Chemical Engineering and Processing - Process Intensification最新文献

英文中文

Facile preparation and characterization of α-aluminum oxide particles by ultrasonic spray pyrolysis

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-03-15 DOI: 10.1016/j.cep.2025.110278

Van Doan Nguyen, Hoa Phan, The Vinh La

The microscopic morphology and purity of alumina are crucial factors in determination of its practical applications in high-tech industries such as ceramics, bioceramics, catalyst carriers, and others. In the present paper, α-Al₂O₃ particles were produced by ultrasonic spray pyrolysis employing the Al(NO₃)₃·6H₂O and AlCl₃·6H₂O precursors. The results of microscopic examinations, mapping investigation, and X-ray diffraction (XRD) patterns revealed that alumina formed separated hollow spherical particles with an averaging 0.8 -1.0 µm in size. The sizes of the experimentally acquired alumina particles were contrasted with the theoretically calculated values. The optimal parameters for alumina production such as the precursor concentration and the phase transition temperature were determined to be 1.0 M and 1223 K, respectively. Fourier transform infrared spectroscopy (FT-IR) confirmed that the γ- phase was converted to the α-Al₂O₃ phase. In addition, energy dispersive X-ray (EDX) and X-ray fluorescence (XRF) measurements were utilized to determine the chemical composition of the alumina powder samples, which revealed that the produced α-Al₂O₃ had purities of 99.9 and 99.8 %, respectively, at a sintering temperature of 1473 K. These results provide significant insights for industrial applications in the aforementioned sectors.

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引用次数: 0

Structural optimization of mining decanter centrifuge based on response surface method and multi-objective genetic algorithm

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-03-12 DOI: 10.1016/j.cep.2025.110276

Peichao Cong, Dong Zhou, Wenbin Li, Murong Deng

A significant quantity of slime water generated during coal mining poses a serious threat to the health of underground workers and the environment. The decanter centrifuge is widely employed in slime water treatment due to its high efficiency in solid-liquid separation. This paper proposes a structural optimization framework for the mine decanter centrifuge based on the Response Surface Method (RSM) and Multi-Objective Genetic Algorithm (MOGA). Firstly, a three-dimensional numerical model of the decanter centrifuge was established, and the reliability of the model was verified by experimental and theoretical analysis. Subsequently, the Box-Behnken design method and RSM were employed to construct a response surface model that links input parameters (drum half cone angle, screw pitch, and spiral blade Inclination angle) with target variables (solid phase recovery rate and overflow liquid phase solids content). The interactions between each input parameter and target variable were assessed using analysis of variance (ANOVA), which confirmed the model's effectiveness and generalization capability. Finally, MOGA was employed to optimize the centrifuge's structural parameters, resulting in an 8.16 % increase in solid recovery rate and a 35.84 % reduction in overflow liquid solid content. It offers a valuable reference for the structural optimization of decanter centrifuges in coal slurry separation.

煤矿开采过程中产生的大量煤泥水严重威胁着井下工人的健康和环境。卧螺离心机因其高效的固液分离效果而被广泛应用于煤泥水处理。本文基于响应面法（RSM）和多目标遗传算法（MOGA），提出了矿用卧螺离心机的结构优化框架。首先，建立了卧螺离心机的三维数值模型，并通过实验和理论分析验证了模型的可靠性。随后，采用盒-贝肯设计法和 RSM 建立了响应面模型，将输入参数（转鼓半锥角、螺距和螺旋叶片倾角）与目标变量（固相回收率和溢流液相固体含量）联系起来。利用方差分析（ANOVA）评估了各输入参数与目标变量之间的交互作用，从而证实了该模型的有效性和泛化能力。最后，利用 MOGA 优化了离心机的结构参数，使固体回收率提高了 8.16%，溢流液固体含量降低了 35.84%。它为煤泥分离中卧螺离心机的结构优化提供了有价值的参考。

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引用次数: 0

Scaling process intensification technologies: what does it take to deploy? 推广加工强化技术：部署需要什么？

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-03-11 DOI: 10.1016/j.cep.2025.110275

Daria C. Boffito

Process intensification (PI) has emerged as a transformative approach to enhancing efficiency, sustainability, and economics across chemical and manufacturing industries. However, within its dedicated communities, there is recognition of a persistent gap in transitioning these innovations from laboratory-scale success to widespread industrial adoption. Scaling up PI technologies is far more complex than simply replicating laboratory conditions on a larger scale. Challenges such as the integration with existing units and processes, proving economic viability, and navigating regulatory requirements often impede the practical implementation of PI innovations. This paper aims to identify the key enablers for scaling up PI technologies by presenting a roadmap to bridge the gap between concept and commercialization. While robust engineering design frameworks and advanced modeling tools are crucial, interdisciplinary collaborations and lab-to-market partnerships (or integrated scaling collaborations) are equally critical to drive the successful adoption of PI at the industrial scale.

引用次数: 0

Improved design and performance study of a novel fixed tube-sheet heat exchanger utilizing a fluid drainage column

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-03-10 DOI: 10.1016/j.cep.2025.110274

Qichao Wang , Zhihui Zhao , Jie Pan , Xiang Li , Haifeng Chen , Huanying Liu , Bingyuan Hong

The carbon emissions in the oil and gas industry are generally high, against the backdrop of low oil and gas recovery rates in oil depots during the summer. This paper proposes a novel fixed tube-sheet heat exchanger with hot fluid drainage column added at the left end cover. The aim is to enhance the heat transfer performance of the heat exchanger (HE), thereby improving the recovery rate. Computational fluid dynamics (CFD) methods are employed to study the performance of the novel fixed tube-sheet heat exchanger (NFTHE). Additionally, the NFTHE is compared with the conventional fixed tube-sheet heat exchanger (FTHE) under various industrial conditions. The results indicate that under the same industrial conditions, the heat transfer rate of the NFTHE increases by 2.46 % to 5.71 %, the overall heat transfer coefficient increases by 22.7 % to 32.6 %, the shell-side heat transfer coefficient increases by 10.6 % to 25.2 %, the effectiveness shows an improvement ranging from 1.72 % to 7.92 %, and the number of transfer units increases by 16.5 % to 44.8 % compared to the FTHE. Comprehensive performance validation parameters show that the NFTHE exhibits superior performance across all metrics, providing a new approach for the design of fixed tube-sheet heat exchangers by adding structures at the end cover.

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引用次数: 0

Micromixing performance of a static mixer with an internal triply periodic minimal surface structure

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-03-10 DOI: 10.1016/j.cep.2025.110264

Xinjun Yang , Xiaohan Lin , Dongxiang Wang , Fangyang Yuan , Wei Yu , Jiyun Du

This study explores TPMS-Diamond structures in static mixers to enhance mixing and reaction processes. Pressure drops were measured in the fine chemicals flow range (0.6–3 L/min), and correlations between Reynolds number, porosity, unit size, and friction factor were established. Energy dissipation rates were calculated, and micromixing performance was evaluated using the Villermaux–Dushman reaction system.The results indicated that micromixing predominantly occurred in the initial contact region, with smaller unit sizes enhancing micromixing performance. When the porosity, ε, is greater than or equal to 0.75, the local energy dissipation rate of the TPMS-Diamond structure was found to be similar to that of the Kenics mixer, yet it achieved significantly better micromixing performance. Additionally, the effects of H+ concentration, flow rate, and volume flow ratio on the micromixing performance of the TPMS-Diamond structure were analyzed. By applying experimental data and agglomeration model techniques, micromixing times for TPMS-Diamond structures with different unit sizes and porosity were determined to range from 0.15 to 1.02 ms, all shorter than those of Kenics mixers. The relationship between micromixing time and energy dissipation rate demonstrates the excellent energy efficiency of TPMS structures. These results demonstrate the substantial potential of TPMS structures in optimizing chemical reaction processes.

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引用次数: 0

Research on the enhancement effect of ultrasonic field combined with monoclinic FeS on arsenic removal behavior

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-03-09 DOI: 10.1016/j.cep.2025.110266

Baoxin Liu , Qingfeng Dong , Jing Li , Zhanqing Lu , Guang Fu , Junchang Liu , Te Zhang

Arsenic is a toxic element in industrial wastewater. The removal of arsenic by sulfide method has been a prominent research topic in the academic community. In this paper, arsenic was removed from arsenic-containing wastewater by ultrasound intensification combined with monoclinic FeS. This method avoids the common problems of H₂S gas spillage and inefficiency in the sulfide method, and has the advantages of being clean and efficient. The effects of S/As molar ratio, initial temperature, reaction time and ultrasonic power on arsenic removal were studied. Under the optimum condition, the arsenic concentration was reduced from 1889 mg/L to 0.32 mg/L, and the arsenic removal rate reached 99.98 %. The precipitation after arsenic removal was characterized by X-ray diffraction (XRD), Scanning electron microscope-energy dispersive spectrometry (SEM-EDS), X-ray fluorescence spectrum analysis method (XRF) and X-ray photoelectron spectroscopy (XPS) to analyze the precipitation phase, surface morphology, element content and chemical composition. A high-speed camera was used to observe the effect of ultrasound on the kinematic behavior of monoclinic FeS.

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引用次数: 0

Effects of the characteristics of silica microcapsules with nanoholes on the reaction rate of calcium chloride for chemical heat pump

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-03-08 DOI: 10.1016/j.cep.2025.110267

Linbin Zeng , Ruri Hidema , Yuxin Tang , Aito Shimamoto , Keiko Fujioka , Hiroshi Suzuki

An optimized-double emulsion method for preparing hollow silica microcapsules with nanoholes was developed for encapsulating calcium chloride to enable its long-term use in chemical heat pumps. The hydration/dehydration of calcium chloride was achieved by permeating water vapour through the surface holes, allowing the thermal upgrading and storage of low-temperature waste heat. The effects of the solution mass and surfactant concentration during the fabrication process on the texture of the microcapsules and thermal properties of the composites were investigated. The results demonstrated the successful encapsulation of calcium chloride in the microcapsules to occupy the entire void and complete hydration/dehydration reaction. Changing the fabrication conditions affected the diameter, shell thickness and opening fraction of microcapsules, thereby further controlling the void fraction and hole specific surface area, which were proven to be key parameters for improving heat storage density and hydration output power density. Composite microcapsules with a heat storage density of 809.1 J·g⁻¹ at a void fraction of 54.7 vol% and a power density of 0.95 W·g⁻¹ at a hole specific surface area of 0.089 μm^-1 and satisfactory thermal stability after 50 cycles were obtained.

{"title":"Effects of the characteristics of silica microcapsules with nanoholes on the reaction rate of calcium chloride for chemical heat pump","authors":"Linbin Zeng , Ruri Hidema , Yuxin Tang , Aito Shimamoto , Keiko Fujioka , Hiroshi Suzuki","doi":"10.1016/j.cep.2025.110267","DOIUrl":"10.1016/j.cep.2025.110267","url":null,"abstract":"<div><div>An optimized-double emulsion method for preparing hollow silica microcapsules with nanoholes was developed for encapsulating calcium chloride to enable its long-term use in chemical heat pumps. The hydration/dehydration of calcium chloride was achieved by permeating water vapour through the surface holes, allowing the thermal upgrading and storage of low-temperature waste heat. The effects of the solution mass and surfactant concentration during the fabrication process on the texture of the microcapsules and thermal properties of the composites were investigated. The results demonstrated the successful encapsulation of calcium chloride in the microcapsules to occupy the entire void and complete hydration/dehydration reaction. Changing the fabrication conditions affected the diameter, shell thickness and opening fraction of microcapsules, thereby further controlling the void fraction and hole specific surface area, which were proven to be key parameters for improving heat storage density and hydration output power density. Composite microcapsules with a heat storage density of 809.1 J·g<sup>−1</sup> at a void fraction of 54.7 vol% and a power density of 0.95 W·g<sup>−1</sup> at a hole specific surface area of 0.089 μm<sup>-1</sup> and satisfactory thermal stability after 50 cycles were obtained.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"212 ","pages":"Article 110267"},"PeriodicalIF":3.8,"publicationDate":"2025-03-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143601709","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Accelerated metal separation from chalcopyrite assisted with ozone

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-03-07 DOI: 10.1016/j.cep.2025.110263

Mingzhu Ren , Jiang Zhang , Zhaomeng Xu , Jing Wang , Jiakai Qiu , Yongbing Xie

Chalcopyrite is a very important mineral resource, but metal separation from chalcopyrite requires a long time and high energy. This work proposed an ozonation enhanced acid leaching strategy, and typical operating parameters were optimized. The results showed that the leaching rates of Cu and Fe reached 35.9 % and 36.9 % after 5 h, respectively, with 0.1 mol/L of H₂SO₄, 100 mg/L of O₃ and a L/S ratio of 50:1 at 45 °C, which were about 29.7 and 10.2 times higher than that without O₃. Two novel approaches are further employed to enhance the leaching rates. It was found that the coupling of UV radiation did not play a synergistic role for metal leaching, while it increased rapidly when H₂O₂ was added into the leaching system, though the enhancement effect was not continuous. In addition, ball milling pretreatment and ozone micro-nano bubbles both greatly improved the metal leaching rates from chalcopyrite. The leaching rate of Cu can reach to 86.5 % after ball milling, and the concentrations of Fe and Cu in the leaching solution with O₃ micro-nano bubbles increased by 7.7 and 10.0 times than those with common O₃ bubbles. This work provides a new idea for the development of novel leaching technology of chalcopyrite.

{"title":"Accelerated metal separation from chalcopyrite assisted with ozone","authors":"Mingzhu Ren , Jiang Zhang , Zhaomeng Xu , Jing Wang , Jiakai Qiu , Yongbing Xie","doi":"10.1016/j.cep.2025.110263","DOIUrl":"10.1016/j.cep.2025.110263","url":null,"abstract":"<div><div>Chalcopyrite is a very important mineral resource, but metal separation from chalcopyrite requires a long time and high energy. This work proposed an ozonation enhanced acid leaching strategy, and typical operating parameters were optimized. The results showed that the leaching rates of Cu and Fe reached 35.9 % and 36.9 % after 5 h, respectively, with 0.1 mol/L of H<sub>2</sub>SO<sub>4</sub>, 100 mg/L of O<sub>3</sub> and a L/S ratio of 50:1 at 45 °C, which were about 29.7 and 10.2 times higher than that without O<sub>3</sub>. Two novel approaches are further employed to enhance the leaching rates. It was found that the coupling of UV radiation did not play a synergistic role for metal leaching, while it increased rapidly when H<sub>2</sub>O<sub>2</sub> was added into the leaching system, though the enhancement effect was not continuous. In addition, ball milling pretreatment and ozone micro-nano bubbles both greatly improved the metal leaching rates from chalcopyrite. The leaching rate of Cu can reach to 86.5 % after ball milling, and the concentrations of Fe and Cu in the leaching solution with O<sub>3</sub> micro-nano bubbles increased by 7.7 and 10.0 times than those with common O<sub>3</sub> bubbles. This work provides a new idea for the development of novel leaching technology of chalcopyrite.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"212 ","pages":"Article 110263"},"PeriodicalIF":3.8,"publicationDate":"2025-03-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143591900","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}

引用次数: 0

Wastewater treatment through a hybrid electrocoagulation and electro-Fenton process with a porous graphite air-diffusion cathode

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-03-06 DOI: 10.1016/j.cep.2025.110258

Ziad T. Alismaeel, Osama F. Saeed, Ali H. Abbar

Wastewater from hospitals is a major source of pollution, and its treatment to protect the environment is a challenge. Different traditional methods have been applied to treat hospital wastewater (HW). Recently, hybrid processes, such as electrocoagulation (EC) with the electro-Fenton (EF) process, have been found to outperform traditional methods in terms of their high removal rate, low sludge generation and energy consumption and environmental sustainability. Herein, a combined EF process integrated with EC was successfully applied to reduce the chemical O demand (COD) of HW. A batch tubular electrochemical reactor composed of a microporous graphite air diffusion cathode and a hollow cylinder Al anode was used as a new design to remove pollutants from HW. Response surface methodology was adopted to explore the effects of operating factors, which were represented by current density, Fe²⁺ concentration and time, on COD removal and identify their interactions. The best operating conditions were a current density of 20 mA/cm², an Fe²⁺ concentration of 6 mM and a reaction time of 63 min. These conditions yielded a COD removal efficiency (RE %) of 93.5 % with an energy consumption of 18.325 kWh/kg COD. Time had the main effect on the RE % due to the synergistic effect of EC and EF. The hybrid system had higher efficiency and lower energy consumption and sludge production than individual EC or EF. Therefore, combining EC with EF could be a promising approach for the treatment of HW.

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引用次数: 0

Comparing a new semi-empirical mathematical model and a neural network for the description and forecasting of reversible fouling in membrane bioreactors

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-03-06 DOI: 10.1016/j.cep.2025.110256

Victorino Diez , José María Cámara , Miguel Cantera , Adrián Bonilla , Cipriano Ramos

This study compares the predictive capability of membrane fouling between a new semi-empirical mathematical model and a neural network. Calibration and validation involved 21 replicated flux-step experiments with 8 filtration fluxes ranging from 9.8 to 18.9 L/m²·h and 40-hour random-flux experiments conducted in an anaerobic membrane bioreactor. The inherent variability of reversible fouling linked to cake build-up was quantified.

In addition to cake build-up and compression, the mathematical model incorporates the restoration of residual fouling not removed by backwashing, including the rearrangement of non-detached particles and colloids, initial pore-blocking, and concentration polarization. The model predicts reversible fouling across a wide range of filtration fluxes, even beyond those used for calibration. Random-flux experiments revealed fouling trends undetectable via direct transmembrane pressure inspection. However, the mathematical model fails when the effective membrane area decreases during filtration.

The neural network predicts fouling patterns independently of underlying mechanisms, offering adaptability across a broader range of operating conditions. Nonetheless, it struggles to predict reversible fouling for flux ranges outside its training dataset, particularly at fluxes significantly higher or lower than those used in training.

The present study offers insight into reversible fouling description in order to enhance the performance of membrane bioreactors.

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