Pub Date : 2025-02-10DOI: 10.1016/j.cep.2025.110217
Konstantinos S. Hatzilyberis , Constantinos E. Salmas , Georgios D. Stefanidis , Georgios P. Androutsopoulos
Rotary kiln-type reactors have been investigated at bench, pilot and demonstration scale for a broad range of processes involving solids thermal conversion and gas-solid chemical reactions, such as (among others) lignite drying and lignite/biomass pyrolysis and gasification by means of either indirect heating (gas or electricity), or direct heating through a chemical looping energy carrier. This work focuses on the evolutionary development of a novel reactor of rotary kiln-type for intensified gas-solid reactions. Design and performance highlights are reported, while relevant processes serve herein as benchmarks for reactor evaluation. In the context of the latter class of processes, which constitute an example of a promising energy technology, we evaluated a pair of advanced rotary kiln-type reactors, that is, a gasifier to produce synthesis gas rich in H2 and a calciner for the regeneration of the solid energy carrier (CaCO3) and the production of clean CO2 for chemical exploitation. The novel reactors feature intensified mass and heat transfer rates enabling in this example up to 80 % LHV gasification efficiency and 96 % overall energy efficiency at 0.36 kg/h/LR solids throughput and 10–12 MJsyngasLHV/Nm3 fuel gas energy density with up to 80 % v/v H2 content when operating in Calcium-chemical looping gasification mode.
{"title":"Development of a novel rotary kiln-type reactor for intensified gas-solid reactions: Performance evaluation for solid fuels processing","authors":"Konstantinos S. Hatzilyberis , Constantinos E. Salmas , Georgios D. Stefanidis , Georgios P. Androutsopoulos","doi":"10.1016/j.cep.2025.110217","DOIUrl":"10.1016/j.cep.2025.110217","url":null,"abstract":"<div><div>Rotary kiln-type reactors have been investigated at bench, pilot and demonstration scale for a broad range of processes involving solids thermal conversion and gas-solid chemical reactions, such as (among others) lignite drying and lignite/biomass pyrolysis and gasification by means of either indirect heating (gas or electricity), or direct heating through a chemical looping energy carrier. This work focuses on the evolutionary development of a novel reactor of rotary kiln-type for intensified gas-solid reactions. Design and performance highlights are reported, while relevant processes serve herein as benchmarks for reactor evaluation. In the context of the latter class of processes, which constitute an example of a promising energy technology, we evaluated a pair of advanced rotary kiln-type reactors, that is, a gasifier to produce synthesis gas rich in H<sub>2</sub> and a calciner for the regeneration of the solid energy carrier (CaCO<sub>3</sub>) and the production of clean CO<sub>2</sub> for chemical exploitation. The novel reactors feature intensified mass and heat transfer rates enabling in this example up to 80 % LHV gasification efficiency and 96 % overall energy efficiency at 0.36 kg/h/L<sub>R</sub> solids throughput and 10–12 MJ<sub>syngasLHV</sub>/Nm<sup>3</sup> fuel gas energy density with up to 80 % v/v H<sub>2</sub> content when operating in Calcium-chemical looping gasification mode.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"211 ","pages":"Article 110217"},"PeriodicalIF":3.8,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143437457","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}
Pub Date : 2025-02-10DOI: 10.1016/j.cep.2025.110215
Yijie Wang , Yi Xing , Chen Hong
Chemical looping gasification (CLG) is an efficient method for energy conversion and utilization. It is an emerging technology to convert bioenergy into high value gas through redox of oxygen carriers (OCs). In this paper, the pyrolysis process of Chlorella vulgaris(CV) with OCs was mainly divided into three stages by TG-FTIR-MS test. Using iron ore as OCs and quartz sand as blank experiment. The addition of OCs increases the reaction rate and exhibits a catalytic effect on tar cracking. The kinetic equations for Stage 2 and Stage 3 are dα/dt=3.12(1-α)3·exp(-1.62 × 104/T) and dα/dt=5.49[(1-α)2/3/(1-(1-α)1/3)]·exp(-4.86 × 104/T), respectively. The most probable mechanism functions are the reaction order models (O3) and the diffusion models (D3), respectively. The average activation energy E0 and pre-exponential factor A0 were 134.44 kJ/mol, 3.12 min-1 and 404.18 kJ/mol, 3.66 min-1 for Stage 2 and Stage 3, respectively. The CLG process of CV&OCs showed that the yields of CO2, H2 and CO were increase by the addition of OCs. The CO yield increased most significantly from 0.097 Nm3/kg to 0.313 Nm3/kg. The carbon conversion and gasification efficiency increased from 41.7 % and 43.4 % to 78.3 % and 54.9 %, respectively. Moreover, appropriately increasing the temperature can promote the deep pyrolysis gasification of CV and generate more pyrolysis gas with high value. The microalgae CLG power generation system was found to have less negative effects on the environment through LAC and is a worthwhile gasification technology.
{"title":"Chemical looping gasification of microalgae biomass with Fe-based oxygen carrier for gas production and kinetic behavior","authors":"Yijie Wang , Yi Xing , Chen Hong","doi":"10.1016/j.cep.2025.110215","DOIUrl":"10.1016/j.cep.2025.110215","url":null,"abstract":"<div><div>Chemical looping gasification (CLG) is an efficient method for energy conversion and utilization. It is an emerging technology to convert bioenergy into high value gas through redox of oxygen carriers (OCs). In this paper, the pyrolysis process of <em>Chlorella vulgaris</em>(CV) with OCs was mainly divided into three stages by TG-FTIR-MS test. Using iron ore as OCs and quartz sand as blank experiment. The addition of OCs increases the reaction rate and exhibits a catalytic effect on tar cracking. The kinetic equations for Stage 2 and Stage 3 are <em>dα</em>/<em>dt</em>=3.12(1-<em>α</em>)<sup>3</sup>·exp(-1.62 × 10<sup>4</sup>/T) and <em>dα</em>/<em>dt</em>=5.49[(1-<em>α</em>)<sup>2/3</sup>/(1-(1-<em>α</em>)<sup>1/3</sup>)]·exp(-4.86 × 10<sup>4</sup>/T), respectively. The most probable mechanism functions are the reaction order models (O3) and the diffusion models (D3), respectively. The average activation energy <em>E</em><sub>0</sub> and pre-exponential factor <em>A</em><sub>0</sub> were 134.44 kJ/mol, 3.12 min<sup>-1</sup> and 404.18 kJ/mol, 3.66 min<sup>-1</sup> for Stage 2 and Stage 3, respectively. The CLG process of CV&OCs showed that the yields of CO<sub>2</sub>, H<sub>2</sub> and CO were increase by the addition of OCs. The CO yield increased most significantly from 0.097 Nm<sup>3</sup>/kg to 0.313 Nm<sup>3</sup>/kg. The carbon conversion and gasification efficiency increased from 41.7 % and 43.4 % to 78.3 % and 54.9 %, respectively. Moreover, appropriately increasing the temperature can promote the deep pyrolysis gasification of CV and generate more pyrolysis gas with high value. The microalgae CLG power generation system was found to have less negative effects on the environment through LAC and is a worthwhile gasification technology.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"210 ","pages":"Article 110215"},"PeriodicalIF":3.8,"publicationDate":"2025-02-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143386544","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 : 2025-02-09DOI: 10.1016/j.cep.2025.110212
Brenda G. Campos , Ivan I.K. Veloso , Maíra M. da Silva , Alberto C. Badino , Antonio J.G. Cruz
This study proposes a novel approach to remove heat and maintain the broth temperature constant during fed-batch ethanol extractive fermentations by using a carbon dioxide (CO2) flow rate. The method offers an alternative to traditional cooling methods, such as water-based plate heat exchangers, which can be inefficient in distilleries located in hot regions. A mathematical model was developed and used to find the optimal CO2 flow rate to maintain constant the broth temperature in simulated fermentations at 30, 32, and 34 °C. The results showed that using multiple CO2 flow rates over an 8-hour stripping period could effectively reduce temperature deviations from the set-point while minimizing the total amount of CO2 used. However, finding the optimal combination of flow rates becomes computationally expensive as the stripping period is split in a greater number of time subintervals. A comprehensive study was carried out to assess the adequate number of time subintervals to keep the broth temperature constant. Experimental fermentation carried out at 34 °C using eight-time subintervals confirmed the accuracy of the model's predictions. A temperature deviation of less than 0.5 °C from the set-point highlights the potential of extractive fermentation for controlling temperature and offers insights to enhance process efficiency.
{"title":"A novel approach to heat removal and temperature control in fed-batch extractive ethanol fermentation using CO2","authors":"Brenda G. Campos , Ivan I.K. Veloso , Maíra M. da Silva , Alberto C. Badino , Antonio J.G. Cruz","doi":"10.1016/j.cep.2025.110212","DOIUrl":"10.1016/j.cep.2025.110212","url":null,"abstract":"<div><div>This study proposes a novel approach to remove heat and maintain the broth temperature constant during fed-batch ethanol extractive fermentations by using a carbon dioxide (CO<sub>2</sub>) flow rate. The method offers an alternative to traditional cooling methods, such as water-based plate heat exchangers, which can be inefficient in distilleries located in hot regions. A mathematical model was developed and used to find the optimal CO<sub>2</sub> flow rate to maintain constant the broth temperature in simulated fermentations at 30, 32, and 34 °C. The results showed that using multiple CO<sub>2</sub> flow rates over an 8-hour stripping period could effectively reduce temperature deviations from the set-point while minimizing the total amount of CO<sub>2</sub> used. However, finding the optimal combination of flow rates becomes computationally expensive as the stripping period is split in a greater number of time subintervals. A comprehensive study was carried out to assess the adequate number of time subintervals to keep the broth temperature constant. Experimental fermentation carried out at 34 °C using eight-time subintervals confirmed the accuracy of the model's predictions. A temperature deviation of less than 0.5 °C from the set-point highlights the potential of extractive fermentation for controlling temperature and offers insights to enhance process efficiency.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"210 ","pages":"Article 110212"},"PeriodicalIF":3.8,"publicationDate":"2025-02-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143420090","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}
To understand the characteristc of the twisted elliptical tube heat exchanger at high Re conditions and the feasibility of its application in MVR system, the effect of geometric parameters on performance of twisted elliptical tubes was numerically studied. The results demonstrate that overall performance decreases rapidly as Re increases within the range of 13,000 < Re < 60,000. While at 60,000 < Re < 110,000, it stabilizes while still being better than that of circular tubes. A novel MVR evaporation crystallization system using a twisted elliptic tube evaporator is firstly developed. The industrial locale experiment indicates that the twisted elliptic tube evaporator enhances heat transfer, reduces the compression ratio and temperature rise of the vapor compressor and significantly reduces the energy consumption of the MVR system. The average specific energy consumption (SEC) and COP of the MVR system are 32.9 kWh·t−1 and 19.0, respectively. These values are 45.2 % lower and 85.4 % higher than those of the conventional MVR system. The novel MVR system reduces standard coal consumption by approximately 76.6 % and 68.8 % compared to conventional three-effect and four-effect evaporation systems, respectively. These findings show significant energy savings can be achieved by using the twisted elliptic tube evaporator for MVR system.
{"title":"Heat transfer enhancement characteristic of twisted elliptical tube heat exchanger at high Re condition and its energy-saving application in mechanical vapor recompression system","authors":"Shijie Liu, Zilin Chen, Shuangzhi Yin, Aimin Tu, Dongsheng Zhu","doi":"10.1016/j.cep.2025.110214","DOIUrl":"10.1016/j.cep.2025.110214","url":null,"abstract":"<div><div>To understand the characteristc of the twisted elliptical tube heat exchanger at high <em>Re</em> conditions and the feasibility of its application in MVR system, the effect of geometric parameters on performance of twisted elliptical tubes was numerically studied. The results demonstrate that overall performance decreases rapidly as <em>Re</em> increases within the range of 13,000 < <em>Re</em> < 60,000. While at 60,000 < <em>Re</em> < 110,000, it stabilizes while still being better than that of circular tubes. A novel MVR evaporation crystallization system using a twisted elliptic tube evaporator is firstly developed. The industrial locale experiment indicates that the twisted elliptic tube evaporator enhances heat transfer, reduces the compression ratio and temperature rise of the vapor compressor and significantly reduces the energy consumption of the MVR system. The average specific energy consumption (<em>SEC</em>) and <em>COP</em> of the MVR system are 32.9 kWh·t<sup>−1</sup> and 19.0, respectively. These values are 45.2 % lower and 85.4 % higher than those of the conventional MVR system. The novel MVR system reduces standard coal consumption by approximately 76.6 % and 68.8 % compared to conventional three-effect and four-effect evaporation systems, respectively. These findings show significant energy savings can be achieved by using the twisted elliptic tube evaporator for MVR system.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"210 ","pages":"Article 110214"},"PeriodicalIF":3.8,"publicationDate":"2025-02-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143403056","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 : 2025-02-08DOI: 10.1016/j.cep.2025.110211
Priya Yadav , Julie Kring , Parag R. Gogate
Sustainable biomass offers potential for obtaining products with added value with most literature focusing on use of cellulose and hemicellulose. The current study focuses on development of lignin-based surfactant utilizing the lignin recovered from pre-treatment of sawdust. Parameters such as sodium chloroacetate to lignin ratio (1:1–4:1 w/w), temperature (60–100° C), reaction time (0.5–3 h), and NaOH concentration (1.5 M) were varied to understand the effect on synthesis using conventional method. Additionally, ultrasonic power (40–120 W) and duty cycle (30–70 %) were varied in the ultrasound assisted approach to establish the best synthesis conditions. The lowest value of critical micellar concentration (CMC) with conventional method was 0.194 at 3:1 sodium chloroacetate to lignin ratio, 90° C and 2 h, while the lowest values of CMC with ultrasound was 0.057 at the optimised parameters of 2:1 sodium chloroacetate to lignin ratio, temperature of 80° C in just 1 h period. FTIR and NMR analysis was also performed on the extracted lignin and the carboxymethylation product with or without ultrasonic treatment. It was clearly demonstrated that improved product with almost 70 % lower CMC value could be obtained using ultrasound with significant reduction in the synthesis time and requirement of sodium chloroacetate as well.
{"title":"Ultrasound-assisted synthesis of carboxy-methyl lignin from sawdust based lignin as a sustainable source","authors":"Priya Yadav , Julie Kring , Parag R. Gogate","doi":"10.1016/j.cep.2025.110211","DOIUrl":"10.1016/j.cep.2025.110211","url":null,"abstract":"<div><div>Sustainable biomass offers potential for obtaining products with added value with most literature focusing on use of cellulose and hemicellulose. The current study focuses on development of lignin-based surfactant utilizing the lignin recovered from pre-treatment of sawdust. Parameters such as sodium chloroacetate to lignin ratio (1:1–4:1 w/w), temperature (60–100° C), reaction time (0.5–3 h), and NaOH concentration (1.5 M) were varied to understand the effect on synthesis using conventional method. Additionally, ultrasonic power (40–120 W) and duty cycle (30–70 %) were varied in the ultrasound assisted approach to establish the best synthesis conditions. The lowest value of critical micellar concentration (CMC) with conventional method was 0.194 at 3:1 sodium chloroacetate to lignin ratio, 90° C and 2 h, while the lowest values of CMC with ultrasound was 0.057 at the optimised parameters of 2:1 sodium chloroacetate to lignin ratio, temperature of 80° C in just 1 h period. FTIR and NMR analysis was also performed on the extracted lignin and the carboxymethylation product with or without ultrasonic treatment. It was clearly demonstrated that improved product with almost 70 % lower CMC value could be obtained using ultrasound with significant reduction in the synthesis time and requirement of sodium chloroacetate as well.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"210 ","pages":"Article 110211"},"PeriodicalIF":3.8,"publicationDate":"2025-02-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143376465","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 : 2025-02-08DOI: 10.1016/j.cep.2025.110213
Sheng Li , Yimin Zhang , Pengcheng Hu , Yizhong Yuan
Microwave heating technology has received considerable attention for vanadium-bearing shale (VBS) leaching. In this paper, a multi-physics model was established to investigate the electromagnetic response of VBS. Simultaneously, microwave enhanced leaching mechanism was revealed from the perspective of VBS thermal response. The simulation results indicated that the heating time of microwave heating is only 1/18 of that of conventional heating. VBS particles during the leaching process generate high-temperature hotspots (235–261 °C) much higher than the leaching environment (100 °C) due to electric field polarization. Higher temperature leads to faster chemical reaction rate, which affects the diffusion efficiency of products outside the sample over time. The VBS leaching process is mainly controlled by two stages: Microwave energy can reduce the activation energy of the stage Ⅰ from 41.57 kJ/mol to 21.28 kJ/mol and the activation energy of the stage Ⅱ from 59.61 kJ/mol to 43.65 kJ/mol. After microwave irradiation, the surface energy of VBS will increase, and the energy of the leaching system will also be higher, accelerating the erosion and damage of H+ on muscovite. Meanwhile, the hydration and hardening phenomenon of gypsum induced by hot spots causes gypsum to transform into hard gypsum on the surface of mica. The growth stress generated during the growth process of hard gypsum will damage the structure of muscovite. The microwave-assisted leaching mechanism of VBS can give more guidance for microwave application.
{"title":"The interaction between microwave and vanadium-bearing shale: A study on the microwave-assisted leaching mechanism of vanadium","authors":"Sheng Li , Yimin Zhang , Pengcheng Hu , Yizhong Yuan","doi":"10.1016/j.cep.2025.110213","DOIUrl":"10.1016/j.cep.2025.110213","url":null,"abstract":"<div><div>Microwave heating technology has received considerable attention for vanadium-bearing shale (VBS) leaching. In this paper, a multi-physics model was established to investigate the electromagnetic response of VBS. Simultaneously, microwave enhanced leaching mechanism was revealed from the perspective of VBS thermal response. The simulation results indicated that the heating time of microwave heating is only 1/18 of that of conventional heating. VBS particles during the leaching process generate high-temperature hotspots (235–261 °C) much higher than the leaching environment (100 °C) due to electric field polarization. Higher temperature leads to faster chemical reaction rate, which affects the diffusion efficiency of products outside the sample over time. The VBS leaching process is mainly controlled by two stages: Microwave energy can reduce the activation energy of the stage Ⅰ from 41.57 kJ/mol to 21.28 kJ/mol and the activation energy of the stage Ⅱ from 59.61 kJ/mol to 43.65 kJ/mol. After microwave irradiation, the surface energy of VBS will increase, and the energy of the leaching system will also be higher, accelerating the erosion and damage of H<sup>+</sup> on muscovite. Meanwhile, the hydration and hardening phenomenon of gypsum induced by hot spots causes gypsum to transform into hard gypsum on the surface of mica. The growth stress generated during the growth process of hard gypsum will damage the structure of muscovite. The microwave-assisted leaching mechanism of VBS can give more guidance for microwave application.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"210 ","pages":"Article 110213"},"PeriodicalIF":3.8,"publicationDate":"2025-02-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143386788","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 : 2025-02-06DOI: 10.1016/j.cep.2025.110207
Yakai Yang , Hao Zhang , Ge Kuang , Huan Li , Hui Guo , Xing Jin , Min Gan , Hongming Long
With the rapid development of lithium-ion batteries, the recycling of spent batteries represents a major future challenge, particularly LiFePO4 batteries (LFP) due to their structural stability and high safety. This study proposes a simple and efficient pretreatment process, employing a combination of ultrasonic-assisted dilute alkali leaching and crushing-gas sorting to separate the cathode and anode material from spent LFP, respectively. The key parameters that affect the recovery efficiency of cathode materials from Al foil have been determined, including alkali concentration, liquid-solid ratio, ultrasonic frequency, and ultrasonic time. The separation efficiency between Al foil and cathode material can achieved 99.85 %. The interface effect generated by the ultrasound cavitation promotes the separations of Al foil and cathode active materials. Meanwhile, the optimal crushing-gas sorting process parameters including particle size and gas flow rate was determined to recover Cu foil and graphite from the anode active material. A Cu recovery efficiency of 87.2 % with a Cu grade of 84.6 % was reached. Additionally, treatment with 3 % HCl for 90 min was introduced to remove the residual Li in the recovered graphite. This method can provide a more efficient and sustainable way for the comprehensive separation and recovery of active materials from spent lithium-ion batteries.
{"title":"Ultrasonic-assisted alkali leaching coupled gas sorting process to separate cathode and anode materials from spent LiFePO4 batteries","authors":"Yakai Yang , Hao Zhang , Ge Kuang , Huan Li , Hui Guo , Xing Jin , Min Gan , Hongming Long","doi":"10.1016/j.cep.2025.110207","DOIUrl":"10.1016/j.cep.2025.110207","url":null,"abstract":"<div><div>With the rapid development of lithium-ion batteries, the recycling of spent batteries represents a major future challenge, particularly LiFePO<sub>4</sub> batteries (LFP) due to their structural stability and high safety. This study proposes a simple and efficient pretreatment process, employing a combination of ultrasonic-assisted dilute alkali leaching and crushing-gas sorting to separate the cathode and anode material from spent LFP, respectively. The key parameters that affect the recovery efficiency of cathode materials from Al foil have been determined, including alkali concentration, liquid-solid ratio, ultrasonic frequency, and ultrasonic time. The separation efficiency between Al foil and cathode material can achieved 99.85 %. The interface effect generated by the ultrasound cavitation promotes the separations of Al foil and cathode active materials. Meanwhile, the optimal crushing-gas sorting process parameters including particle size and gas flow rate was determined to recover Cu foil and graphite from the anode active material. A Cu recovery efficiency of 87.2 % with a Cu grade of 84.6 % was reached. Additionally, treatment with 3 % HCl for 90 min was introduced to remove the residual Li in the recovered graphite. This method can provide a more efficient and sustainable way for the comprehensive separation and recovery of active materials from spent lithium-ion batteries.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"209 ","pages":"Article 110207"},"PeriodicalIF":3.8,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143372135","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 : 2025-02-06DOI: 10.1016/j.cep.2025.110206
A.R. Valagohar, S.A. Hashemifard, A. Khosravi
This research aimed to study the effectiveness of blending Pebax-1657 polymer with GO/SiO2 nanoparticles in developing TFN membranes for N2 gas dehydration. Different concentrations of nanoparticles (0 %, 0.5 %, and 1 %) were incorporated using dip coating. The nanocomposites were analyzed for their chemical structure, morphology, topology, and thermal stability using FTIR, SEM, CA, AFM, and TGA. The results showed that the samples had good thermal stability and a highly hydrophilic surface. The MP0.5–0.5 membrane with 0.5 % GO/SiO2 nanoparticles demonstrated improved performance in water vapor and N2 permeance at 2 × 105 to 6 × 105 Pa pressure and 70 % relative humidity. The addition of 0.5 % GO nanoparticles to the sample further enhanced H2O and N2 permeance and separation factor. However, in the case of the MP0.5–0.5 membrane, a different scenario unfolds, showcasing a synergistic effect and the ideal morphology was observed. The water vapor and nitrogen permeance of the MP0.5–0.5 membrane, under 2 × 105 to 6 × 105 Pa pressure and 70 % humidity, reaches from GPU 158 and GPU 0.23 (for the neat mebrane) to GPU 969 and GPU 31, respectively. The H2O/N2 separation factor was recorded as 679.It was observed that the relative humidity of the gas decreased from approximately 70 % to about 1.2 % during the membrane step, indicating the high efficiency of the membrane. The investigation concluded that the TFN membranes' dehydration characteristics are influenced by various factors, including morphology, plasticization, and hydrophilic properties. Changes in the feed gas flow rate also affected separation factor and nitrogen permeance. The rise in sweep gas flow had a notable impact on enhancing the membrane's separation factor by decreasing the transmembrane concentration gradient. Consequently, a trade-off emerges between water vapor flux and separation factor when employing the sweep gas stream. These discoveries are highly valuable in industrial settings, as they offer a more profound understanding of the topic.
{"title":"An in-depth analysis of Pebax-1657/GO-silica/PEI thin film nano-composite membranes for gas dehydration","authors":"A.R. Valagohar, S.A. Hashemifard, A. Khosravi","doi":"10.1016/j.cep.2025.110206","DOIUrl":"10.1016/j.cep.2025.110206","url":null,"abstract":"<div><div>This research aimed to study the effectiveness of blending Pebax-1657 polymer with GO/SiO<sub>2</sub> nanoparticles in developing TFN membranes for N<sub>2</sub> gas dehydration. Different concentrations of nanoparticles (0 %, 0.5 %, and 1 %) were incorporated using dip coating. The nanocomposites were analyzed for their chemical structure, morphology, topology, and thermal stability using FTIR, SEM, CA, AFM, and TGA. The results showed that the samples had good thermal stability and a highly hydrophilic surface. The MP0.5–0.5 membrane with 0.5 % GO/SiO<sub>2</sub> nanoparticles demonstrated improved performance in water vapor and N<sub>2</sub> permeance at 2 × 10<sup>5</sup> to 6 × 10<sup>5</sup> Pa pressure and 70 % relative humidity. The addition of 0.5 % GO nanoparticles to the sample further enhanced H<sub>2</sub>O and N<sub>2</sub> permeance and separation factor. However, in the case of the MP0.5–0.5 membrane, a different scenario unfolds, showcasing a synergistic effect and the ideal morphology was observed. The water vapor and nitrogen permeance of the MP0.5–0.5 membrane, under 2 × 10<sup>5</sup> to 6 × 10<sup>5</sup> Pa pressure and 70 % humidity, reaches from GPU 158 and GPU 0.23 (for the neat mebrane) to GPU 969 and GPU 31, respectively. The H<sub>2</sub>O/N<sub>2</sub> separation factor was recorded as 679.It was observed that the relative humidity of the gas decreased from approximately 70 % to about 1.2 % during the membrane step, indicating the high efficiency of the membrane. The investigation concluded that the TFN membranes' dehydration characteristics are influenced by various factors, including morphology, plasticization, and hydrophilic properties. Changes in the feed gas flow rate also affected separation factor and nitrogen permeance. The rise in sweep gas flow had a notable impact on enhancing the membrane's separation factor by decreasing the transmembrane concentration gradient. Consequently, a trade-off emerges between water vapor flux and separation factor when employing the sweep gas stream. These discoveries are highly valuable in industrial settings, as they offer a more profound understanding of the topic.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"210 ","pages":"Article 110206"},"PeriodicalIF":3.8,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143378119","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 : 2025-02-06DOI: 10.1016/j.cep.2025.110201
Yuanyuan Zhou , Yang Liu , Chenyu Han , Wenming Jiang , Qi Wang
Supersonic separation technology enables efficient carbon capture, incorporating supersonic fluid dynamics, swirling flow, and enhanced gas-liquid heat and mass transfer processes. The nozzle is the key place to realize the above method, and its structure greatly affects the gas flow and condensation characteristics. To solve the problems of difficulty, accuracy, and high cost of traditional nozzle inner surface machining, a nozzle structure with centroid and straight pipe segment was proposed. Based on droplet growth and classical nucleation theory, a spontaneous condensation model of CH₄-CO₂ mixture gas was established and the spontaneous condensation process of CO₂ was analyzed. The findings indicated that the CO2 liquefaction efficiency in this structure can reach 42.5 %. A swirling condensation model is established, and the influences of swirling and inlet parameters on condensation parameters are considered. The findings indicate that: compared with the increase in inlet CO2 concentration and reduced inlet temperature, the increase in inlet pressure has a more obvious effect on improving the liquefaction effect. When the pressure is increased from 4 MPa to 7 MPa, the liquefaction efficiency is increased from 26.1 % to 60.1 %, which is increased by 1.30 times. The above research helps promote the application of supersonic swirl separation technology.
{"title":"Investigation of CO2 condensation characteristics in nozzle based on Witoszynski curve equivalent centrosome model","authors":"Yuanyuan Zhou , Yang Liu , Chenyu Han , Wenming Jiang , Qi Wang","doi":"10.1016/j.cep.2025.110201","DOIUrl":"10.1016/j.cep.2025.110201","url":null,"abstract":"<div><div>Supersonic separation technology enables efficient carbon capture, incorporating supersonic fluid dynamics, swirling flow, and enhanced gas-liquid heat and mass transfer processes. The nozzle is the key place to realize the above method, and its structure greatly affects the gas flow and condensation characteristics. To solve the problems of difficulty, accuracy, and high cost of traditional nozzle inner surface machining, a nozzle structure with centroid and straight pipe segment was proposed. Based on droplet growth and classical nucleation theory, a spontaneous condensation model of CH₄-CO₂ mixture gas was established and the spontaneous condensation process of CO₂ was analyzed. The findings indicated that the CO<sub>2</sub> liquefaction efficiency in this structure can reach 42.5 %. A swirling condensation model is established, and the influences of swirling and inlet parameters on condensation parameters are considered. The findings indicate that: compared with the increase in inlet CO<sub>2</sub> concentration and reduced inlet temperature, the increase in inlet pressure has a more obvious effect on improving the liquefaction effect. When the pressure is increased from 4 MPa to 7 MPa, the liquefaction efficiency is increased from 26.1 % to 60.1 %, which is increased by 1.30 times. The above research helps promote the application of supersonic swirl separation technology.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"210 ","pages":"Article 110201"},"PeriodicalIF":3.8,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143376466","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 : 2025-02-06DOI: 10.1016/j.cep.2025.110210
Yiming Hao , Hongyuan Zou , Bo Liu , Hongpeng Zhang , Li Sun , Mingsheng Cui
The micro-nanobubbles (MNBs) technology provides an innovative theoretical basis and application prospect for solving the problem of water treatment. However, the fabrication of bubble generators with high MNBs generation efficiency has always been challenging. Herein, we developed a new hydrodynamic cavitation bubble generator by equipping the multi-jet reactor to enhance the shear breakage effect of bubbles. The breakup behavior of bubbles with different diameters and velocities in jet orifices was investigated by numerical simulation. At the same time, the turbulent model of two-phase flow in the Venturi gas-liquid mixer was established to analyze the internal flow field under different intake rates. The bubble size and dissolved oxygen (DO) concentration of bulk MNBs water were determined through image analysis and a DO sensor, respectively. The results showed that the cavitation generator produced bubbles with diameters no larger than 27.85 μm. Moreover, the MNBs generator exhibited a superior oxygen-dissolving capability, which was 1.48 times that of general aerated water. This study has deepened the comprehension of the bubble breakup mechanism, providing a reference for designing and developing of MNBs generation technology.
{"title":"Study on the properties of bulk micro-nanobubbles water generated by multi-jet hydrodynamic cavitation","authors":"Yiming Hao , Hongyuan Zou , Bo Liu , Hongpeng Zhang , Li Sun , Mingsheng Cui","doi":"10.1016/j.cep.2025.110210","DOIUrl":"10.1016/j.cep.2025.110210","url":null,"abstract":"<div><div>The micro-nanobubbles (MNBs) technology provides an innovative theoretical basis and application prospect for solving the problem of water treatment. However, the fabrication of bubble generators with high MNBs generation efficiency has always been challenging. Herein, we developed a new hydrodynamic cavitation bubble generator by equipping the multi-jet reactor to enhance the shear breakage effect of bubbles. The breakup behavior of bubbles with different diameters and velocities in jet orifices was investigated by numerical simulation. At the same time, the turbulent model of two-phase flow in the Venturi gas-liquid mixer was established to analyze the internal flow field under different intake rates. The bubble size and dissolved oxygen (DO) concentration of bulk MNBs water were determined through image analysis and a DO sensor, respectively. The results showed that the cavitation generator produced bubbles with diameters no larger than 27.85 μm. Moreover, the MNBs generator exhibited a superior oxygen-dissolving capability, which was 1.48 times that of general aerated water. This study has deepened the comprehension of the bubble breakup mechanism, providing a reference for designing and developing of MNBs generation technology.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"210 ","pages":"Article 110210"},"PeriodicalIF":3.8,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143420074","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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