in chemical engineering. This study investigates the controlled generation of free-falling hollow droplets in pure water using a coaxial nozzle system. The critical parameters for stable hollow droplet formation were determined by systematically varying the liquid and gas flow rates. The results indicate that within a specific range of liquid Reynolds number (34.69–260.19) and gas Reynolds number (0.38–372), hollow droplets can be consistently generated with a 100 % encapsulation probability. The formation mechanism is governed by the interplay between bubble buoyancy and liquid drag in the annular region, which stabilizes the liquid film and prevents the bubble from escaping. Theoretical models were developed to predict the critical gas Reynolds numbers and droplet generation probabilities, demonstrating strong agreement with experimental results. This study introduces a novel microfluidic strategy to suppress bubble coalescence in pure water, thereby facilitating scalable hollow droplet production for gas-liquid mass transfer applications.
{"title":"Probability-encoded free-falling hollow droplets","authors":"Xiang Liu, Yingchun Zhang, Xiao Xu","doi":"10.1016/j.cherd.2026.01.002","DOIUrl":"10.1016/j.cherd.2026.01.002","url":null,"abstract":"<div><div>Hollow droplets, characterized by their large specific surface areas, thin liquid films, and interfacial oscillations, have attracted significant interest owing to their unique physicochemical properties and broad applicability in chemical engineering. This study investigates the controlled generation of free-falling hollow droplets in pure water using a coaxial nozzle system. The critical parameters for stable hollow droplet formation were determined by systematically varying the liquid and gas flow rates. The results indicate that within a specific range of liquid Reynolds number (34.69–260.19) and gas Reynolds number (0.38–372), hollow droplets can be consistently generated with a 100 % encapsulation probability. The formation mechanism is governed by the interplay between bubble buoyancy and liquid drag in the annular region, which stabilizes the liquid film and prevents the bubble from escaping. Theoretical models were developed to predict the critical gas Reynolds numbers and droplet generation probabilities, demonstrating strong agreement with experimental results. This study introduces a novel microfluidic strategy to suppress bubble coalescence in pure water, thereby facilitating scalable hollow droplet production for gas-liquid mass transfer applications.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"226 ","pages":"Pages 369-377"},"PeriodicalIF":3.9,"publicationDate":"2026-01-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145973737","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}
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