Chemical Engineering Research & Design最新文献

{"title":"Competitive exchange model of aluminium ions and rare earth ions in the leaching of ion-adsorption type rare earth ores","authors":"Ying Huang ,&nbsp;Sihai Luo ,&nbsp;Bengen Hong ,&nbsp;Yanliang Wang ,&nbsp;Ping Long","doi":"10.1016/j.cherd.2026.01.037","DOIUrl":"10.1016/j.cherd.2026.01.037","url":null,"abstract":"<div><div>Aluminium ions (Al³⁺) substantially influence the leaching of rare earth ions (REs). A competitive exchange model between Al³ ⁺ and REs was established to present a rational source-sink term for simulating the leaching process of ion-adsorption type rare earth ores. In this study, the yttrium ions (Y^3 +) were used to represent REs. Isothermal equilibrium ion exchange batch experiments were conducted to investigate the impact of hydrogen ion (H⁺) concentration on the competitive exchange features between Al³ ⁺ and Y³⁺ by using magnesium sulphate solutions at varying pH levels to leach pure yttrium samples, pure aluminium samples and mixed Al-Y samples. The experiments investigated the impact of hydrogen ion (H⁺) concentration on the competitive exchange features between Al³ ⁺ and Y³⁺. The findings demonstrated that H⁺ concentration had an attenuating effect on the initial solid phase concentrations of both Y³⁺ and Al³ ⁺ before exchange. A two-parameter logistic function of H⁺ concentration could describe this attenuation coefficient. Then, integrating the Kerr model, a competitive exchange model for Al³ ⁺ and Y³⁺ was developed. Compared with the experimental data, all the determination coefficients exceeded 0.850, implying that the proposed mathematical model exhibited high accuracy.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 46-53"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146026065","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":"Modeling kinetics of wollastonite dissolution and carbonate precipitation in multi-ionic brine systems","authors":"Harwin Sandhu,&nbsp;Sangeeta Garg,&nbsp;Shashikant Yadav","doi":"10.1016/j.cherd.2026.01.040","DOIUrl":"10.1016/j.cherd.2026.01.040","url":null,"abstract":"<div><div>Mineral carbonation using slurry-phase wollastonite (CaSiO₃) composed of suspended micron-scale particles represents an effective strategy for permanent CO₂ sequestration, yet the interactions among ionic strength, dissolution–precipitation kinetics, and surface passivation remain poorly constrained. This study presents a mechanistic thermodynamic–kinetic model integrating CO₂ solubility, wollastonite dissolution, and silica and calcium carbonate precipitation in multi-ionic brines (NaCl, MgCl₂, CaCl₂, Na₂SO₄) relevant to deep saline aquifers. CO₂ solubility decreases across all brines due to salting-out, most strongly in Mg²⁺ - and SO₄^2--rich systems, while wollastonite buffering enhances uptake with solubility ratio coefficients up to 1.95. Dissolution rates peak near pH 3–4 but drop by more than 30 % in Mg²⁺ -rich solutions because of competitive adsorption of Mg²⁺ with Ca²⁺ at wollastonite surface sites, which suppresses Ca²⁺ release. In sulfate-rich brines, SO₄^2- primarily regulates Ca²⁺ activity through sulfate complexation and potential gypsum buffering, thereby delaying the onset of CaCO₃ supersaturation and precipitation. Silica precipitation evolves from reaction-controlled polymerization to diffusion-limited growth as passivating layers develop. CaCO₃ precipitation is triggered only at high supersaturation, limited by CO₃^2- transport and diffusional barriers at elevated pH. Ion flux declines by over 95 % once silica layers approach ∼500 nm, corresponding to a sharp reduction in effective diffusivity and permeability due to pore-space occlusion by secondary mineral phases. Interactions between silica layers and co-precipitating minerals, such as carbonates, modulate layer porosity and diffusivity, suggesting that insights from shale reservoirs can refine predictions of passivation and reaction–diffusion transitions in engineered brine systems. The model predicts a progressive decrease in porosity and transport capacity as silica and CaCO₃ layers thicken, providing a quantitative mechanistic link between mineral reprecipitation, evolving transport properties, and the observed transition from reaction-controlled to diffusion-limited carbonation.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 54-76"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146026066","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":"PRB based hybrid adsorption-membrane for the treatment of pharmaceutical -contaminated water","authors":"Fatemeh Radaei,&nbsp;Mohsen Jahanshahi,&nbsp;Majid Peyravi,&nbsp;Nima Hosseinzadeh Yekani","doi":"10.1016/j.cherd.2026.01.052","DOIUrl":"10.1016/j.cherd.2026.01.052","url":null,"abstract":"<div><div>The increasing presence of antibiotics in water resources has raised serious environmental concerns, highlighting the need for efficient and practical treatment systems. In this study, a hybrid treatment system consisting of a gravity-driven packed-bed column inspired by the permeable reactive barrier (PRB) concept and a downstream membrane process was developed for the removal of azithromycin (AZI) from water. The PRB-based column was filled with magnetic granular activated carbon (MGAC) and operated as a passive pretreatment unit prior to membrane filtration. The synthesized adsorbent was characterized using FESEM, EDX, XRD, and Raman spectroscopy, while the physicochemical properties of the fabricated polyethersulfone (PES) membranes were evaluated by cross-sectional FESEM and AFM analyses. Batch adsorption experiments demonstrated a maximum AZI removal efficiency of 99.96 % at pH 2, a contact time of 80 min, and an initial AZI concentration of 100 mg/L, with a maximum adsorption capacity of 192.1 mg/g. The adsorption behavior followed the pseudo-second-order kinetic model and the Freundlich isotherm, with correlation coefficients (R²) of 0.9997 and 0.9976, respectively. Column experiments revealed that AZI removal performance was strongly influenced by bed height, inlet flow rate, and influent concentration, with a maximum removal efficiency of 67 % achieved at a bed depth of 10 cm, a flow rate of 5 mL/min, and an inlet AZI concentration of 100 mg/L. Breakthrough curve was well described by the Thomas and Yan models, with the Yan model providing the best fit. The effectiveness of the PRB-based column as a pretreatment step was further evaluated using PES membranes with polymer concentrations of 15 % (M1) and 20 % (M2). Following pretreatment, membrane flux and AZI rejection significantly improved, with flux increasing from 72 to 110 L/m².h and rejection from 30 % to 82 % for M1, and from 30 to 50 L/m².h with rejection increasing from 98 % to 99.9 % for M2. These results demonstrate that the proposed PRB-based hybrid system is an effective and energy-efficient approach for AZI removal and fouling mitigation in membrane processes.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 187-203"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146076151","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":"Regime map of a toroidal fluid bed granulator — Challenging formulation","authors":"Line Koleilat ,&nbsp;Christian Karl Paasche ,&nbsp;Jonathan Wade ,&nbsp;Joshua Hanson ,&nbsp;Carl Wassgren ,&nbsp;Paul Mort","doi":"10.1016/j.cherd.2026.02.045","DOIUrl":"10.1016/j.cherd.2026.02.045","url":null,"abstract":"<div><div>Fluidized bed granulation of fine cohesive powders can be challenging due to poor fluidization and fines elutriation. This study investigates toroidal fluid bed granulation of a pharmaceutical formulation containing 50% micronized acetaminophen, focusing on the effects of airflow rate, inlet air temperature, and binder spray rate. Additionally, a prewetting step, involving pre-blending a small amount of water to the powder blend prior to charging, was introduced to improve particle adhesion and reduce elutriation of the micronized active. The combination of prewetting and the toroidal airflow pattern stabilized fluidization and promoted uniform granule growth. Integrated mass, energy, and pressure analyses were used to develop a regime map linking process parameters, moisture gain, and granule properties. The resulting framework defines a stable operating region for this cohesive formulation, supporting robust scale-up and process optimization in pharmaceutical granulation.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 811-820"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147384983","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":"Evaluation of different exhaust aftertreatment configurations for engines running with methanol","authors":"Erika Croner ,&nbsp;Franz Koschany ,&nbsp;Marian Schenker ,&nbsp;Hans-Philipp Walther ,&nbsp;Olaf Hinrichsen","doi":"10.1016/j.cherd.2026.02.028","DOIUrl":"10.1016/j.cherd.2026.02.028","url":null,"abstract":"<div><div>The maritime sector is a significant contributor to global greenhouse gas emissions. One potential solution to reduce these emissions is the adoption of green methanol (MeOH) as an alternative fuel. For safety reasons, marine engines must be capable of operating as dual fuel systems. When running in the Diesel mode, a selective catalytic reduction (SCR) system is necessary to reduce the <figure><img></figure> emissions. However, when MeOH is used as fuel, the SCR catalyst reacts with the feed, forming unwanted products. To eliminate, suppress or prevent their formation, the integration of an oxidation catalyst is required. For this, two setups and two oxidation catalysts were evaluated across three different combustion modes. The two setups differ in the position of the oxidation catalyst, which was located either upstream or downstream of the SCR unit. The combustion modes consisted of one Diesel mode and two Dual Fuel PFI modes, which were synthetically reproduced based on exhaust emissions of real engines. Furthermore, a conventional Pt oxidation catalyst was evaluated and compared with a modified ammonia slip catalyst (ASC). The goal was to identify an exhaust aftertreatment configuration which is able to sufficiently remove or prevent the formation of all unwanted products for all combustion modes while complying with all essential maritime regulations.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 677-684"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147384985","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":"Development of a stepper motor-driven magnetic actuation system for automated condensate removal in horizontal condensing tubes","authors":"Leigang Zhang ,&nbsp;Liang Li ,&nbsp;Menghao Dun ,&nbsp;Bo Xu ,&nbsp;Shang Mao","doi":"10.1016/j.cherd.2026.02.024","DOIUrl":"10.1016/j.cherd.2026.02.024","url":null,"abstract":"<div><div>The condensation process in horizontal tubes is prevalent in chemical, power, and aerospace thermal management systems, where heat transfer efficiency is hindered by the non-uniform distribution of condensate liquid film. To address this issue, an innovative non-contact magnetic control condensate removal system driven by a stepping motor was developed. This system employs an external stepping motor to accurately drive the magnetic ring into axial reciprocating motion, leveraging magnetic coupling to induce synchronous movement of the ferromagnetic ring within the pipe, thereby mechanically stripping and transporting the attached liquid film. The effects of steam flow rate, inlet dryness, and motor gear on heat transfer performance, pressure drop characteristics, and two-phase flow patterns were systematically investigated. Findings reveal that the system effectively disrupts the liquid film's continuity, with the local heat transfer coefficient increasing by 35.9 % under third gear conditions compared to non-enhanced scenarios. Notably, the local heat transfer enhancement ratio reached 1.364 at a specific dryness level (<em>X</em> = 0.6). Visual analysis confirmed that the iron ring's reciprocating motion facilitated the transition from stratified to annular flow, optimizing gas-liquid two-phase distribution. This technology offers non-contact, efficient, and gravity-independent drainage, making it ideal for mitigating liquid film blockage and poor heat transfer in microgravity environments.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 556-567"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146171266","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":"In situ detection of fouling in crossflow filtration using 3ω sensing","authors":"Simon Ranthe Filtenborg ,&nbsp;Peter Galsøe ,&nbsp;Julie Senius Mølgaard ,&nbsp;Dan Asbjørn Linnemann Axelsen ,&nbsp;Carsten Skovmose Kallesøe ,&nbsp;Maryam Tavakolmoghadam ,&nbsp;Morten Lykkegaard Christensen ,&nbsp;Astrid Ræbild Kjul ,&nbsp;Mads Koustrup Jørgensen","doi":"10.1016/j.cherd.2026.02.010","DOIUrl":"10.1016/j.cherd.2026.02.010","url":null,"abstract":"<div><div>Membrane filtration is a widely applied technology for water and wastewater treatment and for separation and purification in e.g. food and pharmaceutical industry. However, the applicability is severely limited by fouling. Several methods have been proposed to monitor membrane fouling, yet none have proven effective for full-scale implementation. The 3ω sensing is introduced as a novel approach for monitoring membrane fouling and shows promising potential to scale for <em>in situ</em> fouling monitoring. Promising results have been obtained for measuring filter-cake build up and compression (fouling) in dead-end filtration. In the current study, 3ω sensing is investigated for monitoring fouling in crossflow filtration to simultaneously measure how heat convection from the surface of the membrane depends on crossflow and formation of organic and inorganic fouling. A 3ω sensor was integrated onto the surface of a microfiltration membrane, and crossflow filtrations of kaolin and <em>E. coli</em> suspensions were conducted. It was observed that application of crossflow leads to a reduction of 3ω signal as it enhances heat transfer from the sensor. Measurements of 3ω signals at stagnant conditions (no crossflow) showed lower signals for membranes with inorganic fouling (thermally conducting) compared to a clean membrane, while measurements of a membrane fouled with <em>E. coli</em> shows a signal similar to that of a clean membrane due to the similarity in thermal conductivity between the feed and the fouling layer. Hence, the <em>E. coli</em> fouling layer could not be sensed in stagnant conditions. However, measurements in crossflow mode showed increasing 3ω signals by the formation of both kaolin and <em>E. coli</em> fouling layers. This happens because the fouling layer acts as a protective barrier against heat convection from the 3ω sensor, initially increasing the 3ω signal, regardless of the thermal conductivity. This phenomenon is coined shielding and has the notable consequence of increasing resolution of 3ω sensing for a foulant with thermal properties similar to those of water. This makes 3ω sensing an effective technique for detecting membrane fouling, with the potential to characterize both the type and thickness of the fouling layer with high resolution in crossflow filtration. These findings pave the way for advanced fouling diagnostics, predictive maintenance, and optimized cleaning strategies, offering substantial benefits for full-scale membrane operations in water and wastewater treatment, food, and pharmaceutical industries.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 454-464"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146171201","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":"Phenomenological-based kinetics of oxidative cracking of n-hexane to light olefins over tandem (V/Si)-ZSM-5 catalysts","authors":"Ariel Hazril Gursida ,&nbsp;Sagir Adamu ,&nbsp;Shaikh Abdur Razzak ,&nbsp;Mohammad Mozahar Hossain","doi":"10.1016/j.cherd.2026.02.002","DOIUrl":"10.1016/j.cherd.2026.02.002","url":null,"abstract":"<div><div>The kinetics of <em>n</em>-hexane oxidative cracking to olefins using lattice oxygen on (V/Si)-ZSM-5 were examined. The catalyst shows a total acidity of 0.44 mmol g⁻¹ , comprising 47 % weak sites that promote olefin selectivity and 53 % strong sites that enhance <em>n</em>-hexane conversion. TPR confirms that (V/Si)-ZSM-5 is readily reducible. In a CREC Riser simulator, oxidative cracking resulted in ∼72.2 % olefin selectivity at 74.8 % <em>n</em>-hexane conversion. A kinetic model was formulated, including (1) catalytic cracking and (2) oxidative dehydrogenation. The cracking pathway treats adsorption, C–H/C–C bond cleavage, and desorption as elementary steps under a pseudo–steady-state assumption, while the ODH reaction follows a Langmuir–Hinshelwood mechanism. The model reproduces the experiments with strong statistical agreement, and the estimated rate constantly aligns with the observed product selectivity.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 480-491"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146171202","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":"Experimental and simulation study of a novel perovskite-based redox catalyst for ethylbenzene CL–ODH process: Energy, exergy, and CO₂ footprint assessment","authors":"Shokufeh Bagheri,&nbsp;Ali Hafizi","doi":"10.1016/j.cherd.2026.02.015","DOIUrl":"10.1016/j.cherd.2026.02.015","url":null,"abstract":"<div><div>Styrene, an essential monomer in the chemical industry, is conventionally produced via energy-intensive dehydrogenation process with high CO₂ emissions. Chemical Looping Oxidative Dehydrogenation of ethylbenzene (CL–ODH of EB) is a promising route for producing styrene. Herein, a novel CaMn_0.6Fe_0.4O_3–δ perovskite-based redox catalyst was experimentally evaluated in this process. The reactor tests were performed at different reaction temperatures of 540–600 °C under reduced steam conditions. Then, the laboratory-scale catalytic results were used as input data for process simulations compared with a conventional industrial unit for the purpose of investigating energy, exergy analyses, and CO₂ footprint calculations. Based on the experimental results, the catalyst exhibited high catalytic performance under high Weight Hourly Space Velocity (WHSV, 0.4 h⁻¹ vs. 0.2 h⁻¹ in the conventional industrial process), achieving 90.9 % styrene selectivity and 23 % ethylbenzene conversion in the single-reactor configuration at 540°C. Based on the simulation results with overall conversions of 69 % and 70 % across the three reactors for the CL–ODH and conventional industrial processes, respectively. The obtained results indicate that the CL–ODH process reduced energy consumption by 40.6 %, exergy loss by 41.7 %, and reduction in CO₂ emissions by 40.2 %. Generally, styrene production using CL–ODH is superior than the conventional process in energy and emissions.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 540-555"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146171205","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":"Investigating the influence of design and operational parameters on SAG mill energy spectra: A DEM and SHAP-based sensitivity analysis","authors":"Tahir Jauhar ,&nbsp;Dasun Balasooriya ,&nbsp;Ben Wilks ,&nbsp;Stephan Chalup ,&nbsp;Michael Carr ,&nbsp;Craig Wheeler ,&nbsp;Dean Ellis","doi":"10.1016/j.cherd.2026.02.005","DOIUrl":"10.1016/j.cherd.2026.02.005","url":null,"abstract":"<div><div>This study uses a Discrete Element Modelling (DEM) based data-driven approach to identify and quantify the key variables influencing energy distribution in a Semi-Autogenous Grinding (SAG) mill, which is critical for balancing grinding efficiency and liner wear. A set of 36 conditions was simulated using the Discrete Element Method (DEM). Seven input variables were investigated: percentage of critical speed, number of lifters, two variables for lifter geometry (face angle, height), and three variables for charge composition (relative ball diameter and the filling levels for rocks and balls). The resulting energy spectra for two collision types (Rock–Ball and Rock–Belly) were analysed using regression models and SHAP (SHapley Additive exPlanations) to provide insights into variable importance and interactions. The analysis revealed that ball-related variables (percentage fill and diameter) and critical speed are the dominant factors governing collision energies. The SHAP analysis quantified complex, non-linear relationships and competing influences; for instance, the number of lifters significantly impacted Rock–Belly collisions, while lifter angle was more influential on Ball–Belly collisions. To explore the trade-offs identified by this analysis, three types of surrogate models were trained on the pre-wear dataset. Surrogate models exhibiting varying levels of predictive accuracy were subsequently coupled with the NSGA-II genetic algorithm to generate multi-objective Pareto fronts, illustrating the inherent trade-off between maximising Rock–Ball energy (grinding efficiency) and minimising Rock–Belly energy (liner wear).This study presents a detailed sensitivity analysis that quantifies the non-linear influence of key parameters, offering insights to guide future large-scale optimisation studies.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 583-600"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146171327","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}