Pub Date : 2026-03-01Epub Date: 2026-02-18DOI: 10.1016/j.cherd.2026.02.038
Salvatore La Manna, Diego Barletta, Massimo Poletto
Accurate characterisation of granular flow behaviour is necessary for the effective design of equipment used in the processing, storage, and handling of solid materials. Conventional laboratory devices often fail to replicate the extreme conditions encountered in industrial applications, particularly regarding temperature, normal stress, and reactive atmospheres. This study presents a torque-based shear testing prototype capable of quantifying flow properties under conditions reaching 1000°C and 800 kPa, including reactive environments. Designed to extend the investigative range beyond the limitations of commercial rotational shear testers. The device was validated using quartz sand, a standard, non-cohesive granular material, through comparative testing with the Schulze ring shear tester. Dedicated experiments explored the sand behaviour up to 800°C, indicating that its purely frictional flow behaviour is unaffected by temperature. Therefore, this quartz sand can be considered a reference material to assess the consistency of instrument shear test results at high temperature and throughout the instrument's lifetime, ensuring stability even under harsh testing conditions. The preliminary tests reported demonstrate the prototype's potential as a powerful tool for advancing the design and optimisation of industrial systems subjected to variable stresses and elevated temperatures. By enabling the replication of harsh process environments on a laboratory scale, the device bridges the gap between controlled testing and real-world application.
{"title":"An innovative prototype for solid flow characterisation in severe stress and temperature conditions","authors":"Salvatore La Manna, Diego Barletta, Massimo Poletto","doi":"10.1016/j.cherd.2026.02.038","DOIUrl":"10.1016/j.cherd.2026.02.038","url":null,"abstract":"<div><div>Accurate characterisation of granular flow behaviour is necessary for the effective design of equipment used in the processing, storage, and handling of solid materials. Conventional laboratory devices often fail to replicate the extreme conditions encountered in industrial applications, particularly regarding temperature, normal stress, and reactive atmospheres. This study presents a torque-based shear testing prototype capable of quantifying flow properties under conditions reaching 1000°C and 800 kPa, including reactive environments. Designed to extend the investigative range beyond the limitations of commercial rotational shear testers. The device was validated using quartz sand, a standard, non-cohesive granular material, through comparative testing with the Schulze ring shear tester. Dedicated experiments explored the sand behaviour up to 800°C, indicating that its purely frictional flow behaviour is unaffected by temperature. Therefore, this quartz sand can be considered a reference material to assess the consistency of instrument shear test results at high temperature and throughout the instrument's lifetime, ensuring stability even under harsh testing conditions. The preliminary tests reported demonstrate the prototype's potential as a powerful tool for advancing the design and optimisation of industrial systems subjected to variable stresses and elevated temperatures. By enabling the replication of harsh process environments on a laboratory scale, the device bridges the gap between controlled testing and real-world application.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 908-924"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147384904","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 : 2026-03-01Epub Date: 2026-02-11DOI: 10.1016/j.cherd.2026.02.025
Suqi Luo , Guangtao Wei , Yuliang He , Junjie Xin , Junjun Huang , Yi Zhang , Linye Zhang , Chenglong Nong
This study aimed to optimize the design of sonochemical reactors via numerical simulation using COMSOL Multiphysics. First, two reactor configurations were defined: a square reactor with ultrasonic transducers and a cylindrical reactor with ultrasonic horns. Subsequently, the reliability of the simulation was verified through aluminum foil corrosion experiments, and the results showed good agreement between the experimental and simulated results. Finally, acoustic-fluid coupling simulations demonstrated that the influence of the background flow field on the sound pressure distribution was negligible. Based on the validated and simplified simulation method ignoring the background flow field, the effects of several factors on the sound pressure distribution inside the two reactors were systematically investigated. For the square reactor, the factors included the liquid level, as well as the spatial distribution, number, frequency, and power of the transducers. For the cylindrical reactor, the factors included the spatial distribution, number, frequency, power, and insertion depth of the horns. The study provided guidance for constructing and optimizing sonochemical reactors.
{"title":"A systematic parametric optimization and comparative study of square and cylindrical sonochemical reactors by numerical simulation","authors":"Suqi Luo , Guangtao Wei , Yuliang He , Junjie Xin , Junjun Huang , Yi Zhang , Linye Zhang , Chenglong Nong","doi":"10.1016/j.cherd.2026.02.025","DOIUrl":"10.1016/j.cherd.2026.02.025","url":null,"abstract":"<div><div>This study aimed to optimize the design of sonochemical reactors <em>via</em> numerical simulation using COMSOL Multiphysics. First, two reactor configurations were defined: a square reactor with ultrasonic transducers and a cylindrical reactor with ultrasonic horns. Subsequently, the reliability of the simulation was verified through aluminum foil corrosion experiments, and the results showed good agreement between the experimental and simulated results. Finally, acoustic-fluid coupling simulations demonstrated that the influence of the background flow field on the sound pressure distribution was negligible. Based on the validated and simplified simulation method ignoring the background flow field, the effects of several factors on the sound pressure distribution inside the two reactors were systematically investigated. For the square reactor, the factors included the liquid level, as well as the spatial distribution, number, frequency, and power of the transducers. For the cylindrical reactor, the factors included the spatial distribution, number, frequency, power, and insertion depth of the horns. The study provided guidance for constructing and optimizing sonochemical reactors.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 614-628"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147384905","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 : 2026-03-01Epub Date: 2026-02-19DOI: 10.1016/j.cherd.2026.02.039
Asif Shaik , Swantje Pietsch-Braune , Stefan Pirker , Melis Özdemir , Muhammad Adrian , Alexander Penn , Stefan Heinrich
CFD–DEM simulations of industrial fluidized beds suffer from a major computational bottleneck: simulating one second of physical time often requires hours of wall-clock time on modern computer hardware, with hundreds of processors, which makes long-term process analysis impractical. Recurrence-based CFD (rCFD) addresses this challenge by exploiting pseudo-periodic flow patterns to extrapolate short CFD–DEM simulations over extended time periods, but experimental validation of such time-extrapolated predictions has remained absent. To our knowledge, this is the first rigorous experimental validation of rCFD against internal full-field magnetic resonance imaging (MRI) measurement of a cylindrical fluidized bed ( inner diameter, height) operated with poppy seeds () at 1.5 .
First, CFD–DEM predictions were validated against MRI measurements by comparing four drag models (Koch & Hill, Di Felice, Gidaspow, Beetstra) across multiple metrics: bed expansion dynamics, bubble size distributions, radial particle distributions, and bubble rise velocities. The Koch & Hill model demonstrated superior agreement, capturing mean bed heights within a deviation of 0.9 cm of MRI data (17.7 cm vs. 16.8 cm respectively) and correctly predicting most of the bubble formation patterns observed experimentally. Fast Fourier Transform analysis of the validated CFD–DEM data revealed a characteristic recurrence period of 0.27 s, enabling construction of a 5 s rCFD database.
Time-extrapolated rCFD simulations to 10 s maintained excellent agreement with extended MRI measurements, preserving bed expansion behavior, bubble size–velocity correlations without drift or spurious behavior. The approach achieved a computational speed-up, reducing the wall-clock time from 4.5 h to 4 s per simulated physical second while pursuing predictive accuracy. This validated methodology enables previously intractable applications, including real-time process optimization, parametric design studies, and digital twin development for industrial fluidized bed setups.
工业流化床的CFD-DEM模拟存在一个主要的计算瓶颈：在现代计算机硬件上模拟一秒钟的物理时间通常需要几个小时的时钟时间，并且有数百个处理器，这使得长期过程分析变得不切实际。基于递归的CFD （rCFD）通过利用伪周期流动模式在较长时间内外推短CFD - dem模拟来解决这一挑战，但这种时间外推预测的实验验证仍然缺乏。据我们所知，这是rCFD第一次严格的实验验证，针对在1.5 umf下使用罂粟种子（d32=1.16mm）的圆柱形流化床（内径96mm，高度600mm）进行的内部磁场磁共振成像（MRI）测量。首先，通过比较四种阻力模型（Koch & Hill, Di Felice, Gidaspow, Beetstra），通过多个指标（床层膨胀动力学，气泡大小分布，径向颗粒分布和气泡上升速度），通过MRI测量验证了CFD-DEM预测。Koch & Hill模型表现出了优异的一致性，捕获的平均床层高度与MRI数据的偏差在0.9厘米以内（分别为17.7厘米和16.8厘米），并正确预测了实验观察到的大多数气泡形成模式。对验证的CFD-DEM数据进行快速傅里叶变换分析，发现特征重现周期为0.27 s，可以构建5 s的rCFD数据库。时间外推的rCFD模拟与扩展的MRI测量结果保持了良好的一致性，保留了床层膨胀行为，气泡尺寸-速度相关性，没有漂移或虚假行为。该方法实现了4,050倍的计算速度提升，在追求预测准确性的同时，将挂钟时间从每模拟物理秒4.5小时减少到4秒。这种经过验证的方法可以实现以前难以处理的应用，包括实时过程优化、参数化设计研究和工业流化床装置的数字孪生开发。
{"title":"MRI-validated CFD–DEM simulation and recurrence-based time extrapolation (rCFD) of a bubbling fluidized bed: Drag model selection and computational speed-up","authors":"Asif Shaik , Swantje Pietsch-Braune , Stefan Pirker , Melis Özdemir , Muhammad Adrian , Alexander Penn , Stefan Heinrich","doi":"10.1016/j.cherd.2026.02.039","DOIUrl":"10.1016/j.cherd.2026.02.039","url":null,"abstract":"<div><div>CFD–DEM simulations of industrial fluidized beds suffer from a major computational bottleneck: simulating one second of physical time often requires hours of wall-clock time on modern computer hardware, with hundreds of processors, which makes long-term process analysis impractical. Recurrence-based CFD (rCFD) addresses this challenge by exploiting pseudo-periodic flow patterns to extrapolate short CFD–DEM simulations over extended time periods, but experimental validation of such time-extrapolated predictions has remained absent. To our knowledge, this is the first rigorous experimental validation of rCFD against internal full-field magnetic resonance imaging (MRI) measurement of a cylindrical fluidized bed (<span><math><mrow><mn>96</mn><mspace></mspace><mi>mm</mi></mrow></math></span> inner diameter, <span><math><mrow><mn>600</mn><mspace></mspace><mi>mm</mi></mrow></math></span> height) operated with poppy seeds (<span><math><mrow><msub><mrow><mi>d</mi></mrow><mrow><mn>32</mn></mrow></msub><mo>=</mo><mn>1</mn><mo>.</mo><mn>16</mn><mspace></mspace><mi>mm</mi></mrow></math></span>) at 1.5 <span><math><msub><mrow><mi>u</mi></mrow><mrow><mi>m</mi><mi>f</mi></mrow></msub></math></span>.</div><div>First, CFD–DEM predictions were validated against MRI measurements by comparing four drag models (Koch & Hill, Di Felice, Gidaspow, Beetstra) across multiple metrics: bed expansion dynamics, bubble size distributions, radial particle distributions, and bubble rise velocities. The Koch & Hill model demonstrated superior agreement, capturing mean bed heights within a deviation of 0.9 cm of MRI data (17.7 cm vs. 16.8 cm respectively) and correctly predicting most of the bubble formation patterns observed experimentally. Fast Fourier Transform analysis of the validated CFD–DEM data revealed a characteristic recurrence period of 0.27 s, enabling construction of a 5 s rCFD database.</div><div>Time-extrapolated rCFD simulations to 10 s maintained excellent agreement with extended MRI measurements, preserving bed expansion behavior, bubble size–velocity correlations without drift or spurious behavior. The approach achieved a <span><math><mrow><mn>4</mn><mo>,</mo><mn>050</mn><mo>×</mo></mrow></math></span> computational speed-up, reducing the wall-clock time from 4.5 h to 4 s per simulated physical second while pursuing predictive accuracy. This validated methodology enables previously intractable applications, including real-time process optimization, parametric design studies, and digital twin development for industrial fluidized bed setups.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 879-893"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147384980","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 : 2026-03-01Epub Date: 2026-02-13DOI: 10.1016/j.cherd.2026.02.029
Zuo-Qian Jihou , Hui-Long Wei , Zheng-Hong Luo
Acetylene conversion plays a vital role in the industrial synthesis of key chemical products such as polyvinyl chloride and polymer-grade ethylene. Cu-based catalysts have emerged as promising alternatives due to their abundance, environmental friendliness, and improved product selectivity. However, the industrial deployment of Cu-based catalysts is hindered by their tendency to deactivate. This article introduces the recent progress and applications of Cu-based catalysts in acetylene conversions, then systematically summarizes the deactivation mechanism of Cu-based catalysts in various kinds of acetylene conversion reactions. The state-of-the-art tools for studying these deactivation mechanisms such as density functional theory (DFT) are introduced. In addition, the strategies proposed to enhance catalyst stability are summarized. Moving forward, achieving a balance between structural stability and reaction adaptability will be crucial for the efficient and sustainable industrial application of Cu-based catalysts in acetylene conversion.
{"title":"Recent advances in application and deactivation of Cu-based catalysts in acetylene conversion","authors":"Zuo-Qian Jihou , Hui-Long Wei , Zheng-Hong Luo","doi":"10.1016/j.cherd.2026.02.029","DOIUrl":"10.1016/j.cherd.2026.02.029","url":null,"abstract":"<div><div>Acetylene conversion plays a vital role in the industrial synthesis of key chemical products such as polyvinyl chloride and polymer-grade ethylene. Cu-based catalysts have emerged as promising alternatives due to their abundance, environmental friendliness, and improved product selectivity. However, the industrial deployment of Cu-based catalysts is hindered by their tendency to deactivate. This article introduces the recent progress and applications of Cu-based catalysts in acetylene conversions, then systematically summarizes the deactivation mechanism of Cu-based catalysts in various kinds of acetylene conversion reactions. The state-of-the-art tools for studying these deactivation mechanisms such as density functional theory (DFT) are introduced. In addition, the strategies proposed to enhance catalyst stability are summarized. Moving forward, achieving a balance between structural stability and reaction adaptability will be crucial for the efficient and sustainable industrial application of Cu-based catalysts in acetylene conversion.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 685-706"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147384987","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 : 2026-03-01Epub Date: 2026-01-22DOI: 10.1016/j.cherd.2026.01.044
Juan Ramiro Lezama , Sofía Micaela Guerrero Soler , Laura Emilia Giménez , Eleonora Erdmann
The objective of this study is to conduct a comparative analysis of the two principal technologies for obtaining lithium carbonate currently: evaporative processes versus Direct Lithium Extraction (DLE) based on selective adsorption with resins, to determine the production potential for each of them and the convenience of their implementation in salars. The mass and energy balances of each process are resolved, considering a common calculation base. Aspen Plus is used as a simulation tool to access the thermodynamic data of the chemical species involved. Key Performance Indicators (KPIs) are determined, including brine feed, water consumption, reagents used, and energy consumption per ton of lithium carbonate produced. In turn, the interaction between virgin brine and depleted brine is evaluated. Each method has advantages and disadvantages in terms of these indicators, which must be evaluated for each project. In addition, electrical energy consumption was included to compare the peak power demand between both processes.
The selection of these processes necessitates an evaluation of environmental, economic, and social factors to guarantee the sustainable advancement of the lithium sector in these areas. A better approach, from the production point of view, optimizing the factors mentioned, is to propose a combined scheme of both technologies.
{"title":"Evaluation of current processes for lithium carbonate production: Determination of key performance indicators","authors":"Juan Ramiro Lezama , Sofía Micaela Guerrero Soler , Laura Emilia Giménez , Eleonora Erdmann","doi":"10.1016/j.cherd.2026.01.044","DOIUrl":"10.1016/j.cherd.2026.01.044","url":null,"abstract":"<div><div>The objective of this study is to conduct a comparative analysis of the two principal technologies for obtaining lithium carbonate currently: evaporative processes versus Direct Lithium Extraction (DLE) based on selective adsorption with resins, to determine the production potential for each of them and the convenience of their implementation in salars. The mass and energy balances of each process are resolved, considering a common calculation base. Aspen Plus is used as a simulation tool to access the thermodynamic data of the chemical species involved. Key Performance Indicators (KPIs) are determined, including brine feed, water consumption, reagents used, and energy consumption per ton of lithium carbonate produced. In turn, the interaction between virgin brine and depleted brine is evaluated. Each method has advantages and disadvantages in terms of these indicators, which must be evaluated for each project. In addition, electrical energy consumption was included to compare the peak power demand between both processes.</div><div>The selection of these processes necessitates an evaluation of environmental, economic, and social factors to guarantee the sustainable advancement of the lithium sector in these areas. A better approach, from the production point of view, optimizing the factors mentioned, is to propose a combined scheme of both technologies.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 106-119"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146076144","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 : 2026-03-01Epub Date: 2026-01-27DOI: 10.1016/j.cherd.2026.01.054
Dongxiang Wang , Xinjun Yang , Fangyang Yuan , Jiyun Du , Wei Yu , Zhong Chen , Hao Peng , Xiang Ling
This study proposes a novel radially grooved spinning disk reactor (SDR) and evaluates its capability for the high-throughput synthesis of barium sulfate nanoparticles via reactive precipitation. The effect of operating parameters and flow characteristics on particle size were systematically investigated. The radial groove significantly affects the sizes. Increasing rotational Reynolds numbers produce particles with smaller size and narrower distribution. The radially grooved disk requires substantially lower rotational speeds to achieve comparable particle sizes. While the mean particle size increased with the inlet Reynolds number for the smooth disk, it decreased for the grooved disk even at 1.6 L/min, although this effect weakened at high rotational speeds. The mean sizes of smooth disk exhibit a pronounced relationship with Reynolds number ratios as , and a linear relationship with film heights of disk edge. While for the radially grooved disk, the sizes exhibit a power-law relationship with wall-averaged shear rates as . At high shear rates, centrifugal effects dominate the flow, the disk surface exhibit diminished effect on particle size. The specific dispersed power is a key factor affecting influencing the final particle size. For the smooth and radially grooved disks, the sizes can be predicted as and . Although the enhancing effect of the grooves attenuates at high specific power, the particle size is well determined by the dimensionless flow rate and the linear velocity at the disk edge.
{"title":"High-throughput synthesis of BaSO4 nanoparticles via a radially grooved spinning disk reactor: Process intensification and mechanistic elucidation","authors":"Dongxiang Wang , Xinjun Yang , Fangyang Yuan , Jiyun Du , Wei Yu , Zhong Chen , Hao Peng , Xiang Ling","doi":"10.1016/j.cherd.2026.01.054","DOIUrl":"10.1016/j.cherd.2026.01.054","url":null,"abstract":"<div><div>This study proposes a novel radially grooved spinning disk reactor (SDR) and evaluates its capability for the high-throughput synthesis of barium sulfate nanoparticles via reactive precipitation. The effect of operating parameters and flow characteristics on particle size were systematically investigated. The radial groove significantly affects the sizes. Increasing rotational Reynolds numbers produce particles with smaller size and narrower distribution. The radially grooved disk requires substantially lower rotational speeds to achieve comparable particle sizes. While the mean particle size increased with the inlet Reynolds number for the smooth disk, it decreased for the grooved disk even at 1.6 L/min, although this effect weakened at high rotational speeds. The mean sizes of smooth disk exhibit a pronounced relationship with Reynolds number ratios as <span><math><mrow><mo>∼</mo><msup><mrow><msub><mrow><mi>α</mi></mrow><mrow><mi>Re</mi></mrow></msub></mrow><mrow><mo>−</mo><mn>0.546</mn></mrow></msup></mrow></math></span>, and a linear relationship with film heights of disk edge. While for the radially grooved disk, the sizes exhibit a power-law relationship with wall-averaged shear rates as <span><math><mrow><mo>∼</mo><msup><mrow><msub><mrow><mi>γ</mi></mrow><mrow><mi>N</mi><mo>,</mo><mi>a</mi></mrow></msub></mrow><mrow><mo>−</mo><mn>0.412</mn></mrow></msup></mrow></math></span>. At high shear rates, centrifugal effects dominate the flow, the disk surface exhibit diminished effect on particle size. The specific dispersed power is a key factor affecting influencing the final particle size. For the smooth and radially grooved disks, the sizes can be predicted as <span><math><mrow><mn>2.56</mn><msup><mrow><mi>ε</mi></mrow><mrow><mo>−</mo><mn>0.234</mn></mrow></msup></mrow></math></span> and <span><math><mrow><mn>0.97</mn><msup><mrow><mi>ε</mi></mrow><mrow><mo>−</mo><mn>0.22</mn></mrow></msup></mrow></math></span>. Although the enhancing effect of the grooves attenuates at high specific power, the particle size is well determined by the dimensionless flow rate and the linear velocity at the disk edge.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 243-254"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146076072","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 : 2026-03-01Epub Date: 2026-01-29DOI: 10.1016/j.cherd.2026.01.060
Abdul Najim
The passive direct-contact evaporative cooling method has a vast potential to preserve fruits and vegetables after harvest. The coolers employing the method are attractive to areas access to water, as no external energy is required for cooling. However, the coolers cool down the space very slowly, particularly over several hours to half a day, to achieve the maximum temperature drop and saturation effectiveness. This article proposes and assesses a passive direct contact evaporative cooler with rapid cooling capability. A new evaporative cooling pad has been designed and used in the cooler with a storage volume of 47.3 L. In the field experiment, the cooler achieved a maximum temperature drop of 8 °C and a maximum saturation effectiveness of 0.65 in 50 min at the ambient temperature of 35.5 °C. The process duration to achieve the maximum temperature drop and saturation effectiveness was reduced by 58.5–79.3 % compared to an existing cooler in the literature, a crate (56 L storage volume) wrapped in a charcoal blanket. Additionally, the relative humidity inside the cooler was increased by 40.4 % at the ambient air relative humidity of 35.1 %.
{"title":"Experimental study of passive direct-contact evaporative cooler with rapid cooling for preserving fresh fruits and vegetables","authors":"Abdul Najim","doi":"10.1016/j.cherd.2026.01.060","DOIUrl":"10.1016/j.cherd.2026.01.060","url":null,"abstract":"<div><div>The passive direct-contact evaporative cooling method has a vast potential to preserve fruits and vegetables after harvest. The coolers employing the method are attractive to areas access to water, as no external energy is required for cooling. However, the coolers cool down the space very slowly, particularly over several hours to half a day, to achieve the maximum temperature drop and saturation effectiveness. This article proposes and assesses a passive direct contact evaporative cooler with rapid cooling capability. A new evaporative cooling pad has been designed and used in the cooler with a storage volume of 47.3 L. In the field experiment, the cooler achieved a maximum temperature drop of 8 °C and a maximum saturation effectiveness of 0.65 in 50 min at the ambient temperature of 35.5 °C. The process duration to achieve the maximum temperature drop and saturation effectiveness was reduced by 58.5–79.3 % compared to an existing cooler in the literature, a crate (56 L storage volume) wrapped in a charcoal blanket. Additionally, the relative humidity inside the cooler was increased by 40.4 % at the ambient air relative humidity of 35.1 %.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 343-353"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146171265","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 : 2026-03-01Epub Date: 2026-02-05DOI: 10.1016/j.cherd.2026.02.007
Jiawei zhou, Shihao Lv, Xi Wei, Yichen Liu, Shun Guo, Lijian Li
To investigate the influence of material properties on the silo discharge characteristics, a Plexiglas gravity silo experiment system was constructed. Wall pressure measurements and material flow patterns were conducted for analysis. Based on these, the discharge behavior and discharge mass rates of various bulk materials were systematically investigated under both conical and sidewall orifice conditions. Six typical bulk materials were tested, including soybean, carbon black masterbatch, coarse sand, fine sand, industrial salt and white corundum. Quantitative relationships of the discharge coefficient and both the internal and wall friction angles of materials were established based on the Beverloo equation. It indicates that the discharge coefficient is strongly influenced by the internal friction angle of material. Discharge experiments through sidewall openings of internal pipe bundles in a blending silo were carried out using soybeans, carbon black masterbatch, and industrial salt as the test materials. A comparative analysis of mass flow rate characteristics at different material layer depths was performed. A predictive equation for sidewall orifice mass flow rate was developed by dimensional analysis, accounting for material properties and material pressure. The prediction error of the proposed model was within 10 %.
{"title":"Analysis of discharge mass flow rate for gravity blending silo","authors":"Jiawei zhou, Shihao Lv, Xi Wei, Yichen Liu, Shun Guo, Lijian Li","doi":"10.1016/j.cherd.2026.02.007","DOIUrl":"10.1016/j.cherd.2026.02.007","url":null,"abstract":"<div><div>To investigate the influence of material properties on the silo discharge characteristics, a Plexiglas gravity silo experiment system was constructed. Wall pressure measurements and material flow patterns were conducted for analysis. Based on these, the discharge behavior and discharge mass rates of various bulk materials were systematically investigated under both conical and sidewall orifice conditions. Six typical bulk materials were tested, including soybean, carbon black masterbatch, coarse sand, fine sand, industrial salt and white corundum. Quantitative relationships of the discharge coefficient and both the internal and wall friction angles of materials were established based on the Beverloo equation. It indicates that the discharge coefficient is strongly influenced by the internal friction angle of material. Discharge experiments through sidewall openings of internal pipe bundles in a blending silo were carried out using soybeans, carbon black masterbatch, and industrial salt as the test materials. A comparative analysis of mass flow rate characteristics at different material layer depths was performed. A predictive equation for sidewall orifice mass flow rate was developed by dimensional analysis, accounting for material properties and material pressure. The prediction error of the proposed model was within 10 %.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 435-445"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146171269","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 : 2026-03-01Epub Date: 2026-01-30DOI: 10.1016/j.cherd.2026.01.063
Gianluca Lombardini , Sara Badr , Tim Dreckmann , Hirokazu Sugiyama
Pharmaceutical manufacturing increasingly embraces digitalization to enhance reliability, ensure compliance and reduce downtime. This study introduces an integrated modeling framework designed to systematically determine robust operational regions (ROR) in water-for-injection (WFI) distribution loops, which are critical infrastructures subject to variable consumer demand and stringent regulatory constraints. Employing a structured workflow that combines first principles modeling, sensitivity-based parameter identifiability, and Monte Carlo simulations, the framework reliably captures the hydraulic behavior across operational conditions to guide process experts in establishing robust system operation. The approach addresses challenges arising from sparse data and limited sensor coverage, prevalent in current pharmaceutical operations. The application of the framework using industrial data demonstrated identification of conditions likely to trigger system alarms. Consequently, actionable setpoint recommendations were generated to ensure stable and alarm-free operation, offering a transferable blueprint for other fluid distribution networks. The results underscore the broader applicability of rigorous identifiability diagnostics as foundational tools to accelerate Pharma 4.0 adoption, sensor placement optimization, and proactive operational decision-making.
{"title":"An integrated modeling framework to determine robust operational regions in pharmaceutical water-for-injection distribution loops","authors":"Gianluca Lombardini , Sara Badr , Tim Dreckmann , Hirokazu Sugiyama","doi":"10.1016/j.cherd.2026.01.063","DOIUrl":"10.1016/j.cherd.2026.01.063","url":null,"abstract":"<div><div>Pharmaceutical manufacturing increasingly embraces digitalization to enhance reliability, ensure compliance and reduce downtime. This study introduces an integrated modeling framework designed to systematically determine robust operational regions (ROR) in water-for-injection (WFI) distribution loops, which are critical infrastructures subject to variable consumer demand and stringent regulatory constraints. Employing a structured workflow that combines first principles modeling, sensitivity-based parameter identifiability, and Monte Carlo simulations, the framework reliably captures the hydraulic behavior across operational conditions to guide process experts in establishing robust system operation. The approach addresses challenges arising from sparse data and limited sensor coverage, prevalent in current pharmaceutical operations. The application of the framework using industrial data demonstrated identification of conditions likely to trigger system alarms. Consequently, actionable setpoint recommendations were generated to ensure stable and alarm-free operation, offering a transferable blueprint for other fluid distribution networks. The results underscore the broader applicability of rigorous identifiability diagnostics as foundational tools to accelerate Pharma 4.0 adoption, sensor placement optimization, and proactive operational decision-making.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 388-399"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146171256","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 : 2026-03-01Epub Date: 2026-02-12DOI: 10.1016/j.cherd.2026.02.021
Moritz Schulze , Martin Maus , Michael Höfling , Maksym Dosta
The predictive power of process models is closely related to the uncertainties in the identified model parameters. For a fast provision of a reliable process model describing fluid bed granulation, a strategy based on the Fisher information matrix (FIM) is developed to quantify the information of experimental data as a measure of parametric uncertainty. To maximize this information and thereby minimize parametric uncertainty, it is proposed to exploit model-based design of experiments (MBDoE), and to utilize Markov Chain Monte Carlo (MCMC) in the post-design phase to assess the prediction uncertainty on a global level. Following MBDoE, 95 % prediction interval widths for the measured quantities were between 20 % and 142 % wider on average for the experiment with low information compared to the reference case. The FIM and MCMC results also showed that elevated inlet air temperatures and, less pronounced, lower spray rates increase the information, while the effect of changing the inlet volumetric air flow does not allow a distinct conclusion. The proposed strategy offers a computationally efficient means of rapidly generating process models with low prediction uncertainty.
{"title":"Fast identification of model parameters for fluid bed granulation ensuring low uncertainty","authors":"Moritz Schulze , Martin Maus , Michael Höfling , Maksym Dosta","doi":"10.1016/j.cherd.2026.02.021","DOIUrl":"10.1016/j.cherd.2026.02.021","url":null,"abstract":"<div><div>The predictive power of process models is closely related to the uncertainties in the identified model parameters. For a fast provision of a reliable process model describing fluid bed granulation, a strategy based on the Fisher information matrix (FIM) is developed to quantify the information of experimental data as a measure of parametric uncertainty. To maximize this information and thereby minimize parametric uncertainty, it is proposed to exploit model-based design of experiments (MBDoE), and to utilize Markov Chain Monte Carlo (MCMC) in the post-design phase to assess the prediction uncertainty on a global level. Following MBDoE, 95 % prediction interval widths for the measured quantities were between 20 % and 142 % wider on average for the experiment with low information compared to the reference case. The FIM and MCMC results also showed that elevated inlet air temperatures and, less pronounced, lower spray rates increase the information, while the effect of changing the inlet volumetric air flow does not allow a distinct conclusion. The proposed strategy offers a computationally efficient means of rapidly generating process models with low prediction uncertainty.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"227 ","pages":"Pages 746-757"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147384907","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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