Pub Date : 2025-12-31DOI: 10.1016/j.cep.2025.110689
Carmen M. Sánchez-Arévalo , Laura García-Suarez , Maria Salud Camilleri-Rumbau , Jörg Vogel , Silvia Álvarez-Blanco , M. Cinta Vincent-Vela , Beatriz Cuartas-Uribe
The concerning and abundant textile wastewater can be treated by forward osmosis (FO) in order to reduce its volume and simultaneously recover clean water. However, the productivity of FO depends on the concentration of the draw solution that is used. In this work, a simultaneous application of FO and reverse osmosis (RO) is proposed. The HFFO14® FO membrane (Aquaporin, Denmark) was employed to concentrate a real textile wastewater, whereas the SW30-2540 (DuPont, USA) RO membrane was employed to simultaneously regenerate the draw solution, which consisted in a 0.7 M NaCl solution, and to obtain a clean water stream. The concentration of the textile wastewater increased until 90% water recovery was achieved. The rejection values obtained for the chemical oxygen demand and total organic carbon were in the range 99 – 100%. Afterwards, the previously concentrated textile wastewater was again processed until a volume concentration factor of 16.5 was reached. Stable values of permeate flux (around 4 L/h·m2) were obtained in the FO process, whereas the reverse osmosis step permitted the maintenance of a stable conductivity in the draw solution and provided clean water as permeate.
利用正向渗透技术处理大量的纺织废水，既可以减少废水的体积，又可以回收清洁水。然而，FO的生产效率取决于所使用的拉伸溶液的浓度。在这项工作中，提出了FO和反渗透（RO）的同时应用。采用HFFO14®FO膜（丹麦Aquaporin公司）对真实纺织废水进行浓缩，同时采用SW30-2540（美国杜邦公司）反渗透膜对含有0.7 M NaCl溶液的提取液进行再生，获得干净的水流。纺织废水的浓度不断提高，直至水回收率达到90%。化学需氧量和总有机碳的截留值在99 ~ 100%之间。然后再对先前浓缩的纺织废水进行处理，使其体积浓度系数达到16.5。在FO过程中获得了稳定的渗透通量值（约4 L/h·m2），而反渗透步骤允许在抽取溶液中保持稳定的电导率，并提供清洁的水作为渗透。
{"title":"Continuous regeneration of the draw solution in textile wastewater treatment using a combination of simultaneous forward osmosis and reverse osmosis","authors":"Carmen M. Sánchez-Arévalo , Laura García-Suarez , Maria Salud Camilleri-Rumbau , Jörg Vogel , Silvia Álvarez-Blanco , M. Cinta Vincent-Vela , Beatriz Cuartas-Uribe","doi":"10.1016/j.cep.2025.110689","DOIUrl":"10.1016/j.cep.2025.110689","url":null,"abstract":"<div><div>The concerning and abundant textile wastewater can be treated by forward osmosis (FO) in order to reduce its volume and simultaneously recover clean water. However, the productivity of FO depends on the concentration of the draw solution that is used. In this work, a simultaneous application of FO and reverse osmosis (RO) is proposed. The HFFO14® FO membrane (Aquaporin, Denmark) was employed to concentrate a real textile wastewater, whereas the SW30-2540 (DuPont, USA) RO membrane was employed to simultaneously regenerate the draw solution, which consisted in a 0.7 M NaCl solution, and to obtain a clean water stream. The concentration of the textile wastewater increased until 90% water recovery was achieved. The rejection values obtained for the chemical oxygen demand and total organic carbon were in the range 99 – 100%. Afterwards, the previously concentrated textile wastewater was again processed until a volume concentration factor of 16.5 was reached. Stable values of permeate flux (around 4 L/h·m<sup>2</sup>) were obtained in the FO process, whereas the reverse osmosis step permitted the maintenance of a stable conductivity in the draw solution and provided clean water as permeate.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110689"},"PeriodicalIF":3.9,"publicationDate":"2025-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145923577","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 : 2025-12-31DOI: 10.1016/j.cep.2025.110690
Hao CHENG , Yongli LI , Dominique TARLET , Lingai LUO , Yilin FAN
The power-to-gas (PtG) process converts surplus renewable electricity into hydrogen via electrolysis, followed by methanation to produce synthetic methane. This integrated approach enhances the flexibility of hydrogen energy storage and transportation while achieves valorization, supporting and advancing the UN's sustainable development goals. Traditional methanation in large fixed-bed equipment suffers from limited heat and mass transfer efficiency, leading to the catalyst deactivation and compromised methanation performance. To overcome these challenges, microchannel-based reactors have been proposed as an alternate solution, offering enhanced heat and mass transfer performance, compact system volume, higher volumetric productivity and improved energy efficiency.
This paper presents a comprehensive literature review on research advances of the microchannel reactor technology for methanation. The review covers various aspects, including catalysts configuration, effects of operating factors, and strategies to intensify the methanation performance. In addition, special attention was given to integrated process coupling within methanation reaction, improving both reaction regulation and thermal energy management in methanation systems. The work provides a useful reference for developing high-efficiency microchannel reactor systems for methanation, offering fundamental insights for future industrial-scale implementation.
{"title":"Microreactor technology for CO2 methanation: A review on process intensification and system integration","authors":"Hao CHENG , Yongli LI , Dominique TARLET , Lingai LUO , Yilin FAN","doi":"10.1016/j.cep.2025.110690","DOIUrl":"10.1016/j.cep.2025.110690","url":null,"abstract":"<div><div>The power-to-gas (PtG) process converts surplus renewable electricity into hydrogen via electrolysis, followed by <span><math><mrow><mi>C</mi><msub><mi>O</mi><mn>2</mn></msub></mrow></math></span> methanation to produce synthetic methane. This integrated approach enhances the flexibility of hydrogen energy storage and transportation while achieves <span><math><mrow><mi>C</mi><msub><mi>O</mi><mn>2</mn></msub></mrow></math></span> valorization, supporting and advancing the UN's sustainable development goals. Traditional <span><math><mrow><mi>C</mi><msub><mi>O</mi><mn>2</mn></msub></mrow></math></span>methanation in large fixed-bed equipment suffers from limited heat and mass transfer efficiency, leading to the catalyst deactivation and compromised methanation performance. To overcome these challenges, microchannel-based reactors have been proposed as an alternate solution, offering enhanced heat and mass transfer performance, compact system volume, higher volumetric productivity and improved energy efficiency.</div><div>This paper presents a comprehensive literature review on research advances of the microchannel reactor technology for <span><math><mrow><mi>C</mi><msub><mi>O</mi><mn>2</mn></msub></mrow></math></span> methanation. The review covers various aspects, including catalysts configuration, effects of operating factors, and strategies to intensify the <span><math><mrow><mi>C</mi><msub><mi>O</mi><mn>2</mn></msub></mrow></math></span> methanation performance. In addition, special attention was given to integrated process coupling within methanation reaction, improving both reaction regulation and thermal energy management in methanation systems. The work provides a useful reference for developing high-efficiency microchannel reactor systems for <span><math><mrow><mi>C</mi><msub><mi>O</mi><mn>2</mn></msub></mrow></math></span> methanation, offering fundamental insights for future industrial-scale implementation.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110690"},"PeriodicalIF":3.9,"publicationDate":"2025-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145923581","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}
Currently, Mexican sugar mills, in addition to producing saccharose as their main product, obtain molasses as a byproduct and bagasse as an agro-industrial waste. Molasses is marketed or used in distilleries within the mill to produce anhydrous ethanol, but with low profitability. Bagasse is burned to produce steam and electricity, generating environmental problems. Therefore, from a circular economy perspective, the objective of this study is to propose a strategy for the modernization and adaptation of a sugar mill to a biorefinery to diversify the commercialization of its products, improving the economics and sustainability of the industrial process. The proposed methodology considers the design, simulation, and technoeconomic evaluation of a sugarcane biorefinery to produce citric acid and biofertilizer using two scenarios: one using bagasse and the other using molasses as feedstocks. The study first considers an analysis of the Mexican market to determine the availability of feedstocks and the installed capacity of the proposed biorefinery. Next, the operation mode of the fermentation reactor (i.e., batch or fed-batch) is studied as a strategy to increase citric acid productivity. Finally, the biorefinery is technically and economically evaluated under different operating conditions to determine the feasibility and profitability of the industrial process.
{"title":"Citric acid production: A comprehensive assessment from a fermentation strategy to a circular economy process","authors":"Teresa Lopez-Arenas , Kevin Palacios-Samano , Hector Hernandez-Escoto , Mauricio Sales-Cruz","doi":"10.1016/j.cep.2025.110694","DOIUrl":"10.1016/j.cep.2025.110694","url":null,"abstract":"<div><div>Currently, Mexican sugar mills, in addition to producing saccharose as their main product, obtain molasses as a byproduct and bagasse as an agro-industrial waste. Molasses is marketed or used in distilleries within the mill to produce anhydrous ethanol, but with low profitability. Bagasse is burned to produce steam and electricity, generating environmental problems. Therefore, from a circular economy perspective, the objective of this study is to propose a strategy for the modernization and adaptation of a sugar mill to a biorefinery to diversify the commercialization of its products, improving the economics and sustainability of the industrial process. The proposed methodology considers the design, simulation, and technoeconomic evaluation of a sugarcane biorefinery to produce citric acid and biofertilizer using two scenarios: one using bagasse and the other using molasses as feedstocks. The study first considers an analysis of the Mexican market to determine the availability of feedstocks and the installed capacity of the proposed biorefinery. Next, the operation mode of the fermentation reactor (i.e., batch or fed-batch) is studied as a strategy to increase citric acid productivity. Finally, the biorefinery is technically and economically evaluated under different operating conditions to determine the feasibility and profitability of the industrial process.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110694"},"PeriodicalIF":3.9,"publicationDate":"2025-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145923578","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 : 2025-12-30DOI: 10.1016/j.cep.2025.110688
Lei Zhang , Yuyao Lou , Liwei Meng , Tianxiang Li , Tongxun Liu , Xue Han , Yafei Wang
Pd-based membrane reactors (PMRs) offer a promising approach for on-board bioethanol reforming hydrogen production in fuel cell vehicles (FCVs). However, the model of the palladium membrane reactor (PMR) is urgently needed for on-board hydrogen supply. This study developed a kinetic model for single-tube Pd membrane reactors (PMRs) with autothermal reforming (ATR) to systematically evaluate key parameters: reactor length-to-diameter ratio (L/D), gas hourly space velocity (GHSV = 1, 000–3, 000 h-1), membrane insertion ratio (20–80 %), and catalyst stacking ratio (Volumetric catalyst stacking per unit palladium film area) (2–5 mL/cm2). When membrane insertion ratios ranged from 40 % to 50 %, hydrogen yield (∼5.7 mol/mol), hydrogen recovery (∼96 %), and hydrogen production rate (1.24 g/h) simultaneously reached peak values. In a 7-tube PMR configuration, the hydrogen production rate increased to 7.7 g/h, but hydrogen yield and recovery decreased. The incorporation of baffle plates as turbulence promoters enhanced hydrogen recovery from 80 % to 91 %. In the optimized four-layer PMR design with 37 tubes, the hydrogen production rate reached 41.3 g/h. Furthermore, the conceptual full-scale PMR for fuel cell vehicles is more compact than conventional high-pressure hydrogen storage tanks. This integrated ATR approach with multitubular designs and turbulence promoters enables efficient compact on-board hydrogen production.
{"title":"Enhancing hydrogen production in Pd-based membrane reactors via bioethanol autothermal reforming: Turbulence promoters and multitubular designs","authors":"Lei Zhang , Yuyao Lou , Liwei Meng , Tianxiang Li , Tongxun Liu , Xue Han , Yafei Wang","doi":"10.1016/j.cep.2025.110688","DOIUrl":"10.1016/j.cep.2025.110688","url":null,"abstract":"<div><div>Pd-based membrane reactors (PMRs) offer a promising approach for on-board bioethanol reforming hydrogen production in fuel cell vehicles (FCVs). However, the model of the palladium membrane reactor (PMR) is urgently needed for on-board hydrogen supply. This study developed a kinetic model for single-tube Pd membrane reactors (PMRs) with autothermal reforming (ATR) to systematically evaluate key parameters: reactor length-to-diameter ratio (L/D), gas hourly space velocity (GHSV = 1, 000–3, 000 h<sup>-1</sup>), membrane insertion ratio (20–80 %), and catalyst stacking ratio (Volumetric catalyst stacking per unit palladium film area) (2–5 mL/cm<sup>2</sup>). When membrane insertion ratios ranged from 40 % to 50 %, hydrogen yield (∼5.7 mol/mol), hydrogen recovery (∼96 %), and hydrogen production rate (1.24 g/h) simultaneously reached peak values. In a 7-tube PMR configuration, the hydrogen production rate increased to 7.7 g/h, but hydrogen yield and recovery decreased. The incorporation of baffle plates as turbulence promoters enhanced hydrogen recovery from 80 % to 91 %. In the optimized four-layer PMR design with 37 tubes, the hydrogen production rate reached 41.3 g/h. Furthermore, the conceptual full-scale PMR for fuel cell vehicles is more compact than conventional high-pressure hydrogen storage tanks. This integrated ATR approach with multitubular designs and turbulence promoters enables efficient compact on-board hydrogen production.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"220 ","pages":"Article 110688"},"PeriodicalIF":3.9,"publicationDate":"2025-12-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145880887","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 : 2025-12-30DOI: 10.1016/j.cep.2025.110691
Reyes Mallada
The development of an intensified process, it is not only a question of finding synergies between process intensification and catalyst, but also finding the most suitable material for the framework conditions of the new process, which in most cases differs from the conventional process. In this paper I present lessons learnt and future perspectives in heterogeneous catalysis for different intensification strategies including, membrane reactors, structured reactors and process electrification with microwaves.
{"title":"The central role of materials in heterogeneous catalytic intensified processes","authors":"Reyes Mallada","doi":"10.1016/j.cep.2025.110691","DOIUrl":"10.1016/j.cep.2025.110691","url":null,"abstract":"<div><div>The development of an intensified process, it is not only a question of finding synergies between process intensification and catalyst, but also finding the most suitable material for the framework conditions of the new process, which in most cases differs from the conventional process. In this paper I present lessons learnt and future perspectives in heterogeneous catalysis for different intensification strategies including, membrane reactors, structured reactors and process electrification with microwaves.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110691"},"PeriodicalIF":3.9,"publicationDate":"2025-12-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145923582","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 : 2025-12-29DOI: 10.1016/j.cep.2025.110687
Antarim Dutta, Md. Siraj Alam, Shabih Ul Hasan
This work introduces the first conceptual design framework for reactive distillation (RD) columns in the equilibrium reaction-extent space, enabling feasible designs with desired selectivity in two-equilibrium-reaction systems. Our previous work on selectivity engineering using hybrid RD configurations in the traditional mole-fraction space suffers from dimensionality constraints, and achieving desired selectivity is challenging in multireaction systems sensitive to component volatility. Existing algorithms for two-equilibrium-reaction systems require complex hybrid RD columns for more than three components and are typically limited to five. To address these challenges, we propose a novel conceptual design algorithm that enables the desired selectivity of intermediate products. Formulated in the equilibrium reaction-extent space, the methodology employs a combined graphical-simulation approach. The locus of equilibrium reaction extents along the RD column is determined for the desired selectivity, and its intersection with the locus of a single reactive stage RD-obtained by varying separation attributes-identifies feasible RD designs. Demonstrated via ethyl methyl carbonate production in both the design spaces, the method, currently applicable to two equilibrium reactions with intermediate-volatility reactants and single-feed hybrid RD columns; however, it can be extended to three equilibrium reactions and multi-feed configurations.
{"title":"Selectivity engineering with single-feed hybrid reactive distillation (RD) columns for a wider range of reaction networks - Part I : Elimination of complex hybrid RD configurations for two equilibrium reactions","authors":"Antarim Dutta, Md. Siraj Alam, Shabih Ul Hasan","doi":"10.1016/j.cep.2025.110687","DOIUrl":"10.1016/j.cep.2025.110687","url":null,"abstract":"<div><div>This work introduces the first conceptual design framework for reactive distillation (RD) columns in the equilibrium reaction-extent space, enabling feasible designs with desired selectivity in two-equilibrium-reaction systems. Our previous work on selectivity engineering using hybrid RD configurations in the traditional mole-fraction space suffers from dimensionality constraints, and achieving desired selectivity is challenging in multireaction systems sensitive to component volatility. Existing algorithms for two-equilibrium-reaction systems require complex hybrid RD columns for more than three components and are typically limited to five. To address these challenges, we propose a novel conceptual design algorithm that enables the desired selectivity of intermediate products. Formulated in the equilibrium reaction-extent space, the methodology employs a combined graphical-simulation approach. The locus of equilibrium reaction extents along the RD column is determined for the desired selectivity, and its intersection with the locus of a single reactive stage RD-obtained by varying separation attributes-identifies feasible RD designs. Demonstrated via ethyl methyl carbonate production in both the design spaces, the method, currently applicable to two equilibrium reactions with intermediate-volatility reactants and single-feed hybrid RD columns; however, it can be extended to three equilibrium reactions and multi-feed configurations.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110687"},"PeriodicalIF":3.9,"publicationDate":"2025-12-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145923580","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}
This study investigated the effects of magnetization and simultaneous magnetization and activation (SMA) on the adsorption of the azo dyes (i.e., Congo red (CR) and amaranth (AM)) by walnut shell biochars (WSB). SMA-modified walnut shell biochar (WSBSMA) has a larger specific surface area (626.2 m²/g) than that of WSB (9.4 m²/g) and magnetized WSB (WSBM; 482.6 m²/g) because ZnCl2 inhibited tar formation during pyrolysis. Consequently, WSBSMA showed superior adsorption capacities (Qmax = 8.13–13.25 mg/g) compared to WSB (Qmax = 0.44–1.65 mg/g) and WSBM (Qmax = 7.70–12.95 mg/g). The pseudo-second-order and Langmuir models better described the adsorption kinetics and isotherm, suggesting that chemisorption primarily governs the adsorption process. The EDS and XPS analyses revealed that CR and AM adsorption onto WSB, WSBM, and WSBSMA was mainly governed by π-π electron-donor-acceptor interaction. In the case of WSBM and WSBSMA, electrostatic interaction was additionally involved in the adsorption of CR and AM due to the presence of iron oxides, resulting in higher removal efficiencies compared to WSB. Furthermore, WSBSMA maintained excellent reusability (reuse efficiencies ≥ 60 %) after six adsorption-desorption cycles. Therefore, SMA is considered a viable approach to enhance the adsorption capacity of CR and AM onto WSB.
{"title":"Simultaneous magnetization and activation as a facile way to improve the adsorption capacity of walnut shell biochars for anionic azo dyes","authors":"Gayeon Kim , Jaeyeong Choi , Jaegwan Shin , Jinwoo Kwak , Kangmin Chon","doi":"10.1016/j.cep.2025.110686","DOIUrl":"10.1016/j.cep.2025.110686","url":null,"abstract":"<div><div>This study investigated the effects of magnetization and simultaneous magnetization and activation (SMA) on the adsorption of the azo dyes (i.e., Congo red (CR) and amaranth (AM)) by walnut shell biochars (WSB). SMA-modified walnut shell biochar (WSB<sub>SMA</sub>) has a larger specific surface area (626.2 m²/g) than that of WSB (9.4 m²/g) and magnetized WSB (WSB<sub>M</sub>; 482.6 m²/g) because ZnCl<sub>2</sub> inhibited tar formation during pyrolysis. Consequently, WSB<sub>SMA</sub> showed superior adsorption capacities (Q<sub>max</sub> = 8.13–13.25 mg/g) compared to WSB (Q<sub>max</sub> = 0.44–1.65 mg/g) and WSB<sub>M</sub> (Q<sub>max</sub> = 7.70–12.95 mg/g). The pseudo-second-order and Langmuir models better described the adsorption kinetics and isotherm, suggesting that chemisorption primarily governs the adsorption process. The EDS and XPS analyses revealed that CR and AM adsorption onto WSB, WSB<sub>M</sub>, and WSB<sub>SMA</sub> was mainly governed by π-π electron-donor-acceptor interaction. In the case of WSB<sub>M</sub> and WSB<sub>SMA</sub>, electrostatic interaction was additionally involved in the adsorption of CR and AM due to the presence of iron oxides, resulting in higher removal efficiencies compared to WSB. Furthermore, WSB<sub>SMA</sub> maintained excellent reusability (reuse efficiencies ≥ 60 %) after six adsorption-desorption cycles. Therefore, SMA is considered a viable approach to enhance the adsorption capacity of CR and AM onto WSB.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"220 ","pages":"Article 110686"},"PeriodicalIF":3.9,"publicationDate":"2025-12-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145922073","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 : 2025-12-27DOI: 10.1016/j.cep.2025.110683
Panayiota Adamou , Eleana Harkou , Lukas Jasiunas , Rozalia Persiani , María José Valero-Romero , Ramiro Ruiz-Rosas , Valerio Natale , Savvas Kamenos , Andreas Andreou , George Manos , S.M. Al-Salem , Robert Wojcieszak , Nikolaos Dimitratos , Achilleas Constantinou
The use of bio-based feedstocks is necessary, since industries still rely on fossil fuels or food-competitive feedstocks. Aim of this work is the design of an integrated process consisting of liquefaction and pyrolysis processes that use waste biomass for the production of biopolyol and biophenolic compounds for bio-based polyurethane (PU) and phenol-formaldehyde (PF) materials production. Aspen Plus models were developed using power-law kinetics for the pyrolysis process, validating literature-based results, with maximum error of 10 % showcasing the good predictability of the power-law kinetics. The integrated liquefaction and pyrolysis process was then modelled based on our experimental results, showing 77 % biopolyols yield after liquefaction and 59 % bio-oil yield after pyrolysis, which consisted of approximately 2.3 % phenols from the compounds detected. The modelling of components distribution of the bio-oil had a maximum error of 13 %. Lastly, an energy optimisation study was conducted in Aspen Plus, utilising the hot outlet stream from pyrolysis to heat the feedstock before entering the pre-heating step, reducing in that way the heating load of the heater by 13 kW. Future studies aim on a more detailed integrated liquefaction-pyrolysis process flow diagram to perform techno-economical and life-cycle analysis for the generation of bio-oil rich in biopolyols and phenolics.
{"title":"Process modelling for sustainable production of bio-oil from waste biomass","authors":"Panayiota Adamou , Eleana Harkou , Lukas Jasiunas , Rozalia Persiani , María José Valero-Romero , Ramiro Ruiz-Rosas , Valerio Natale , Savvas Kamenos , Andreas Andreou , George Manos , S.M. Al-Salem , Robert Wojcieszak , Nikolaos Dimitratos , Achilleas Constantinou","doi":"10.1016/j.cep.2025.110683","DOIUrl":"10.1016/j.cep.2025.110683","url":null,"abstract":"<div><div>The use of bio-based feedstocks is necessary, since industries still rely on fossil fuels or food-competitive feedstocks. Aim of this work is the design of an integrated process consisting of liquefaction and pyrolysis processes that use waste biomass for the production of biopolyol and biophenolic compounds for bio-based polyurethane (PU) and phenol-formaldehyde (PF) materials production. Aspen Plus models were developed using power-law kinetics for the pyrolysis process, validating literature-based results, with maximum error of 10 % showcasing the good predictability of the power-law kinetics. The integrated liquefaction and pyrolysis process was then modelled based on our experimental results, showing 77 % biopolyols yield after liquefaction and 59 % bio-oil yield after pyrolysis, which consisted of approximately 2.3 % phenols from the compounds detected. The modelling of components distribution of the bio-oil had a maximum error of 13 %. Lastly, an energy optimisation study was conducted in Aspen Plus, utilising the hot outlet stream from pyrolysis to heat the feedstock before entering the pre-heating step, reducing in that way the heating load of the heater by 13 kW. Future studies aim on a more detailed integrated liquefaction-pyrolysis process flow diagram to perform techno-economical and life-cycle analysis for the generation of bio-oil rich in biopolyols and phenolics.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"220 ","pages":"Article 110683"},"PeriodicalIF":3.9,"publicationDate":"2025-12-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145880885","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 : 2025-12-27DOI: 10.1016/j.cep.2025.110685
Yubo Wang, Ping Gong
This study proposes a single-layer split-and- recombination (SAR) micromixer characterized by a concentric ring mixing chamber and adjacent connecting channels with a designed angle, aiming to enhance mixing efficiency. The performance of micromixers with varying connection channel angles (θ) was evaluated via mixing index, pressure drop, and mixing energy cost under Reynolds numbers (Re) ranging from 1 to 100. Results demonstrate that the CCRM-90° (90° connection channel angle) achieves superior mixing efficiency, exceeding 97 % at Re > 20 and consistently surpassing 99 % when Re > 30, while reducing θ effectively lowers pressure drop. Furthermore, the central circle, defined as a circle with a diameter equal to half the sum of the inner and outer diameters of the concentric ring, scales the mixing chamber size by adjusting its diameter Φ under constant flow channel cross-sectional area. Performance evaluations of CCRM-120°, CCRM-105°, and CCRM-90° micromixers with varying central circle diameter (Φ) revealed that increasing Φ in CCRM-120° mitigated mixing index fluctuations but significantly raised energy consumption. In contrast, CCRM-105° and CCRM-90° achieved stable mixing index above 99 % across a wide Re range (30 – 100) without enlarging Φ, demonstrating superior energy efficiency.
{"title":"Numerical simulation of the mixing performance of a novel SAR micromixer with concentric circular ring mixing chamber and angle between connecting channel","authors":"Yubo Wang, Ping Gong","doi":"10.1016/j.cep.2025.110685","DOIUrl":"10.1016/j.cep.2025.110685","url":null,"abstract":"<div><div>This study proposes a single-layer split-and- recombination (SAR) micromixer characterized by a concentric ring mixing chamber and adjacent connecting channels with a designed angle, aiming to enhance mixing efficiency. The performance of micromixers with varying connection channel angles (θ) was evaluated via mixing index, pressure drop, and mixing energy cost under Reynolds numbers (Re) ranging from 1 to 100. Results demonstrate that the CCRM-90° (90° connection channel angle) achieves superior mixing efficiency, exceeding 97 % at Re > 20 and consistently surpassing 99 % when Re > 30, while reducing θ effectively lowers pressure drop. Furthermore, the central circle, defined as a circle with a diameter equal to half the sum of the inner and outer diameters of the concentric ring, scales the mixing chamber size by adjusting its diameter Φ under constant flow channel cross-sectional area. Performance evaluations of CCRM-120°, CCRM-105°, and CCRM-90° micromixers with varying central circle diameter (Φ) revealed that increasing Φ in CCRM-120° mitigated mixing index fluctuations but significantly raised energy consumption. In contrast, CCRM-105° and CCRM-90° achieved stable mixing index above 99 % across a wide Re range (30 – 100) without enlarging Φ, demonstrating superior energy efficiency.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110685"},"PeriodicalIF":3.9,"publicationDate":"2025-12-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145895871","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 : 2025-12-26DOI: 10.1016/j.cep.2025.110681
Han Wang , Hongwei Cui , Junnan Wang , George UGWU Kenechukwu , Sehar Muzaffar Hussain , Chunying Zhu , Youguang Ma , Taotao Fu
To improve the yield of glyoxylic acid, a capillary microreactor system based on the reaction-extraction coupling method was developed. The process of liquid-liquid two-phase flow was simulated using CFD simulation to investigate the effects of flow velocity ratio of two phases and total flow velocity on the droplet length. The effects of factors such as the injection point and concentration of the extractant, volumetric ratio of two phases, and total flow rate on the reaction, were investigated. When the molar ratio of nitric acid (35 wt %), glyoxal (40 wt %), and sodium nitrite was 1.4:1:0.15, temperature was 68 °C, diameter and length of tube were 0.8 mm and 36 m, the extractant Tri-n-octylamine at a volume fraction of 50 % added at 24 m, volumetric ratio of extraction to reaction phase was 1:1, and total flow rate was 2.76 mL/min, a glyoxal conversion of 97.43 % and a glyoxylic acid yield of 86.88 % were obtained. This reaction-extraction coupling method fully exploits the characteristics of process intensification within a capillary microreactor to accomplish simultaneous reaction and separation. By minimizing side reactions, it significantly improves the yield of glyoxylic acid and simplifies subsequent purification steps, exhibiting high efficiency, environmental friendliness through reduced solvent usage and lower energy consumption, and suitability for continuous production.
{"title":"High-efficiency synthesis and separation of glyoxylic acid based on reaction-extraction coupling method in a microreactor","authors":"Han Wang , Hongwei Cui , Junnan Wang , George UGWU Kenechukwu , Sehar Muzaffar Hussain , Chunying Zhu , Youguang Ma , Taotao Fu","doi":"10.1016/j.cep.2025.110681","DOIUrl":"10.1016/j.cep.2025.110681","url":null,"abstract":"<div><div>To improve the yield of glyoxylic acid, a capillary microreactor system based on the reaction-extraction coupling method was developed. The process of liquid-liquid two-phase flow was simulated using CFD simulation to investigate the effects of flow velocity ratio of two phases and total flow velocity on the droplet length. The effects of factors such as the injection point and concentration of the extractant, volumetric ratio of two phases, and total flow rate on the reaction, were investigated. When the molar ratio of nitric acid (35 wt %), glyoxal (40 wt %), and sodium nitrite was 1.4:1:0.15, temperature was 68 °C, diameter and length of tube were 0.8 mm and 36 m, the extractant Tri-n-octylamine at a volume fraction of 50 % added at 24 m, volumetric ratio of extraction to reaction phase was 1:1, and total flow rate was 2.76 mL/min, a glyoxal conversion of 97.43 % and a glyoxylic acid yield of 86.88 % were obtained. This reaction-extraction coupling method fully exploits the characteristics of process intensification within a capillary microreactor to accomplish simultaneous reaction and separation. By minimizing side reactions, it significantly improves the yield of glyoxylic acid and simplifies subsequent purification steps, exhibiting high efficiency, environmental friendliness through reduced solvent usage and lower energy consumption, and suitability for continuous production.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"220 ","pages":"Article 110681"},"PeriodicalIF":3.9,"publicationDate":"2025-12-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145880884","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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