Acetone, methanol and chloroform are extensively utilized in industrial applications as essential organic solvents. In this study, we employ COSMO-SAC, relative volatility analysis and electrostatic potential calculations to select glycerol as the optimal entrainer for separating the acetone/methanol/chloroform mixture. Based on conventional extractive distillation, we integrate heat pump-assisted distillation with heat integration to improve economic and environmental performance. This approach is particularly designed for heat recovery in systems with high-boiling-point entrainers or significant temperature rises at the column bottom. Furthermore, we implement a multi-objective optimization strategy, with minimization targets including total annual cost, entropy production and gas emissions. Ultimately, the economic, environmental and energy losses of various processes are analyzed. Optimization results show that, compared to conventional extractive distillation, the proposed heat pump assisted distillation and heat integration process offered significant advantages, reducing total annual costs by 14.74 %, reducing entropy production by 74.80 % and gas emissions by 38.77 %.
{"title":"Energy-saving process for extractive distillation separation of acetone/methanol/chloroform azeotropic mixtures based on multi-objective optimization algorithm","authors":"Xiaoyu Kang, Zeyang Li, Ruijie Wang, Xiyuan Chen, Xiaoxin Gao","doi":"10.1016/j.cep.2026.110712","DOIUrl":"10.1016/j.cep.2026.110712","url":null,"abstract":"<div><div>Acetone, methanol and chloroform are extensively utilized in industrial applications as essential organic solvents. In this study, we employ COSMO-SAC, relative volatility analysis and electrostatic potential calculations to select glycerol as the optimal entrainer for separating the acetone/methanol/chloroform mixture. Based on conventional extractive distillation, we integrate heat pump-assisted distillation with heat integration to improve economic and environmental performance. This approach is particularly designed for heat recovery in systems with high-boiling-point entrainers or significant temperature rises at the column bottom. Furthermore, we implement a multi-objective optimization strategy, with minimization targets including total annual cost, entropy production and gas emissions. Ultimately, the economic, environmental and energy losses of various processes are analyzed. Optimization results show that, compared to conventional extractive distillation, the proposed heat pump assisted distillation and heat integration process offered significant advantages, reducing total annual costs by 14.74 %, reducing entropy production by 74.80 % and gas emissions by 38.77 %.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110712"},"PeriodicalIF":3.9,"publicationDate":"2026-01-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146023425","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-19DOI: 10.1016/j.cep.2026.110716
Nan Zhang , Xiaoping Guan , Kangjun Wang , Ning Yang
Scale-up effects on the hydrodynamics in bubble columns are particularly critical for reactor design and optimization. However, unlike empty bubble columns, there remains a lack of comprehensive understanding of scale-up effects in the presence of vertical internals. To address the gap, this study investigated the effects of column scale on gas holdup, flow field and turbulence properties in the bubble columns with tube bundle internals at superficial gas velocity 0.12 m/s through CFD simulation. The predictions indicated that, the radial distribution of gas holdup becomes more uniform with scale-up. Moreover, as the column scale increases, the flow pattern in the empty columns consistently exhibits typical gulf-stream pattern. However, for the bubble columns with internals, the flow pattern shifts from the gulf-stream to a dual-circulation pattern with the flow reversal in the center. The effects of column scale on the turbulence properties are also completely different for the empty column and the column with internals. Mechanism analysis demonstrated that the gas holdup distribution governs the large-scale liquid circulation pattern, while turbulence viscosity plays a pivotal role in regulating circulation intensity. We believe that these findings could provide more insight for the design and scale-up of bubble column reactors with internals.
{"title":"Dependence of flow pattern on column scale in bubble columns with internals","authors":"Nan Zhang , Xiaoping Guan , Kangjun Wang , Ning Yang","doi":"10.1016/j.cep.2026.110716","DOIUrl":"10.1016/j.cep.2026.110716","url":null,"abstract":"<div><div>Scale-up effects on the hydrodynamics in bubble columns are particularly critical for reactor design and optimization. However, unlike empty bubble columns, there remains a lack of comprehensive understanding of scale-up effects in the presence of vertical internals. To address the gap, this study investigated the effects of column scale on gas holdup, flow field and turbulence properties in the bubble columns with tube bundle internals at superficial gas velocity 0.12 m/s through CFD simulation. The predictions indicated that, the radial distribution of gas holdup becomes more uniform with scale-up. Moreover, as the column scale increases, the flow pattern in the empty columns consistently exhibits typical gulf-stream pattern. However, for the bubble columns with internals, the flow pattern shifts from the gulf-stream to a dual-circulation pattern with the flow reversal in the center. The effects of column scale on the turbulence properties are also completely different for the empty column and the column with internals. Mechanism analysis demonstrated that the gas holdup distribution governs the large-scale liquid circulation pattern, while turbulence viscosity plays a pivotal role in regulating circulation intensity. We believe that these findings could provide more insight for the design and scale-up of bubble column reactors with internals.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110716"},"PeriodicalIF":3.9,"publicationDate":"2026-01-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146023429","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-19DOI: 10.1016/j.cep.2026.110714
Nicolò Maria Ippolito , Lorenzo Francesco Gandini , Marco Passadoro , Paolo Rosa , Francesco Vegliò
End-of-Life Vehicles (ELVs) represent a valuable secondary source of critical and precious metals, including those embedded in Printed Circuit Boards (PCBs) from Internal Combustion Engine (ICE) vehicles. With the ongoing transition toward electrified mobility, demand for these metals is expected to increase significantly. Sustainable materials management and circular economy principles require recovering and reintroducing these metals into the supply chain rather than allowing them to become waste. This study investigates the recovery of precious metals from automotive PCBs extracted from SEAT ICE vehicle dashboards. The compositional complexity of electronic components necessitates tailored treatment strategies to achieve maximum extraction efficiency. The disassembly of Surface Mount Devices (SMDs) was performed using a collaborative robot (cobot), reducing operator effort and costs while also promoting circular economy practices among car dismantlers. Hydrometallurgical processing, based on a patented method, was optimized using factorial experimental design to minimize chemical consumption and achieve a Minimal Liquid Discharge (MLD) approach. Two scenarios were compared: direct leaching of whole boards, yielding 45.3% gold recovery, and selective disassembly followed by leaching, achieving 80.5% recovery. These results demonstrate the added value of robotic disassembly and the potential for scalable, industrially relevant recycling practices that support sustainable and efficient end-of-life vehicle management.
{"title":"Collaborative disassembly and optimized hydrometallurgical processing for sustainable gold recovery from automotive PCBs","authors":"Nicolò Maria Ippolito , Lorenzo Francesco Gandini , Marco Passadoro , Paolo Rosa , Francesco Vegliò","doi":"10.1016/j.cep.2026.110714","DOIUrl":"10.1016/j.cep.2026.110714","url":null,"abstract":"<div><div>End-of-Life Vehicles (ELVs) represent a valuable secondary source of critical and precious metals, including those embedded in Printed Circuit Boards (PCBs) from Internal Combustion Engine (ICE) vehicles. With the ongoing transition toward electrified mobility, demand for these metals is expected to increase significantly. Sustainable materials management and circular economy principles require recovering and reintroducing these metals into the supply chain rather than allowing them to become waste. This study investigates the recovery of precious metals from automotive PCBs extracted from SEAT ICE vehicle dashboards. The compositional complexity of electronic components necessitates tailored treatment strategies to achieve maximum extraction efficiency. The disassembly of Surface Mount Devices (SMDs) was performed using a collaborative robot (cobot), reducing operator effort and costs while also promoting circular economy practices among car dismantlers. Hydrometallurgical processing, based on a patented method, was optimized using factorial experimental design to minimize chemical consumption and achieve a Minimal Liquid Discharge (MLD) approach. Two scenarios were compared: direct leaching of whole boards, yielding 45.3% gold recovery, and selective disassembly followed by leaching, achieving 80.5% recovery. These results demonstrate the added value of robotic disassembly and the potential for scalable, industrially relevant recycling practices that support sustainable and efficient end-of-life vehicle management.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110714"},"PeriodicalIF":3.9,"publicationDate":"2026-01-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146023426","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-16DOI: 10.1016/j.cep.2026.110711
Gabriel Contreras-Zarazúa
In recent years, the aviation industry has intensified its efforts to reduce CO₂ emissions, and one of the most promising routes to produce sustainable aviation fuel is the furan route, in which the furfural purification and aldol condensation stages are crucial for the process efficiency. In this work, different process alternatives for both stages were studied, including azeotropic distillation and liquid-liquid extraction processes for the furfural purification stage, while reactive distillation alternatives are explored for the aldol condensation stage. The design considers the evaluation of sustainability indicators such as Total Annual Cost (TAC), Eco-Indicator 99, CO₂ emissions, and individual risk. The results indicate that azeotropic distillation is the most efficient and cost-effective alternative, with a TAC 50% lower and 3% less CO₂ emissions than the LLE options. Additionally, methanol recovery, which is a byproduct of the purification stage, generates revenue that covers nearly 100% of operational costs, significantly improving economic sustainability. Finally, in the aldol condensation stage, conventional reaction–separation processes were compared with intensified configurations such as reactive distillation and thermally coupled reactive distillation. The latter showed the best performance, reducing utility costs by 60%, emissions by 66%, and individual risk by 40%, despite an 18% higher investment cost.
{"title":"Process intensification through furfural purification and reactive distillation in the furan based pathway to sustainable aviation fuel","authors":"Gabriel Contreras-Zarazúa","doi":"10.1016/j.cep.2026.110711","DOIUrl":"10.1016/j.cep.2026.110711","url":null,"abstract":"<div><div>In recent years, the aviation industry has intensified its efforts to reduce CO₂ emissions, and one of the most promising routes to produce sustainable aviation fuel is the furan route, in which the furfural purification and aldol condensation stages are crucial for the process efficiency. In this work, different process alternatives for both stages were studied, including azeotropic distillation and liquid-liquid extraction processes for the furfural purification stage, while reactive distillation alternatives are explored for the aldol condensation stage. The design considers the evaluation of sustainability indicators such as Total Annual Cost (TAC), Eco-Indicator 99, CO₂ emissions, and individual risk. The results indicate that azeotropic distillation is the most efficient and cost-effective alternative, with a TAC 50% lower and 3% less CO₂ emissions than the LLE options. Additionally, methanol recovery, which is a byproduct of the purification stage, generates revenue that covers nearly 100% of operational costs, significantly improving economic sustainability. Finally, in the aldol condensation stage, conventional reaction–separation processes were compared with intensified configurations such as reactive distillation and thermally coupled reactive distillation. The latter showed the best performance, reducing utility costs by 60%, emissions by 66%, and individual risk by 40%, despite an 18% higher investment cost.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110711"},"PeriodicalIF":3.9,"publicationDate":"2026-01-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146023485","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-15DOI: 10.1016/j.cep.2026.110710
Shubham Bonde, Aditya Potode, Bharat Bhanvase
The potential of ultrasound-assisted processes to intensify Fe oxidation, accelerate Fe(OH)3 formation, and produce value-added products such as Fe2O3 nanomaterials directly from industrial waste have not been explored in the present investigation. In the present study, ultrasound-assisted coprecipitation method was employed for the synthesis of α-Fe2O3 nanoparticles using acid pickling waste as the precursor. With a specific focus on the role of air flow rate as a key intensification parameter. The methodology integrates calcium hydroxide neutralization under ultrasound with controlled aeration. The results show that ultrasound with air significantly enhanced the oxidation, achieving 94.27% Fe2+ and 89.27% Fe3+ conversion at 10 LPM air flow. Reaction kinetics were modeled using a second-order rate equation, confirming the role of ultrasound in enhancing mass transfer and accelerating nucleation. Reaction kinetics, particle formation behavior, and structural evolution were systematically evaluated using atomic absorption spectrophotometer (AAS), UV–Vis, Fourier-transform infrared (FTIR), and X-ray diffraction (XRD) analysis. XRD analysis indicated a rhombohedral hematite structure with a 21 nm crystalline size. The results demonstrate that ultrasound not only facilitates effective waste valorization but also enables the controlled synthesis of iron oxide nanoparticles. This approach provides a dual benefit of environmental remediation and the production of value-added nanomaterials from hazardous waste.
{"title":"Intensified sonochemical co-precipitation of α-Fe2O3 nanoparticles from pickling waste: Impact of ultrasound and air flow on particle formation","authors":"Shubham Bonde, Aditya Potode, Bharat Bhanvase","doi":"10.1016/j.cep.2026.110710","DOIUrl":"10.1016/j.cep.2026.110710","url":null,"abstract":"<div><div>The potential of ultrasound-assisted processes to intensify Fe oxidation, accelerate Fe(OH)<sub>3</sub> formation, and produce value-added products such as Fe<sub>2</sub>O<sub>3</sub> nanomaterials directly from industrial waste have not been explored in the present investigation. In the present study, ultrasound-assisted coprecipitation method was employed for the synthesis of α-Fe<sub>2</sub>O<sub>3</sub> nanoparticles using acid pickling waste as the precursor. With a specific focus on the role of air flow rate as a key intensification parameter. The methodology integrates calcium hydroxide neutralization under ultrasound with controlled aeration. The results show that ultrasound with air significantly enhanced the oxidation, achieving 94.27% Fe<sup>2+</sup> and 89.27% Fe<sup>3+</sup> conversion at 10 LPM air flow. Reaction kinetics were modeled using a second-order rate equation, confirming the role of ultrasound in enhancing mass transfer and accelerating nucleation. Reaction kinetics, particle formation behavior, and structural evolution were systematically evaluated using atomic absorption spectrophotometer (AAS), UV–Vis, Fourier-transform infrared (FTIR), and X-ray diffraction (XRD) analysis. XRD analysis indicated a rhombohedral hematite structure with a 21 nm crystalline size. The results demonstrate that ultrasound not only facilitates effective waste valorization but also enables the controlled synthesis of iron oxide nanoparticles. This approach provides a dual benefit of environmental remediation and the production of value-added nanomaterials from hazardous waste.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110710"},"PeriodicalIF":3.9,"publicationDate":"2026-01-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146023428","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-12DOI: 10.1016/j.cep.2026.110709
Li Guo , Cheng Gu , Ming Zhai , Bisheng Wang , Xun Zou , Li Liu
The application of an external electric field is widely recognized to improve flame stability significantly. However, most existing studies to date have focused on flames in the open space. For further practical applications, investigations into flame dynamics within confined spaces—where flame-wall interactions are pronounced—are imperative. In this work, we systematically investigate the dynamic characteristics of methane/air flames in a micro-plate combustor with dynamically adjustable gaps under direct current (DC) electric fields. The primary objective of this research is to elucidate the effects of electric fields on key flame characteristics, namely flame stabilization, the onset of flame repetitive extinction and ignition (FREI), and global quenching during progressive reduction of the combustion space. Experimental results demonstrate that electrode polarity plays a critical role in flame stability. A positive electric field (aligned with the flow direction) enhances stability by improving fuel-oxidizer mixing via ionic wind effects. In contrast, a negative electric field triggers flame oscillations at a frequency of 28 Hz, which arises from the interplay between counterflow and buoyancy effects. Both polarities increase FREI frequency by accelerating flame propagation, attributed to ionic wind-induced enlargement of the flame surface and localized flow modifications. Moreover, DC electric fields are found to reduce the quenching distance, with the positive and negative polarities achieving a 6.6 % reduction (from 2.12 mm to 1.98 mm) and a 20 % reduction (from 2.12 mm to 1.76 mm), respectively. These results demonstrate the effectiveness of a DC electric field in stabilizing micro-confined combustion, with the dominant mechanism arising from ionic wind effects.
{"title":"Effect of DC electric fields on methane/air flame characteristics in a micro confined combustion space","authors":"Li Guo , Cheng Gu , Ming Zhai , Bisheng Wang , Xun Zou , Li Liu","doi":"10.1016/j.cep.2026.110709","DOIUrl":"10.1016/j.cep.2026.110709","url":null,"abstract":"<div><div>The application of an external electric field is widely recognized to improve flame stability significantly. However, most existing studies to date have focused on flames in the open space. For further practical applications, investigations into flame dynamics within confined spaces—where flame-wall interactions are pronounced—are imperative. In this work, we systematically investigate the dynamic characteristics of methane/air flames in a micro-plate combustor with dynamically adjustable gaps under direct current (DC) electric fields. The primary objective of this research is to elucidate the effects of electric fields on key flame characteristics, namely flame stabilization, the onset of flame repetitive extinction and ignition (FREI), and global quenching during progressive reduction of the combustion space. Experimental results demonstrate that electrode polarity plays a critical role in flame stability. A positive electric field (aligned with the flow direction) enhances stability by improving fuel-oxidizer mixing via ionic wind effects. In contrast, a negative electric field triggers flame oscillations at a frequency of 28 Hz, which arises from the interplay between counterflow and buoyancy effects. Both polarities increase FREI frequency by accelerating flame propagation, attributed to ionic wind-induced enlargement of the flame surface and localized flow modifications. Moreover, DC electric fields are found to reduce the quenching distance, with the positive and negative polarities achieving a 6.6 % reduction (from 2.12 mm to 1.98 mm) and a 20 % reduction (from 2.12 mm to 1.76 mm), respectively. These results demonstrate the effectiveness of a DC electric field in stabilizing micro-confined combustion, with the dominant mechanism arising from ionic wind effects.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110709"},"PeriodicalIF":3.9,"publicationDate":"2026-01-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146023424","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-10DOI: 10.1016/j.cep.2026.110708
Juan Gabriel Segovia-Hernández
Electronic waste represents both a rapidly growing environmental challenge and a valuable secondary resource. Conventional mechanical, thermal, and hydrometallurgical recycling routes are industrially established but remain energy- and reagent-intensive and increasingly mismatched with heterogeneous feedstocks and distributed generation scenarios. Process-intensified strategies—including microwave- and ultrasound-assisted leaching, high-gravity or high-shear contactors, compact continuous-flow reactors, intensified solvent extraction, electrochemical separation, and targeted thermal pretreatment—have demonstrated significant improvements in mass transfer, dissolution kinetics, extraction selectivity, throughput density, and footprint reduction. Reported case studies show enhanced recovery of copper, nickel, cobalt, precious metals, and selected rare earth elements, alongside reduced residence times and chemical consumption relative to conventional processes. Integrated techno-economic and life-cycle assessments further indicate that intensification can amplify the lower greenhouse gas emissions typically associated with hydrometallurgical routes compared with high-temperature pyrometallurgy, although industrial deployment requires careful consideration of capital costs and electricity demand associated with intensified equipment. This work adopts process intensification as the central analytical framework to critically assess emerging e-waste valorization technologies. The review evaluates how intensified transport phenomena, functional integration, alternative energy inputs, and modular process architectures address fundamental bottlenecks of conventional recycling routes, clarifying the conditions under which laboratory-scale gains translate into industrially viable and sustainable systems.
{"title":"Process intensification for e-waste valorization: Economic & energy advantages over conventional recovery routes","authors":"Juan Gabriel Segovia-Hernández","doi":"10.1016/j.cep.2026.110708","DOIUrl":"10.1016/j.cep.2026.110708","url":null,"abstract":"<div><div>Electronic waste represents both a rapidly growing environmental challenge and a valuable secondary resource. Conventional mechanical, thermal, and hydrometallurgical recycling routes are industrially established but remain energy- and reagent-intensive and increasingly mismatched with heterogeneous feedstocks and distributed generation scenarios. Process-intensified strategies—including microwave- and ultrasound-assisted leaching, high-gravity or high-shear contactors, compact continuous-flow reactors, intensified solvent extraction, electrochemical separation, and targeted thermal pretreatment—have demonstrated significant improvements in mass transfer, dissolution kinetics, extraction selectivity, throughput density, and footprint reduction. Reported case studies show enhanced recovery of copper, nickel, cobalt, precious metals, and selected rare earth elements, alongside reduced residence times and chemical consumption relative to conventional processes. Integrated techno-economic and life-cycle assessments further indicate that intensification can amplify the lower greenhouse gas emissions typically associated with hydrometallurgical routes compared with high-temperature pyrometallurgy, although industrial deployment requires careful consideration of capital costs and electricity demand associated with intensified equipment. This work adopts process intensification as the central analytical framework to critically assess emerging e-waste valorization technologies. The review evaluates how intensified transport phenomena, functional integration, alternative energy inputs, and modular process architectures address fundamental bottlenecks of conventional recycling routes, clarifying the conditions under which laboratory-scale gains translate into industrially viable and sustainable systems.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110708"},"PeriodicalIF":3.9,"publicationDate":"2026-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145974072","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-10DOI: 10.1016/j.cep.2026.110707
Juan A. Betancourt, Mario A. Céspedes, Iván D. Gil
n-Butyl lactate is a promising green solvent whose production can be efficiently intensified using reactive distillation (RD). However, the optimal design of such a process is a complex challenge due to its highly non-linear nature and the interplay between reaction, separation, and economics. In this work, a rigorous rate-based model of an industrial-scale n‑butyl lactate production process was developed and optimized. A custom Genetic Algorithm (GA) was implemented to solve the complex, mixed-integer optimization problem, with the objective of minimizing the Total Annualized Cost (TAC). The GA successfully converged to a superior design, achieving a TAC of 1679 USD/t, compared to a validated base case (1725 USD/t). The feasibility and superiority of the optimized design were confirmed through a comprehensive post-optimization analysis, leveraging the high fidelity of the rate-based model, which accounts for mass and heat transfer limitations. Detailed hydraulic, thermal (via Column Grand Composite Curves), and sustainability analyses demonstrated that the new design is not only more economical but also operationally stable and more energy-efficient (with an energy intensity reduction of 262 kJ/kg), while maintaining excellent mass efficiency. This study provides a holistic and validated framework for the design of an industrial process for n‑butyl lactate production.
{"title":"Rate-based modeling and optimization of a Butyl-lactate production process by reactive distillation","authors":"Juan A. Betancourt, Mario A. Céspedes, Iván D. Gil","doi":"10.1016/j.cep.2026.110707","DOIUrl":"10.1016/j.cep.2026.110707","url":null,"abstract":"<div><div>n-Butyl lactate is a promising green solvent whose production can be efficiently intensified using reactive distillation (RD). However, the optimal design of such a process is a complex challenge due to its highly non-linear nature and the interplay between reaction, separation, and economics. In this work, a rigorous rate-based model of an industrial-scale n‑butyl lactate production process was developed and optimized. A custom Genetic Algorithm (GA) was implemented to solve the complex, mixed-integer optimization problem, with the objective of minimizing the Total Annualized Cost (TAC). The GA successfully converged to a superior design, achieving a TAC of 1679 USD/t, compared to a validated base case (1725 USD/t). The feasibility and superiority of the optimized design were confirmed through a comprehensive post-optimization analysis, leveraging the high fidelity of the rate-based model, which accounts for mass and heat transfer limitations. Detailed hydraulic, thermal (via Column Grand Composite Curves), and sustainability analyses demonstrated that the new design is not only more economical but also operationally stable and more energy-efficient (with an energy intensity reduction of 262 kJ/kg), while maintaining excellent mass efficiency. This study provides a holistic and validated framework for the design of an industrial process for n‑butyl lactate production.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110707"},"PeriodicalIF":3.9,"publicationDate":"2026-01-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145974071","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-09DOI: 10.1016/j.cep.2026.110706
Melike Duvanoglu , Sena Kurban , Gizem Kuşoğlu Kaya , Erdal Aydin
This study proposes a data-driven prediction–optimization framework to improve operational efficiency and extend furnace run length in an industrial visbreaker unit subject to coke formation. Using ten years of real refinery operating data, Decision Tree and Artificial Neural Network (ANN) models were developed to predict furnace coil skin temperatures and the remaining operational days before shutdown. The ANN achieved acceptable test-set Mean Absolute Errors for four critical coils and approximately 15 days for remaining-cycle prediction, corresponding to less than 13 % of a typical furnace run length.
The trained ANN was embedded into a Genetic Algorithm to optimize seven controllable operating variables under industrial constraints. This framework contributes to predicted run-length extensions of 7.5–12.5 % during early-cycle operation and up to 50 % near end-of-cycle conditions. These improvements translate into delayed decoking requirements, improved thermal stability, and enhanced maintenance planning.
The main contribution of this work lies in the integration of long-horizon industrial data, lag-based dynamic feature representation, and ANN–GA optimization for an industrial visbreaker unit. Unlike prior studies based on simulated or short-term datasets, the proposed framework demonstrates industrial feasibility and provides actionable decision support for proactive coking mitigation and operational optimization.
{"title":"Machine learning assisted optimization of an industrial visbreaker plant","authors":"Melike Duvanoglu , Sena Kurban , Gizem Kuşoğlu Kaya , Erdal Aydin","doi":"10.1016/j.cep.2026.110706","DOIUrl":"10.1016/j.cep.2026.110706","url":null,"abstract":"<div><div>This study proposes a data-driven prediction–optimization framework to improve operational efficiency and extend furnace run length in an industrial visbreaker unit subject to coke formation. Using ten years of real refinery operating data, Decision Tree and Artificial Neural Network (ANN) models were developed to predict furnace coil skin temperatures and the remaining operational days before shutdown. The ANN achieved acceptable test-set Mean Absolute Errors for four critical coils and approximately 15 days for remaining-cycle prediction, corresponding to less than 13 % of a typical furnace run length.</div><div>The trained ANN was embedded into a Genetic Algorithm to optimize seven controllable operating variables under industrial constraints. This framework contributes to predicted run-length extensions of 7.5–12.5 % during early-cycle operation and up to 50 % near end-of-cycle conditions. These improvements translate into delayed decoking requirements, improved thermal stability, and enhanced maintenance planning.</div><div>The main contribution of this work lies in the integration of long-horizon industrial data, lag-based dynamic feature representation, and ANN–GA optimization for an industrial visbreaker unit. Unlike prior studies based on simulated or short-term datasets, the proposed framework demonstrates industrial feasibility and provides actionable decision support for proactive coking mitigation and operational optimization.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110706"},"PeriodicalIF":3.9,"publicationDate":"2026-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145974069","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-06DOI: 10.1016/j.cep.2026.110698
Halina Murasiewicz , Jerzy Maćkowiak , Jan F. Maćkowiak , Reiner Chromik
To date, developing robust design principles for distillation and absorption processes using random and structured packing has necessitated expensive and time-consuming experimental investigations. These studies are essential for predicting basic performance data (BPD), such as flooding gas velocity and pressure drop within the operating range. The upper limit, the flooding line, has traditionally been estimated primarily through experiments on air-water simulator plants. This established procedure, while effective, is very costly and requires significant time and effort, presenting a major challenge for manufacturers and researchers seeking to reduce this reliance on physical testing.
In this work, a novel method is presented to address this challenge. The proposed approach is based on a physical model of a suspended bed of droplets (SBD) combined with CFD simulation. This methodology allows for the generation of a packing's complete operating range, including the flooding line, without any need for experimental data.
To validate this new concept, an experimental hydraulic investigation using a laboratory distillation plant under low and normal pressure with various test systems were conducted. The results were then compared with data from CFD simulations for the commercial structured packing R500Y from RVT. A satisfactory agreement was observed between the experimental and simulated data, with a deviation of less than ±10%. This successful validation demonstrates that this approach offers a simple, fast, and reliable method to significantly reduce the experimental effort required for modeling, optimizing, and predicting the performance of structured packing.
{"title":"Rapid method for the prediction of basic performance data of a packed bed with a structured packing using a simple CFD simulation","authors":"Halina Murasiewicz , Jerzy Maćkowiak , Jan F. Maćkowiak , Reiner Chromik","doi":"10.1016/j.cep.2026.110698","DOIUrl":"10.1016/j.cep.2026.110698","url":null,"abstract":"<div><div>To date, developing robust design principles for distillation and absorption processes using random and structured packing has necessitated expensive and time-consuming experimental investigations. These studies are essential for predicting basic performance data (BPD), such as flooding gas velocity and pressure drop within the operating range. The upper limit, the flooding line, has traditionally been estimated primarily through experiments on air-water simulator plants. This established procedure, while effective, is very costly and requires significant time and effort, presenting a major challenge for manufacturers and researchers seeking to reduce this reliance on physical testing.</div><div>In this work, a novel method is presented to address this challenge. The proposed approach is based on a physical model of a suspended bed of droplets (SBD) combined with CFD simulation. This methodology allows for the generation of a packing's complete operating range, including the flooding line, without any need for experimental data.</div><div>To validate this new concept, an experimental hydraulic investigation using a laboratory distillation plant under low and normal pressure with various test systems were conducted. The results were then compared with data from CFD simulations for the commercial structured packing R500Y from RVT. A satisfactory agreement was observed between the experimental and simulated data, with a deviation of less than ±10%. This successful validation demonstrates that this approach offers a simple, fast, and reliable method to significantly reduce the experimental effort required for modeling, optimizing, and predicting the performance of structured packing.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110698"},"PeriodicalIF":3.9,"publicationDate":"2026-01-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145974070","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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