Chemical Engineering Research & Design最新文献_第3页

Inverse optimization of spray drying by surrogate models trained on frozen-field CFD simulations 利用冷冻场CFD模拟训练的代理模型对喷雾干燥进行逆优化

IF 3.9 3区工程技术 Q2 ENGINEERING, CHEMICAL

Chemical Engineering Research & Design

Pub Date : 2026-01-16 DOI: 10.1016/j.cherd.2026.01.036

Nikolai A. Jessen , Alexander Findeisen , Krist V. Gernaey , Ulrich Krühne

Spray dryers are highly dynamic systems in which complex airflow patterns, heat and mass transfer, and particle motion interact across multiple length and time scales. Accurately resolving these interactions with fully transient CFD-DPM simulations is computationally expensive, limiting their use for process optimization. This study addresses this challenge by developing and validating a frozen time-averaged airflow CFD-DPM approach for a co-current spray dryer and embedding it within a surrogate-based inverse optimization framework. Compared to fully transient simulations, the frozen airflow approach reproduces key product outputs with comparable accuracy while reducing computational time from approximately 72 h to 15 min, corresponding to a speedup close to 300 for a pilot-scale co-current spray dryer. The workflow is used to train a polynomial surrogate model embedded in an inverse optimization framework. The differences between surrogate and CFD-DPM results remain small, with mean particle temperature deviations below 2 °C, particle diameter differences under 1.2 µm, moisture discrepancies below 0.024 kg kg⁻¹ , and product yield differences below 0.01. The proposed framework can be used as a practical tool for examining the operating input space and for rapid spray dryer optimization without the need for expensive computational hardware.

喷雾干燥机是高度动态的系统，其中复杂的气流模式，传热和传质，以及粒子运动在多个长度和时间尺度上相互作用。通过完全瞬态CFD-DPM模拟准确地解决这些相互作用在计算上是昂贵的，限制了它们在工艺优化中的使用。本研究通过开发和验证用于共流喷雾干燥机的冻结时间平均气流CFD-DPM方法，并将其嵌入基于代理的逆优化框架，解决了这一挑战。与完全瞬态模拟相比，冻结气流方法以相当的精度再现了关键产品的输出，同时将计算时间从大约72 h减少到15 min，相当于中试规模的共流喷雾干燥机的加速接近300。该工作流用于训练嵌入在逆优化框架中的多项式代理模型。代孕法和CFD-DPM法的结果差异很小，平均颗粒温度偏差小于2°C，颗粒直径偏差小于1.2 µm，水分偏差小于0.024 kg kg⁻¹ ，产物得率差异小于0.01。所提出的框架可以用作检查操作输入空间和快速喷雾干燥机优化的实用工具，而不需要昂贵的计算硬件。

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引用次数: 0

Enhanced size-split flotation of sulphide tailings: Mechanical, HydroFloat™, REFLUX ™ flotation benchmarking 强化硫化物尾矿的粒度分离浮选：机械，HydroFloat™，回流™浮选基准

IF 3.9 3区工程技术 Q2 ENGINEERING, CHEMICAL

Chemical Engineering Research & Design

Pub Date : 2026-01-15 DOI: 10.1016/j.cherd.2026.01.025

Richel Annan Dadzie , Massimiliano Zanin , William Skinner , Richmond Asamoah , Jonas Addai-Mensah , George Blankson Abaka-Wood

Reprocessing copper flotation tailings is limited by particle-size effects and mineralogical challenges, especially poor liberation. Preliminary studies aimed at recovering copper minerals from complex, low-grade rougher flotation tailings have shown limited success, with values within the intermediate particle size range (-150 +53 µm) failing in conventional mechanical flotation cells. To improve copper recovery, the current study employs a flowsheet that uses Hydrofloat ™ fluidised-bed flotation on the deslimed + 53 µm fraction, considers the REFLUX ™ Flotation Cell (RFC) for the (-53µm) slimes, and compares performance against a Denver mechanical cell. Flotation performance (recovery, grade, size-by-size) was combined with data from Quantitative Evaluation of Minerals by Scanning Electron Microscopy (QEMSCAN), including liberation and locking statistics, to explain the flotation response observed. At similar mass pull (29.3–33 %), Hydrofloat ™ achieved 61.8 % Cu recovery at 0.74 % Cu (upgrade ratio 3.44), outperforming the mechanical flotation cell (44. 6 % Cu at 0. 10 % Cu grade; upgrade ratio 0.6) when processing the deslimed feed, rather than the whole (unsplit) tailings feed. Preliminary RFC tests on the - 53 µm stream maintained high recoveries of fine particles (often >80 %) with improved Cu concentrate grades, aligning with the presence of well-liberated chalcopyrite in slimes. Overall, the results support a split-flotation process for complex copper low grade ores. Although liberation ultimately limits recovery this integrated method significantly enhances copper recovery and upgrade relative to conventional mechanical cells, offering a practical route to unlock value from low-grade sulphide tailings.

铜浮选尾矿的再处理受到粒度效应和矿物学挑战的限制，尤其是解离性差。从复杂的、低品位的粗细浮选尾矿中回收铜矿物的初步研究表明，在常规机械浮选池中，在中等粒度范围内（-150 +53 µm）的数值是失败的。为了提高铜的回收率，目前的研究采用了一个流程，在脱泥+ 53 µm部分使用Hydrofloat™流化床浮选，考虑了（-53µm）泥的REFLUX™浮选池（RFC），并将其性能与丹佛机械池进行了比较。浮选性能（回收率、品位、粒度）与QEMSCAN矿物定量评价（Quantitative Evaluation of Minerals by Scanning Electron Microscopy， QEMSCAN）的数据（包括解离和锁定统计）相结合，来解释观察到的浮选反应。在相同的质量拉力（29.3-33 %）下，Hydrofloat™的铜回收率为61.8 %，铜回收率为0.74 %（升级比3.44），优于机械浮选池（44）。6 % Cu at 0。10 % Cu品位；在处理脱泥料时升级比0.6)，而不是处理整个（未分裂）尾矿料。在- 53 µm流上进行的初步RFC测试保持了高细颗粒回收率（通常为>； 80% %），铜精矿品位提高，与泥中黄铜矿的充分释放一致。总体而言，研究结果支持对复杂低品位铜矿石进行分选浮选。尽管释放最终限制了铜的回收，但与传统的机械电池相比，这种集成方法显著提高了铜的回收和升级，为从低品位硫化物尾矿中释放价值提供了实用的途径。

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引用次数: 0

Multi-objective optimization for sustainable dimethyl oxalate synthesis: A plant-wide framework balancing economic benefits and carbon emissions 可持续草酸二甲酯合成的多目标优化：平衡经济效益和碳排放的全厂框架

IF 3.9 3区工程技术 Q2 ENGINEERING, CHEMICAL

Chemical Engineering Research & Design

Pub Date : 2026-01-15 DOI: 10.1016/j.cherd.2026.01.035

Shida Gao , Cuimei Bo , Guo Yu , Quanling Zhang , Furong Gao , Genke Yang , Jian Chu

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.

乙二醇（EG）是聚酯工业的主要原料，合成气制草酸二甲酯（DMO）转化是先进的乙二醇生产方法。然而，这一过程遇到了经济效益最大化和碳排放最小化的目标冲突，特别是由于限制和市场价格而加剧。为了解决这一挑战，我们开发了一个针对各种工况的多目标优化框架：首先，我们建立了一个包含反应动力学和机制的稳态模拟系统来模拟DMO合成过程。然后，建立了创新的经济-碳排放多目标优化问题，通过灵敏度分析确定关键运行参数的取值范围，并采用响应面法获得不同条件下的参考点。最后，利用Pareto边界（PF）估计算法求解优化问题，以解决各种工况和价格条件下过程变量之间复杂的非线性相互作用所产生的不规则PF问题。在正常工况下，将得到的Pareto解集的拐点与参考点进行比较，结果表明，该框架的碳排放量减少了19.63% (129.5 kmol/h)，经济效益增加了1.38%（1253.1元/h）。考虑到DMC价格急剧上涨、产能有限和短期负利润三种典型情况，我们的框架确定了在所得的PF中占主导地位的参考点和原始转折点的解决方案，结果验证了本研究能够支持决策，在各种工作和价格条件下提供经济与碳排放之间良好平衡的解决方案。

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引用次数: 0

Experimental study on in-vessel filtration characteristics of Fischer-Tropsch slurry bed reactors considering influence of gas leakage 考虑气体泄漏影响的费托浆床反应器内过滤特性实验研究

IF 3.9 3区工程技术 Q2 ENGINEERING, CHEMICAL

Chemical Engineering Research & Design

Pub Date : 2026-01-15 DOI: 10.1016/j.cherd.2026.01.022

Ping Gu , Yongmin Zhang , Hui Du

Insufficient filtration performance had long been a critical issue for industrial slurry bed reactors, which hindered plant capacity improvement and increased production costs. To address this, this study experimentally investigated in-vessel filtration characteristics with gas leakage considered, aiming to develop solutions. Gas leakage flux (J_g,l) was originally defined to characterize gas leakage effects, and pressure variation-based method was proposed to measure liquid filtration flux (J) and its average (J_avg) for quantifying filtration performance. Results showed that when superficial gas velocity (u_g) increased from 0.027 to 0.063 m/s, J_g,l increased by 684.4 %, impairing filtrate outflow and reducing J_avg by 44 %. When particle concentration (C_w) increased from 5 % to 15 %, J_avg and J_g,l decreased by 74.6 % and 69 %, with J_avg dropping more sharply. J_avg for 30 μm filter tubes was 325.93 L/(m²·h), which was much lower than for 50 μm (496.98 L/(m²·h)) and 80 μm (568.65 L/(m²·h)), indicating excessively high u_g, high C_w, and smaller filter tube pore size (d_f) as key causes. Increasing d_f from 30 to 80 μm boosted J_avg by 74.5 %, while increasing J_g,l by 178.8 %. Filtrate analysis showed low particle concentrations and no substantial long-term particle loss, confirming reasonably increasing d_f as a feasible solution for in-vessel filtration performance enhancement. This study identified the root causes of insufficient filtration performance and proposed a feasible solution, which could serve as a viable reference for addressing analogous issues and thus held considerable academic and engineering significance.

长期以来，过滤性能不佳一直是困扰工业浆床反应器的关键问题，阻碍了工厂产能的提高，增加了生产成本。为了解决这个问题，本研究对考虑气体泄漏的容器内过滤特性进行了实验研究，旨在找到解决方案。最初定义了气体泄漏通量（Jg,l）来表征气体泄漏效应，并提出了基于压力变化的方法来测量液体过滤通量(J)及其平均值（Javg）来量化过滤性能。结果表明，当表面气速（ug）从0.027 ~ 0.063 m/s增加时，Jg、l增加684.4 %，滤液流出量减少，Javg降低44 %。当颗粒浓度（Cw）从5 %增加到15 %时，Javg和Jg，l分别下降74.6 %和69 %，其中Javg下降幅度更大。30 μm滤管的Javg值为325.93 L/(m2·h)，远低于50 μm滤管的Javg值（496.98 L/(m2·h)）和80 μm滤管的Javg值（568.65 L/(m2·h)），说明过高的ug值、过高的Cw值和滤管孔径（df）过小是主要原因。df从30 μm增加到80 μm， Javg提高了74.5 %,Jg，l提高了178.8 %。滤液分析显示，滤液颗粒浓度低，长期颗粒损失不明显，合理增加df是提高管内过滤性能的可行方案。本研究发现了过滤性能不足的根本原因，并提出了可行的解决方案，为解决类似问题提供了可行的参考，具有重要的学术和工程意义。

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引用次数: 0

Oxygen-enhanced conversion-based process retrofit and assessment of natural gas steam reforming for synthetic ammonia production 合成氨生产天然气蒸汽重整的增氧转化工艺改造及评价

IF 3.9 3区工程技术 Q2 ENGINEERING, CHEMICAL

Chemical Engineering Research & Design

Pub Date : 2026-01-14 DOI: 10.1016/j.cherd.2026.01.029

Fuyao Yan , Wenpeng Shen , Bo Qi , Longgang Mo , Xueying Fan , Wei Song , Dongliang Wang

The ammonia industry faces critical challenges of high energy consumption and carbon emissions. Conventional steam methane reforming (SMR) process suffers from excessive fuel gas demand due to the strongly endothermic reactions in the primary reformer (PR) and the nitrogen surplus caused by excess air injection in the secondary reformer (SR) for methane conversion. This study investigates the effects of temperature, steam-to-carbon ratio, and oxygen content on reformer performance. It proposes an oxygen-enhanced conversion (OEC) process that redistributes methane conversion loads between reformers: reducing the load in the PR decreases fuel natural gas consumption, while introducing oxygen-enriched air (OEA) into the SR converts residual methane. Results demonstrate increased methane content at the PR outlet from 10 vol% to 30 vol%, reduced PR heat duty from 62.99 MW to 35.02 MW, and elevated oxygen content in SR air from 21 % to 28 %. A systematic comparison reveals that, compared to the conventional SMR process, the OEC process reduces fuel natural gas input from 186.54 to 51.49 Nm³ /t NH₃, lowers direct CO₂ emissions from 1707.06 to 1533.04 kg/t NH₃, improves energy efficiency from 55.78 % to 59.68 %, and decreases production costs by 2.6 %. This offers a viable pathway for energy conservation and carbon reduction in ammonia synthesis.

合成氨行业面临着高能耗和高碳排放的严峻挑战。传统的蒸汽甲烷重整（SMR）工艺由于一次转化塔（PR）的吸热反应强烈，以及二次转化塔（SR）注气过多导致的氮气过剩，导致燃料气体需求量过大。本研究考察了温度、汽碳比和氧含量对重整器性能的影响。它提出了一种氧增强转化（OEC）过程，该过程在转化炉之间重新分配甲烷转化负荷：减少PR中的负荷可以减少燃料天然气消耗，同时将富氧空气（OEA）引入SR转化剩余甲烷。结果表明，PR出口的甲烷含量从10 vol%增加到30 vol%， PR热负荷从62.99 MW降低到35.02 MW， SR空气中的氧含量从21 %提高到28 %。系统比较表明，与传统SMR工艺相比，OEC工艺将燃料天然气投入从186.54 Nm³ /t NH3减少到51.49 Nm³ /t NH3，将二氧化碳直接排放量从1707.06降低到1533.04 kg/t NH3，将能源效率从55.78 %提高到59.68 %，降低生产成本2.6 %。这为氨合成的节能减碳提供了一条可行的途径。

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引用次数: 0

Assessing mixing performance and power consumption in the ambr® 250 bioreactor 评估ambr®250生物反应器的混合性能和功耗

IF 3.9 3区工程技术 Q2 ENGINEERING, CHEMICAL

Chemical Engineering Research & Design

Pub Date : 2026-01-14 DOI: 10.1016/j.cherd.2026.01.030

Laia Miranda , Sara Rodriguez-Conde , Olalekan Daramola , Andrea Ducci , Martina Micheletti

The ambr® 250, a miniaturized bioreactor extensively used in biopharmaceutical R&D, was characterized to evaluate power and mixing dynamics for mammalian cell culture applications. The study analyzed the effects of agitation speed, impeller configuration, internal components, working volume, and feed placement on dimensionless mixing number (

{Nt}_{m}

) and power number (

N_{P})

. Six impeller designs, including single and dual elephant ear (EE) configurations with varied angles and diameters, were investigated. Down-pumping (DP) mode reduced

{Nt}_{m}

by 54 % and increased cumulative

N_{P}

by 14–22 % compared to up-pumping (UP) mode. Mixing time (

t_{m}

) remained consistent between single and dual EE impellers, though cumulative

N_{P}

was 33 % higher for single EE impellers. Dual EE impellers in DP mode achieved the lowest power input per volume (

P / V

) for similar

t_{m}

. Spatial mixing time distribution and probe-induced effects on mixing parameters were also assessed. An early transition to turbulence was observed at Reynolds numbers (

Re

) below 10,000 in unbaffled systems, regardless of the presence of internal components such as baffles and probes. Probes increased

N_{P}

and

{Nt}_{m}

by 49 % and 26 %, respectively. This characterization advances understanding of milliliter-scale bioreactor performance and provides a foundation for optimizing the design and operation of mammalian cell-based processes.

ambr®250是一种广泛用于生物制药研发的小型生物反应器，用于评估哺乳动物细胞培养应用的功率和混合动力学。研究分析了搅拌转速、叶轮构型、内部部件、工作体积和进料位置对无量纲混合数（Ntm）和功率数（NP）的影响。研究了不同角度和直径的单象耳和双象耳叶轮设计。与上抽（UP）模式相比，下抽（DP）模式减少了54%的Ntm，增加了14 - 22%的累积NP。混合时间（tm）在单叶轮和双叶轮之间保持一致，尽管单叶轮的累积NP高33%。DP模式下的双EE叶轮在类似的tm中实现了最低的每体积功率输入（P/V）。研究了混合时间的空间分布和探针对混合参数的影响。在无挡板系统中，无论是否存在挡板和探针等内部组件，在雷诺数（Re）低于10,000时，都观察到早期过渡到湍流。探针使NP和ntm分别增加了49%和26%。这种表征促进了对毫升级生物反应器性能的理解，并为优化哺乳动物细胞工艺的设计和操作提供了基础。

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引用次数: 0

Realisation of mathematical conditions ensuring smooth transition of heat and mass transfer at the boundaries of solids and liquids 实现数学条件，确保在固体和液体边界的传热和传质的平稳过渡

IF 3.9 3区工程技术 Q2 ENGINEERING, CHEMICAL

Chemical Engineering Research & Design

Pub Date : 2026-01-14 DOI: 10.1016/j.cherd.2026.01.032

J.E. Safarov , Sh.A. Sultanova , D.I. Samandarov , Gurbuz Gunes , M.R. Najafli , A.A. Mambetsheripova , M.M. Pulatov , Gunel Imanova

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.

涉及固液界面传热传质的干燥过程在食品、制药和纺织等各个行业中都是至关重要的。这种现象最具挑战性的方面之一是确保在固液界面上的平稳传热和传质，因为边界条件的不连续性可能导致不准确的结果和复杂的过程控制。本研究致力于制定数学条件，以确保在组合干燥过程中固体-液体界面的平稳过渡。提出了一种基于傅里叶方程和菲克方程的过渡态模型来描述食品中的热交换和水分扩散。该模型考虑了材料的热物理性质、传热系数和系统的运行条件。本文还讨论了有效建模所需的基本理论和数学方法，以提高对干燥过程的理解和控制。

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引用次数: 0

Limitations for improving selectivity in chemical reactors 提高化学反应器选择性的限制

IF 3.9 3区工程技术 Q2 ENGINEERING, CHEMICAL

Chemical Engineering Research & Design

Pub Date : 2026-01-14 DOI: 10.1016/j.cherd.2026.01.033

William L. Luyben

The design of chemical plants involves many engineering tradeoffs that balance capital cost, energy cost, operability, efficiency, safety, reliability, complexity, environmental impact and sustainability, to name a few. The classical tradeoff between reactor costs and separation costs dominates many decisions particularly when material and energy recycles are incorporated in the plant topology. Chemical reactors have several size and operating variables that must be selected to achieve an efficient and profitable system: size, temperature, pressure and reactant recycle. All of these parameters impact selectivity if undesirable byproducts are formed. The purpose of this paper is to quantitatively explores how reactor design variables can be adjusted to achieve very high selectivity in those cases in which the suppression of the production of the undesired product is critical because of safety, toxicity, environmental or sequestration issues.

化工厂的设计涉及许多工程权衡，以平衡资金成本，能源成本，可操作性，效率，安全性，可靠性，复杂性，环境影响和可持续性，仅举几例。反应器成本和分离成本之间的传统权衡主导了许多决策，特别是当材料和能源回收被纳入工厂拓扑结构时。化学反应器有几个尺寸和操作变量，必须选择，以实现一个有效和有利可图的系统：尺寸，温度，压力和反应物回收。如果形成不需要的副产物，所有这些参数都会影响选择性。本文的目的是定量地探讨如何调整反应器设计变量，以在由于安全、毒性、环境或封存问题而抑制不期望产品的生产至关重要的情况下实现非常高的选择性。

引用次数: 0

All-weather anti-icing material: Biomimetic sponge coupling phase change energy storage with photothermal superhydrophobic surface 全天候防冰材料：具有光热超疏水表面的仿生海绵耦合相变储能

IF 3.9 3区工程技术 Q2 ENGINEERING, CHEMICAL

Chemical Engineering Research & Design

Pub Date : 2026-01-13 DOI: 10.1016/j.cherd.2026.01.028

Zhe Li , Peng Wang , Yafeng Zhang , Jiaxuan Zhang , Hangyu Miao , Jie Liu , Tong Huang , Ziheng Zheng , Wei Duan , Ying Yue

The new material integrating passive anti-icing and active de-icing features ensures long-lasting low-temperature protection, overcoming the poor durability of traditional superhydrophobic materials and the sunlight dependency of photothermal materials. Inspired by polar bear fur, this study develops a multifunctional silicone sponge with phase-change, superhydrophobic, and photothermal properties for anti-icing. By incorporating an n-tetradecane phase-change material (PCM) into a porous polydimethylsiloxane (PDMS) sponge to form an energy storage layer and combining squid ink powder-modified superhydrophobic photothermal coatings, performance synergy optimization can be achieved. Microscopic analysis showed that the phase-change material filled the sponge pores, while the surface coating formed micro/nanostructures, providing superhydrophobicity (CA 155.6°, RA 3.1°) and self-cleaning properties. Photothermal tests demonstrated a significant increase in solar absorption, with surface temperatures reaching 94.3°C under twice the solar light intensity. Combining PCM heat storage/release created a thermal plateau lasting up to 17,100 s, delaying temperature drops. Outdoor tests showed the material extended freezing time to 3633 ± 215 s at –15°C and enabled rapid de-icing within 105 ± 26 s under sunlight. Inspired by polar bear fur and fat, this biomimetic design achieves all-weather anti-icing, delaying ice formation over 8 h. It provides a new approach for extreme-environment materials with aerospace, power, and polar applications.

这种新型材料集成了被动防冰和主动除冰功能，确保了持久的低温保护，克服了传统超疏水材料耐久性差和光热材料对阳光的依赖。受北极熊皮毛的启发，本研究开发了一种具有相变、超疏水和光热性能的多功能防冰硅胶海绵。将正十四烷相变材料（PCM）加入多孔聚二甲基硅氧烷（PDMS）海绵中形成储能层，并结合鱿鱼墨粉改性超疏水光热涂层，实现性能协同优化。微观分析表明，相变材料填充了海绵孔隙，表面涂层形成微纳米结构，具有超疏水性（CA为155.6°，RA为3.1°）和自清洁性能。光热测试表明，太阳能吸收显著增加，在两倍的太阳光强度下，表面温度达到94.3°C。结合PCM热存储/释放创造了一个热平台，持续时间长达17,100 s，延迟温度下降。室外试验表明，该材料在-15°C条件下的冻结时间可延长至3633 ± 215 s，在阳光下可在105 ± 26 s内快速除冰。这款仿生设计的灵感来自北极熊的皮毛和脂肪，可以实现全天候防冰，将结冰时间推迟到8 小时以上。它为航空航天、电力和极地应用的极端环境材料提供了一种新的方法。

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引用次数: 0

Mechanisms of stratification and gel deposition during hot-cold blending of waxy crude oil 含蜡原油冷热调合过程中的分层和凝胶沉积机理

IF 3.9 3区工程技术 Q2 ENGINEERING, CHEMICAL

Chemical Engineering Research & Design

Pub Date : 2026-01-13 DOI: 10.1016/j.cherd.2026.01.016

Xingyue Pu , Yu Zhang , Yijie Wang , Mingzhang Xu , Ziyue Wang , Qiyu Huang , Zicheng Liu , Hongyu Wang

Hot-cold blending of waxy crude oils in interconnected pipelines can trigger rapid cooling, wax precipitation, and gel formation, posing serious risks to flow assurance. To address this challenge, a loop apparatus with a T-junction was developed to systematically investigate flow behavior and deposition characteristics under different temperature differences (ΔT) and momentum ratios (M). Flow visualization showed that increasing main-stream velocity transformed the branch jet from impinging to deflected and finally to wall jet, leading to reduced blending efficiency and enhanced flow heterogeneity. Wax deposition tests revealed that rapid cooling produced gels with smaller, loosely connected wax crystals, weaker intermolecular forces, and significantly lower yield stress compared with slow cooling. Based on differential scanning calorimetry (DSC) results and the Avrami equation, a predictive model for gel strength was established and validated against experimental data, achieving deviations within ±15 %. This work clarifies the mechanisms of rapid-cooling gel formation during hot–cold blending and provides a practical tool for evaluating deposition strength, offering guidance for blending operation design and pigging strategies in high pour point crude oil pipelines.

含蜡原油在相互连接的管道中进行冷热共混，会引发快速冷却、蜡沉淀和凝胶形成，给流动保障带来严重风险。为了解决这一挑战，研究人员开发了一种带有t型结的环路装置，以系统地研究不同温差（ΔT）和动量比(M)下的流动行为和沉积特征。流动可视化表明，随着主流速度的增加，分支射流由撞击型向偏转型转变，最终向壁面型转变，混合效率降低，流动非均质性增强。蜡沉积试验表明，与缓慢冷却相比，快速冷却产生的凝胶具有更小、连接松散的蜡晶体，分子间力更弱，屈服应力显著降低。基于差示扫描量热法（DSC）结果和Avrami方程，建立了凝胶强度预测模型，并根据实验数据进行了验证，误差在±15 %以内。该研究阐明了冷热调合过程中快速冷却凝胶形成的机理，为沉积强度评估提供了实用工具，为高凝点原油管道的调合作业设计和清管策略提供了指导。

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