Chemical Engineering and Processing - Process Intensification最新文献

英文中文

Numerical simulation on electrical-intensified separator: The development of the flow field and its separation performance

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-04-01 DOI: 10.1016/j.cep.2025.110281

Chen Huo , Bao Yu , Ling Chen , Ye Peng , Hong Yin , Ping Ouyang , Haifeng Gong

Wastewater treatment for improving energy efficiency to promote water resource recycling is required globally. Centrifugation technology has been widely applied in industrial wastewater pretreatment. However, conventional hydrocyclones induce high breakage rate of droplets owing to the high shear force. Therefore, the electrical-intensified separator was designed. It provides preseparation and strengthened environments and applies electrical field to intensify separation effect. A simulation of the separator was conducted. The separation performance was investigated, and the reason for low energy loss was discussed. Simultaneously, the simulation was verified through experiment. The results show that the electrical-intensified separator not only increases efficiency by 20 % but also decreases dynamic energy loss by >120 Pa under V = 5 m/s compared to the conventional hydrocyclone. And numerical results agree with experiment. The separator decreases the rate of droplet breakup and enhances separation due to the separation with progressive process, making the region distribution of tangential velocity wider and greater. Additionally, the role of electrical field intensifies the droplet migration, which is conducive to increase the movement of mixture in flow field. Therefore, the dynamic pressure loss of this separator is significantly lower than conventional hydrocyclone.

{"title":"Numerical simulation on electrical-intensified separator: The development of the flow field and its separation performance","authors":"Chen Huo , Bao Yu , Ling Chen , Ye Peng , Hong Yin , Ping Ouyang , Haifeng Gong","doi":"10.1016/j.cep.2025.110281","DOIUrl":"10.1016/j.cep.2025.110281","url":null,"abstract":"<div><div>Wastewater treatment for improving energy efficiency to promote water resource recycling is required globally. Centrifugation technology has been widely applied in industrial wastewater pretreatment. However, conventional hydrocyclones induce high breakage rate of droplets owing to the high shear force. Therefore, the electrical-intensified separator was designed. It provides preseparation and strengthened environments and applies electrical field to intensify separation effect. A simulation of the separator was conducted. The separation performance was investigated, and the reason for low energy loss was discussed. Simultaneously, the simulation was verified through experiment. The results show that the electrical-intensified separator not only increases efficiency by 20 % but also decreases dynamic energy loss by >120 Pa under <em>V</em> = 5 m/s compared to the conventional hydrocyclone. And numerical results agree with experiment. The separator decreases the rate of droplet breakup and enhances separation due to the separation with progressive process, making the region distribution of tangential velocity wider and greater. Additionally, the role of electrical field intensifies the droplet migration, which is conducive to increase the movement of mixture in flow field. Therefore, the dynamic pressure loss of this separator is significantly lower than conventional hydrocyclone.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110281"},"PeriodicalIF":3.8,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143737964","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

Comparative analysis of flow behavior during the nanofluid Phase transition at serpentine microchannel bends

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-04-01 DOI: 10.1016/j.cep.2025.110298

Juhui Chen , Hanchi Xu , Dan Li , Jin Guo , Michael Zhuravkov , Siarhel Lapatsin , Wenrui Jiang

With the growing demand for high-flux thermal management in electronics, understanding nanofluid flow dynamics during phase transitions in complex microchannel geometries remains a critical yet underexplored frontier. This study pioneers a comprehensive investigation into the flow characteristics of four nanofluids (Cu-water, Al₂O₃-water, Al-water, SiO₂-water) before and after liquid-vapor phase transitions in serpentine microchannel bends, integrating the Mixture model with the RNG k-ε turbulence model. The novelty lies in the coupled analysis of multiphase flow, flow behavior and geometric effects during the phase transition of nanoparticles at different Reynolds numbers (100–400), volume fractions (0.1 %–1.3 %) and heat fluxes (50–80kW/m²). Key findings reveal that the change of heat flux density in pre-phase transition has little effect on pressure drop, but escalates with Reynolds number and volume fraction, with Cu-water exhibiting the highest growth rates (66.91 % and 42.96 %, respectively). Post-phase transition, despite lower absolute pressure drops, growth rates surpass pre-transition values (Cu-water: 67.16 % and 43.15 %), driven by vapor-induced turbulence and altered flow resistance mechanisms. These insights challenge the traditional single-phase cooling paradigm by quantifying how phase transitions modulate the behavior of nanofluids within serpentine microchannels, and can provide theoretical references for fields such as high-power electronics and aerospace thermal management.

{"title":"Comparative analysis of flow behavior during the nanofluid Phase transition at serpentine microchannel bends","authors":"Juhui Chen , Hanchi Xu , Dan Li , Jin Guo , Michael Zhuravkov , Siarhel Lapatsin , Wenrui Jiang","doi":"10.1016/j.cep.2025.110298","DOIUrl":"10.1016/j.cep.2025.110298","url":null,"abstract":"<div><div>With the growing demand for high-flux thermal management in electronics, understanding nanofluid flow dynamics during phase transitions in complex microchannel geometries remains a critical yet underexplored frontier. This study pioneers a comprehensive investigation into the flow characteristics of four nanofluids (Cu-water, Al<sub>2</sub>O<sub>3</sub>-water, Al-water, SiO<sub>2</sub>-water) before and after liquid-vapor phase transitions in serpentine microchannel bends, integrating the Mixture model with the RNG k-ε turbulence model. The novelty lies in the coupled analysis of multiphase flow, flow behavior and geometric effects during the phase transition of nanoparticles at different Reynolds numbers (100–400), volume fractions (0.1 %–1.3 %) and heat fluxes (50–80kW/m²). Key findings reveal that the change of heat flux density in pre-phase transition has little effect on pressure drop, but escalates with Reynolds number and volume fraction, with Cu-water exhibiting the highest growth rates (66.91 % and 42.96 %, respectively). Post-phase transition, despite lower absolute pressure drops, growth rates surpass pre-transition values (Cu-water: 67.16 % and 43.15 %), driven by vapor-induced turbulence and altered flow resistance mechanisms. These insights challenge the traditional single-phase cooling paradigm by quantifying how phase transitions modulate the behavior of nanofluids within serpentine microchannels, and can provide theoretical references for fields such as high-power electronics and aerospace thermal management.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110298"},"PeriodicalIF":3.8,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143777479","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

Optimizing multi-source ultrasound configuration for process intensification: numerical simulation and experimental validation

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-03-29 DOI: 10.1016/j.cep.2025.110294

Zeying Wang , Guo Lin , Tu Hu , Shixing Wang , Shiwei Li , Zhen Zhong , Likang Fu , Hongying Xia , Libo Zhang

This paper investigates the application of ultrasonic simulation in metallurgy, focusing on the effects of ultrasonic power density, number of transducers, and multi-source array mode on the acoustic field distribution characteristics. The simulation results reveal that as power density increases from 375 W/L to 750 W/L at 28 kHz, the maximum sound pressure rises from 4.13 × 10⁶ Pa to 4.37 × 10⁶ Pa, and the cavitation volume fraction increases from 19% to 50%. The maximum sound pressure (4.13 × 10⁶ Pa) and cavitation volume fraction (49%) of two transducers are higher than three transducers. The isosceles triangle array method exhibits the optimal sound field characteristics, with a maximum sound pressure of 2.87 × 10⁶ Pa and a cavitation volume fraction of 52%. The maximum sound pressure of 4.13 × 10⁶ Pa is achieved when two transducers are 45 mm from the reaction chamber bottom and the peak offset distance is zero. The simulation results are confirmed by measuring the sound pressure in water using a hydrophone under 140–200 W. This research visualizes the ultrasonic process intensification parameters, addressing the issue of random arrangement of transducer in industrial applications and enhancing work efficiency.

{"title":"Optimizing multi-source ultrasound configuration for process intensification: numerical simulation and experimental validation","authors":"Zeying Wang , Guo Lin , Tu Hu , Shixing Wang , Shiwei Li , Zhen Zhong , Likang Fu , Hongying Xia , Libo Zhang","doi":"10.1016/j.cep.2025.110294","DOIUrl":"10.1016/j.cep.2025.110294","url":null,"abstract":"<div><div>This paper investigates the application of ultrasonic simulation in metallurgy, focusing on the effects of ultrasonic power density, number of transducers, and multi-source array mode on the acoustic field distribution characteristics. The simulation results reveal that as power density increases from 375 W/L to 750 W/L at 28 kHz, the maximum sound pressure rises from 4.13 × 10<sup>6</sup> Pa to 4.37 × 10<sup>6</sup> Pa, and the cavitation volume fraction increases from 19% to 50%. The maximum sound pressure (4.13 × 10<sup>6</sup> Pa) and cavitation volume fraction (49%) of two transducers are higher than three transducers. The isosceles triangle array method exhibits the optimal sound field characteristics, with a maximum sound pressure of 2.87 × 10<sup>6</sup> Pa and a cavitation volume fraction of 52%. The maximum sound pressure of 4.13 × 10<sup>6</sup> Pa is achieved when two transducers are 45 mm from the reaction chamber bottom and the peak offset distance is zero. The simulation results are confirmed by measuring the sound pressure in water using a hydrophone under 140–200 W. This research visualizes the ultrasonic process intensification parameters, addressing the issue of random arrangement of transducer in industrial applications and enhancing work efficiency.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110294"},"PeriodicalIF":3.8,"publicationDate":"2025-03-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143777478","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

Design and optimization of etherification reaction-assisted separation process for dimethyl carbonate/methanol azeotrope system

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-03-29 DOI: 10.1016/j.cep.2025.110293

Yajuan Qu , Siyuan Liu , Haifeng Cong , Xingang Li

Dimethyl carbonate (DMC) has high commercial value as an important raw material for diesel. Aiming at the industry problem of high energy consumption in DMC/methanol (MeOH) azeotrope separation, a new idea of MeOH/DMC azeotropic system with mixed C4 etherification reaction-assisted separation was proposed for the first time in this study. The process couples the transesterification segment of ethylene carbonate (EC) with the etherification segment of methyl tert-butyl ether (MTBE), which breaks the azeotropic state of MeOH and DMC by inducing the reaction of MeOH with isobutylene to produce MTBE. First, the kinetic parameters of the transesterification and etherification reactions were investigated. Then the process was designed and simulated in Aspen Plus. Finally, in order to further recover the waste heat of the reaction section, the optimal configuration of steam-driven heat pump coupled with Rankine cycle was designed. The results showed that the EC conversion reached 100 %, the purity of DMC and MTBE reached 99.99 % and 99.5 %, respectively, and the total energy consumption, environmental pollutant emission and TAC were reduced by 36.0 %, 40.0 % and 32.7 %, respectively, compared with that of the original conventional process.

{"title":"Design and optimization of etherification reaction-assisted separation process for dimethyl carbonate/methanol azeotrope system","authors":"Yajuan Qu , Siyuan Liu , Haifeng Cong , Xingang Li","doi":"10.1016/j.cep.2025.110293","DOIUrl":"10.1016/j.cep.2025.110293","url":null,"abstract":"<div><div>Dimethyl carbonate (DMC) has high commercial value as an important raw material for diesel. Aiming at the industry problem of high energy consumption in DMC/methanol (MeOH) azeotrope separation, a new idea of MeOH/DMC azeotropic system with mixed C4 etherification reaction-assisted separation was proposed for the first time in this study. The process couples the transesterification segment of ethylene carbonate (EC) with the etherification segment of methyl tert-butyl ether (MTBE), which breaks the azeotropic state of MeOH and DMC by inducing the reaction of MeOH with isobutylene to produce MTBE. First, the kinetic parameters of the transesterification and etherification reactions were investigated. Then the process was designed and simulated in Aspen Plus. Finally, in order to further recover the waste heat of the reaction section, the optimal configuration of steam-driven heat pump coupled with Rankine cycle was designed. The results showed that the EC conversion reached 100 %, the purity of DMC and MTBE reached 99.99 % and 99.5 %, respectively, and the total energy consumption, environmental pollutant emission and TAC were reduced by 36.0 %, 40.0 % and 32.7 %, respectively, compared with that of the original conventional process.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110293"},"PeriodicalIF":3.8,"publicationDate":"2025-03-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143747705","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

Molecular investigation of pyrolysis and thermal gasification pathways in polyethylene microplastics degradation

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-03-28 DOI: 10.1016/j.cep.2025.110285

Thi Be Ta Truong , Do Tuong Ha , Hien Duy Tong , Thuat T. Trinh

Polyethylene (PE) microplastics are a persistent environmental threat due to their widespread presence and potential for long-range transport. This study uses reactive molecular dynamics (ReaxFF) simulations to explore the atomic-level thermal degradation mechanisms of PE microplastics through pyrolysis and thermal gasification (TG). A key finding of the research is the comparison of activation energies for pyrolysis and TG. Results show that pyrolysis begins with chain scission, producing volatile compounds, while TG generates hydrogen, carbon monoxide, water, and small hydrocarbons. Oxygen plays a key role in controlling gas fractions during TG. The activation energy for pyrolysis is 315 kJ/mol, higher than TG, which ranges from 197 to 262 kJ/mol depending on oxygen content, indicating TG is a more efficient degradation pathway. These findings offer molecular insights into PE microplastic degradation, aiding the development of targeted remediation strategies and advancing research on microplastic waste treatment.

{"title":"Molecular investigation of pyrolysis and thermal gasification pathways in polyethylene microplastics degradation","authors":"Thi Be Ta Truong , Do Tuong Ha , Hien Duy Tong , Thuat T. Trinh","doi":"10.1016/j.cep.2025.110285","DOIUrl":"10.1016/j.cep.2025.110285","url":null,"abstract":"<div><div>Polyethylene (PE) microplastics are a persistent environmental threat due to their widespread presence and potential for long-range transport. This study uses reactive molecular dynamics (ReaxFF) simulations to explore the atomic-level thermal degradation mechanisms of PE microplastics through pyrolysis and thermal gasification (TG). A key finding of the research is the comparison of activation energies for pyrolysis and TG. Results show that pyrolysis begins with chain scission, producing volatile compounds, while TG generates hydrogen, carbon monoxide, water, and small hydrocarbons. Oxygen plays a key role in controlling gas fractions during TG. The activation energy for pyrolysis is 315 kJ/mol, higher than TG, which ranges from 197 to 262 kJ/mol depending on oxygen content, indicating TG is a more efficient degradation pathway. These findings offer molecular insights into PE microplastic degradation, aiding the development of targeted remediation strategies and advancing research on microplastic waste treatment.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110285"},"PeriodicalIF":3.8,"publicationDate":"2025-03-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143734537","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

Performance evaluation of helical tangential porous tube-in-tube microchannel mixer: Effect of cross-sectional area ratio and volumetric flow rate ratio

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-03-28 DOI: 10.1016/j.cep.2025.110296

Xiao Xu , Jinfeng Zhang , Jia Chen , Dongbo Zhao , Shaodong Qin

The tube-in-tube microchannel mixer (TMM) is a passive micromixer primarily applied in chemical engineering and pharmaceutical fields. This study investigates the performance optimization of a helical tangential porous tube-in-tube microchannel mixer (HTP-TMM) using computational fluid dynamics (CFD) simulations. A critical structural parameter, the cross-sectional area ratio (R_a), defined as the ratio of the annular microchannel cross-sectional area to the total micropore cross-sectional area, was introduced. The effects of various R_a and volumetric flow rate ratios (R_f) on mixing efficiency, turbulent kinetic energy, pressure drop, and mixing energy cost were evaluated across flow rates ranging from 10 to 300 mL/min. Results indicate that R_a = 1.5 demonstrates higher mixing efficiency and turbulent kinetic energy at low flow rates. Decreasing R_f improves mixing efficiency and turbulent kinetic energy, with optimal mixing performance occurring at R_f = 1. Additionally, larger R_a and smaller R_f values induce higher pressure drops, with maximum recorded values of 23,449 Pa for R_a = 2 and 19,990 Pa for R_f = 1, both within acceptable ranges for practical applications. Moreover, varying R_a minimally affects mixing energy cost, while increasing R_f raises mixing energy cost. These findings provide valuable guidance for TMM design and application in chemical engineering.

{"title":"Performance evaluation of helical tangential porous tube-in-tube microchannel mixer: Effect of cross-sectional area ratio and volumetric flow rate ratio","authors":"Xiao Xu , Jinfeng Zhang , Jia Chen , Dongbo Zhao , Shaodong Qin","doi":"10.1016/j.cep.2025.110296","DOIUrl":"10.1016/j.cep.2025.110296","url":null,"abstract":"<div><div>The tube-in-tube microchannel mixer (TMM) is a passive micromixer primarily applied in chemical engineering and pharmaceutical fields. This study investigates the performance optimization of a helical tangential porous tube-in-tube microchannel mixer (HTP-TMM) using computational fluid dynamics (CFD) simulations. A critical structural parameter, the cross-sectional area ratio (<em>R</em><sub>a</sub>), defined as the ratio of the annular microchannel cross-sectional area to the total micropore cross-sectional area, was introduced. The effects of various <em>R</em><sub>a</sub> and volumetric flow rate ratios (<em>R</em><sub>f</sub>) on mixing efficiency, turbulent kinetic energy, pressure drop, and mixing energy cost were evaluated across flow rates ranging from 10 to 300 mL/min. Results indicate that <em>R</em><sub>a</sub> = 1.5 demonstrates higher mixing efficiency and turbulent kinetic energy at low flow rates. Decreasing <em>R</em><sub>f</sub> improves mixing efficiency and turbulent kinetic energy, with optimal mixing performance occurring at <em>R</em><sub>f</sub> = 1. Additionally, larger <em>R</em><sub>a</sub> and smaller <em>R</em><sub>f</sub> values induce higher pressure drops, with maximum recorded values of 23,449 Pa for <em>R</em><sub>a</sub> = 2 and 19,990 Pa for <em>R</em><sub>f</sub> = 1, both within acceptable ranges for practical applications. Moreover, varying <em>R</em><sub>a</sub> minimally affects mixing energy cost, while increasing <em>R</em><sub>f</sub> raises mixing energy cost. These findings provide valuable guidance for TMM design and application in chemical engineering.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110296"},"PeriodicalIF":3.8,"publicationDate":"2025-03-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143747704","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

Axial dispersion modelling of the residence time distribution in a millistructured plate reactor

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-03-28 DOI: 10.1016/j.cep.2025.110295

Lucas Schaare , Alexander Rave , Rafael Kuwertz , Georg Fieg , Mirko Skiborowski

Micro- and millistructured reactors offer significant advantages compared to conventional batch reactors in terms of heat and mass transfer as well as process safety. Especially in case of fast and exothermic reactions, the space-time-yield of batch reactors is often limited by poor heat transfer and slow mixing. The use of millistructured reactors, such as the ART plate reactor PR37 of Ehrfeld Mikrotechnik, can overcome heat and mass transfer limitations and significantly extend applicable process windows, while providing sufficient capacity for industrial applications. Previous investigations showed that the reactor offers high heat transfer coefficients as well as short micromixing times at moderates Reynolds numbers. In order to further characterize the performance of the reactor and the possible operating window, the current work provides a thorough study of the residence time distribution on the basis of pulse experiments and a model-based evaluation of the deviation from ideal plug flow on the basis of the axial dispersion model. The results demonstrate that the reactor closely resembles the ideal plug flow even for Reynolds numbers of just about Re

\approx

100. Due to its meandering, periodically diverging/converging process channels, the formation of secondary flow is promoted resulting in an increased cross-mixing and thus a considerably reduced axial dispersion compared straight channels. For further analysis, as well as model-based assessment and design of the reactor, a correlation for the axial dispersion coefficient is derived which is applicable for a wide process window.

{"title":"Axial dispersion modelling of the residence time distribution in a millistructured plate reactor","authors":"Lucas Schaare , Alexander Rave , Rafael Kuwertz , Georg Fieg , Mirko Skiborowski","doi":"10.1016/j.cep.2025.110295","DOIUrl":"10.1016/j.cep.2025.110295","url":null,"abstract":"<div><div>Micro- and millistructured reactors offer significant advantages compared to conventional batch reactors in terms of heat and mass transfer as well as process safety. Especially in case of fast and exothermic reactions, the space-time-yield of batch reactors is often limited by poor heat transfer and slow mixing. The use of millistructured reactors, such as the ART plate reactor PR37 of Ehrfeld Mikrotechnik, can overcome heat and mass transfer limitations and significantly extend applicable process windows, while providing sufficient capacity for industrial applications. Previous investigations showed that the reactor offers high heat transfer coefficients as well as short micromixing times at moderates Reynolds numbers. In order to further characterize the performance of the reactor and the possible operating window, the current work provides a thorough study of the residence time distribution on the basis of pulse experiments and a model-based evaluation of the deviation from ideal plug flow on the basis of the axial dispersion model. The results demonstrate that the reactor closely resembles the ideal plug flow even for Reynolds numbers of just about <em>Re</em> <span><math><mo>≈</mo></math></span> 100. Due to its meandering, periodically diverging/converging process channels, the formation of secondary flow is promoted resulting in an increased cross-mixing and thus a considerably reduced axial dispersion compared straight channels. For further analysis, as well as model-based assessment and design of the reactor, a correlation for the axial dispersion coefficient is derived which is applicable for a wide process window.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110295"},"PeriodicalIF":3.8,"publicationDate":"2025-03-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143748331","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

An efficient heat-pump extractive distillation process for recovering lower alcohols from bioethanol fusel oil

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-03-28 DOI: 10.1016/j.cep.2025.110291

Zhishan Zhang, Jinyu Wang, Kunao Zhu, Siyuan Li, Min Li, Xing Fan, Jun Gao

Fusel oil is a common mixture of several alcohols produced as a by-product of alcoholic fermentation. After removing the main ingredient (amyl alcohol), it also contains lower alcohols such as ethanol (EtOH), n-propanol (NPA) and isobutanol (IBA), each of which forms an azeotrope with water and has a similar boiling point. In order to efficient recover high purity products from the EtOH/NPA/IBA/water mixture, this article investigates different extractive distillation processes with heat pump in terms of economic, environment and thermodynamic properties. Firstly, 1,4-butanediol is screened as the best dehydration solvent based on the thermodynamic and molecular quantization analysis; Next, a conventional extractive distillation sequence (CED) is proposed and optimized using total annual costs (TAC) and CO₂ emissions as dual objectives. Finally, introducing heat integration, vapor recompressed heat pump and bottom flash heat pump into the CED process, three energy-saving processes (i.e., HICED, DVRHPs-HICED and BFVRHPs-HICED) are designed. The results show that compared with the CED process, the DVRHPs-HICED process reduces TAC by 17.5 %, exergy loss by 42.2 %, and gas emissions (CO₂, SO₂, NO_x) by 49.2 % while the BFVRHPs-HICED process reduce TAC by 17.8 %, exergy loss by 40.8 %, and gas emissions (CO₂, SO₂, NO_x) by 48.5 %.

{"title":"An efficient heat-pump extractive distillation process for recovering lower alcohols from bioethanol fusel oil","authors":"Zhishan Zhang, Jinyu Wang, Kunao Zhu, Siyuan Li, Min Li, Xing Fan, Jun Gao","doi":"10.1016/j.cep.2025.110291","DOIUrl":"10.1016/j.cep.2025.110291","url":null,"abstract":"<div><div>Fusel oil is a common mixture of several alcohols produced as a by-product of alcoholic fermentation. After removing the main ingredient (amyl alcohol), it also contains lower alcohols such as ethanol (EtOH), n-propanol (NPA) and isobutanol (IBA), each of which forms an azeotrope with water and has a similar boiling point. In order to efficient recover high purity products from the EtOH/NPA/IBA/water mixture, this article investigates different extractive distillation processes with heat pump in terms of economic, environment and thermodynamic properties. Firstly, 1,4-butanediol is screened as the best dehydration solvent based on the thermodynamic and molecular quantization analysis; Next, a conventional extractive distillation sequence (CED) is proposed and optimized using total annual costs (TAC) and CO<sub>2</sub> emissions as dual objectives. Finally, introducing heat integration, vapor recompressed heat pump and bottom flash heat pump into the CED process, three energy-saving processes (i.e., HICED, DVRHPs-HICED and BFVRHPs-HICED) are designed. The results show that compared with the CED process, the DVRHPs-HICED process reduces TAC by 17.5 %, exergy loss by 42.2 %, and gas emissions (CO<sub>2</sub>, SO<sub>2</sub>, NO<sub>x</sub>) by 49.2 % while the BFVRHPs-HICED process reduce TAC by 17.8 %, exergy loss by 40.8 %, and gas emissions (CO<sub>2</sub>, SO<sub>2</sub>, NO<sub>x</sub>) by 48.5 %.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110291"},"PeriodicalIF":3.8,"publicationDate":"2025-03-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143747706","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

CFD analysis of the intensification mechanism of bubble breakup by perforated plates in a bubble column

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-03-28 DOI: 10.1016/j.cep.2025.110288

Rongtao Wang, Xinya Guo, Mengqin Zhan, Yefei Liu

Conventional bubble column reactors suffer from some drawbacks like severe backmixing and poor heat/mass transfer performance. The process intensification by the utilization of perforated plates has been an important strategy to overcome these problems. However, a fundamental understanding of the bubble breakup by perforated plates is still very limited. CFD simulations are carried out to reveal the interaction between the rising bubbles and perforated plates. It is found that no bubbles break up when they just pass through the hole. A bubble can be broken into three small daughter bubbles when it collides with the bridge connecting three holes. The bubble breakup is mainly attributed to the bridge cutting, whereas it is not sensitive to large hole diameters. A large bubble cap is formed underneath the plate due to very small hole diameter. The plate thickness has no significant influence on bubble breakup. When the inclined angle of a perforated plate is larger than 45°, the bubbles slide beneath the plate more readily and no bubbles pass through it. The perforated plate with large inclined angle fails to induce bubble breakup. This study would provide deep insights into bubble breakup mechanism related to process intensification by perforated plates.

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引用次数: 0

Dual modification of red rice starch: Combining hydrothermal pretreatment with acid hydrolysis for the production of nanomaterials

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-03-27 DOI: 10.1016/j.cep.2025.110292

Raphael Lucas Jacinto Almeida , Newton Carlos Santos , Waleska Rayane Dantas Bezerra de Medeiros , Anna Paula Rocha de Queiroga , Nathália Saraiva Rios , Everaldo Silvino dos Santos

This study evaluated the combination of acid hydrolysis with hydrothermal pretreatment (HPT) for the production of nanomaterials using red rice starch. Native red rice starch (A0) was subjected to HPT in an autoclave at 121°C/10 min (A3) or cooked at 100°C/10 min (A4) and then hydrolyzed with 3.16M sulfuric acid at 25°C for a period of 5 days. The A3 treatment enhanced acid diffusion, leading to the efficient production of starch nanomaterials with a diameter of 106.97 nm. This process resulted in a crystallinity of 31.94%, a higher degree of polymerization of amylopectin (DP ≥ 37: 31.39–34.98%), and a yield of 33.48% on the third day, surpassing A0′s 10.12%. These characteristics classify A3 as starch nanocrystals (SNC). In contrast, A4 exhibited an increased diameter of 260.81 nm, and crystallinity remained in the range of 15%. It is classified as starch nanoparticles (SNP) and displayed higher gelatinization temperatures due to amorphous regions. DP was most affected by A4 with lower values DP ≥ 37 (25.68-30.16%) throughout acid hydrolysis, confirming the lower crystallinity. Finally, it was found that autoclaving was efficient as a pretreatment for native red rice starch to produce SNC through acid hydrolysis in a reduced time.

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