Chemical Engineering and Processing - Process Intensification最新文献_第3页

Particle tuning in reactive crystallization via microwave-assisted temperature cycling for improved downstream performance

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-02-20 DOI: 10.1016/j.cep.2025.110241

Athanasios Arampatzis , Ioannis Papaioannou , Tom Van Gerven , Georgios D. Stefanidis

Efficient particle processing during and downstream of a crystallization process is a paramount task in pharmaceutical industry regarding production of Active Pharmaceutical Ingredients (APIs). Due to mass transfer limitations, supersaturation is often not uniformly controlled in reactive crystallization processes generating an excessive amount of fine particles, which often tend to agglomerate causing issues in downstream operations, such as filtration and drying. We demonstrate rapid microwave-assisted temperature cycling (RMWTC) as a post-treatment approach that can effectively address these problems. Specifically, we report that in the event of high solids load systems, RMWTC intensifies fines dissolution during rapid heating and promotes faster recrystallization on surviving surfaces during rapid cooling. The RMWTC approach facilitates tuning not only of particle size, but possibly of crystal morphology by increasing the number of stable agglomerates with a positive concomitant impact on particle filterability and process time. A thermal parametric study on an aromatic amine API intermediate system revealed that there is an optimal temperature operating window (60 °C-105 °C) that shifts particle size distribution (PSD) towards larger particle sizes and yields up to 82 % improved filterability at 50 % less process time compared to the traditional particle control strategy, currently applied in industry for this process.

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引用次数: 0

Ultrasonic demulsification of water-in-crude oil emulsions: Influence of rheological properties

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-02-20 DOI: 10.1016/j.cep.2025.110242

Yuliya N. Romanova , Marina Y. Koroleva , Natalya S. Musina , Tatyana А. Maryutina

In this work, we have studied the rheological properties of commercial water-in-crude oil emulsions of different compositions and the effect of their properties on ultrasonic demulsification. Shear rheological measurements in the temperature range of 10 to 30 °C showed that the emulsion with an aqueous phase concentration of 9.7 wt% behaved as a Newtonian fluid. The emulsion with a water content of 15.0 wt% changed from non-Newtonian to Newtonian flow with an increase in temperature. The more concentrated emulsions with water contents of 37.5 and 54.0 wt% behaved as non-Newtonian pseudoplastic fluids. The Ostwald-Weil model best described the rheological properties of all the non-Newtonian emulsions studied. Ultrasonic treatment of Newtonian emulsions at the power and exposure time parameters studied had a slight effect on water separation and resulted in an increase in viscosity, indicating the ineffectiveness of ultrasonic demulsification of these emulsions. In the case of non-Newtonian emulsions, an intensification of the demulsification process reached 46–61 %. The most effective water separation from all emulsions was observed with the ultrasonic treatment at a power of 0.2 kW after 2 min. However, the demulsification and emulsification processes occur simultaneously in emulsions treated with ultrasound. For this reason, the power and the exposure time are the parameters that need to be optimised for each specific type of crude oil emulsion depending on the concentrations of the aqueous phase, natural emulsifiers and solid impurities.

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引用次数: 0

Intensification and enhancement of phenolic compounds extraction using cooperative formulation

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-02-19 DOI: 10.1016/j.cep.2025.110220

Sazmin Sufi Suliman , Norasikin Othman , Muhammad Abbas Ahmad Zaini , Norul Fatiha Mohamed Noah , Izzat Naim Shamsul Kahar

In this study, intensification of palm oil mill steriliser condensate as a potential secondary source of phenolic compounds (PCs) were investigated. Synergistic reactive extraction with cooperative formulation appeared as a promising approach for recovering PCs, offering several advantages such as high selectivity, simplicity, ease of scale-up, and efficiency. The organic phase was formulated using mixture of vegetable oils as a sustainable green diluent. The carrier was added into the organic phase to select the potential base and synergist carriers in order to improve the extraction performance of PCs. The complexes of carrier-PC was study for the recovery purpose. A synergist stripping agent was formulated using mixture of salt. The finding indicated that about 93.33% of PCs were successfully extracted with a synergistic coefficient (SC) value of 5.09 using 0.25 M Aliquat 336 and 2.0 mM D2EHPA diluted in mixed vegetable oils of sunflower and palm oil at a ratio of 60:40. Meanwhile, the recovery study demonstrated that 0.04 M Na₂CO₃/1.00 M NaOH was selected as the stripping performance was up to 99.99% with SC value of 2.13. Consequently, the synergistic formulation employed in reactive extraction process demonstrates potential for the recovery of PCs from palm oil mill steriliser condensate.

{"title":"Intensification and enhancement of phenolic compounds extraction using cooperative formulation","authors":"Sazmin Sufi Suliman , Norasikin Othman , Muhammad Abbas Ahmad Zaini , Norul Fatiha Mohamed Noah , Izzat Naim Shamsul Kahar","doi":"10.1016/j.cep.2025.110220","DOIUrl":"10.1016/j.cep.2025.110220","url":null,"abstract":"<div><div>In this study, intensification of palm oil mill steriliser condensate as a potential secondary source of phenolic compounds (PCs) were investigated. Synergistic reactive extraction with cooperative formulation appeared as a promising approach for recovering PCs, offering several advantages such as high selectivity, simplicity, ease of scale-up, and efficiency. The organic phase was formulated using mixture of vegetable oils as a sustainable green diluent. The carrier was added into the organic phase to select the potential base and synergist carriers in order to improve the extraction performance of PCs. The complexes of carrier-PC was study for the recovery purpose. A synergist stripping agent was formulated using mixture of salt. The finding indicated that about 93.33% of PCs were successfully extracted with a synergistic coefficient (SC) value of 5.09 using 0.25 M Aliquat 336 and 2.0 mM D2EHPA diluted in mixed vegetable oils of sunflower and palm oil at a ratio of 60:40. Meanwhile, the recovery study demonstrated that 0.04 M Na<sub>2</sub>CO<sub>3</sub>/1.00 M NaOH was selected as the stripping performance was up to 99.99% with SC value of 2.13. Consequently, the synergistic formulation employed in reactive extraction process demonstrates potential for the recovery of PCs from palm oil mill steriliser condensate.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"211 ","pages":"Article 110220"},"PeriodicalIF":3.8,"publicationDate":"2025-02-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143437456","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Impact of structure of a rotating zigzag bed with block-rotor on separation performance in distillation

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-02-18 DOI: 10.1016/j.cep.2025.110239

Kang-jie Lou , Yu-min Li , Di Tang , Guang-quan Wang , Jian-bing Ji

A high centrifugal force is used to intensify distillation, which is called Higee distillation. Rotating zigzag bed(RZB) has successfully applied in the industrialization of Higee distillation. In order to develop further the RZB, a RZB with zigzag block-rotor(RZB-BR) was provided. Rotating as a whole, the RZB-BR rotor had a set of concentric circular baffles between two disks, providing a zigzag passage for gas/liquid flow. A total reflux distillation experiment was carried out with an ethanol-water system to investigate separation efficiency, gas pressure drop and power consumption. A power consumption efficiency was proposed for the first time to compare power consumption of Higee devices with various structures and sizes. The RZB-BR had good performance, and the fine steel bars that were fixed to the baffles as well as the upper and lower disks could improve the mass-transfer. Compared to RZB and RPB, the separation efficiency of the RZB-BR was lower and higher than RZB and RPB respectively, and the pressure drop and power consumption of the RZB-BR were both lower and higher than RZB and RPB respectively. Therefore, the RZB-BR may be an alternative to the RZB and RPB, applied in Higee distillation.

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引用次数: 0

Comprehensive performance investigation of the novel mixed flow field for proton exchange membrane fuel cells: Three-dimensional multiphase simulation of a full-scale cell

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-02-17 DOI: 10.1016/j.cep.2025.110234

Fan Fan , Meng Gu , Yangyang Chen , Dongjian Zhang , Haoyan Fang , Baofeng Hu , Yong Zhang , Qingshan Liu

This study addresses the challenges associated with proton exchange membrane fuel cells, specifically focusing on the bipolar plates which often suffer from weak mass transfer capabilities, significant pressure losses, and uneven internal liquid distribution. Initially, the research explores the advantages and disadvantages inherent in single-channel serpentine flow fields and interdigitated flow fields. By integrating these two configurations, a novel mixed flow field (MFF) is developed to enhance the output performance of fuel cells while maintaining consistent water distribution within the porous electrodes. Subsequently, an experimental test platform for a single cell is established. It is observed that the experimental results are slightly lower than the simulations, particularly in the ohmic voltage loss region. Further investigation is conducted into the impact of inlet/outlet arrangements of the MFF on the comprehensive characteristics of the cell, and the third arrangement method demonstrates optimal uniformity in membrane water content distribution. Finally, the study examines the macroscopic performance characteristics and spatial distribution of various physical quantities of the MFF under different operating conditions, such as cathode inlet humidity and operating voltage. The findings indicate that the MFF exhibits optimal comprehensive output performance at an inlet humidity of 60 % and an operating voltage of 0 .5V.

本研究探讨了质子交换膜燃料电池所面临的挑战，特别是双极板通常存在传质能力弱、压力损失大和内部液体分布不均匀等问题。研究首先探讨了单通道蛇形流场和交错流场固有的优缺点。通过整合这两种配置，开发出一种新型混合流场 (MFF)，以提高燃料电池的输出性能，同时保持多孔电极内水分布的一致性。随后，建立了单个电池的实验测试平台。据观察，实验结果略低于模拟结果，尤其是在欧姆电压损失区域。研究还进一步探究了 MFF 的入口/出口布置对电池综合特性的影响，第三种布置方法展示了膜含水量分布的最佳均匀性。最后，研究考察了 MFF 在阴极入口湿度和工作电压等不同工作条件下的宏观性能特征和各种物理量的空间分布。研究结果表明，在入口湿度为 60%、工作电压为 0.5V 的条件下，MFF 的综合输出性能最佳。

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引用次数: 0

Enhanced chloroquine adsorption using cobalt-modified mesoporous silicas for water treatment

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-02-17 DOI: 10.1016/j.cep.2025.110224

Renata Mariane de Souza , Grace Anne Vieira Magalhães-Ghiotto , Rosângela Bergamasco

The widespread use of chloroquine (CQ) during the COVID-19 pandemic has led to its accumulation in water bodies due to the inefficiency of wastewater treatment plants (WWTPs). This study synthesized, characterized, and evaluated mesoporous silicas MCM-41 and MCM-48 modified with cobalt oxide nanoparticles for CQ removal. Characterization was conducted to assess the adsorbent properties and their correlation with the adsorption process. The materials exhibited high surface areas (S_BET > 369.49 m² g⁻¹) and uniform mesoporous structures, confirming their suitability for adsorption and desirable properties for recalcitrant contaminant removal. Adsorption kinetics followed the Elovich model, with equilibrium capacities of 25.3 mg g⁻¹ (MCM-41-CoO) and 24.04 mg g⁻¹ (MCM-48-CoO), and intraparticle diffusion governed by a multi-step process. Isotherms were best described by the Sips model, with maximum adsorption capacities of 24.78 mg g⁻¹ (MCM-41-CoO) and 24.00 mg g⁻¹ (MCM-48-CoO) at temperatures ranging from 15 to 45 °C. Thermodynamic parameters indicated a spontaneous, endothermic process with low randomness, suggesting chemical interaction in a monolayer followed by electrostatic interactions. These findings highlight the efficiency of modified mesoporous silicas as adsorbents for CQ, a critical pharmaceutical contaminant, and contribute to developing sustainable water treatment technologies essential for environmental protection and public health.

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引用次数: 0

Development of 3D-printed electrodes using polyacrylonitrile/ graphene composites for application in polysulfide bromide flow battery

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-02-15 DOI: 10.1016/j.cep.2025.110233

Rungsima Yeetsorn , Saksitt Chitvuttichot , Adisorn Tuantranont , Tanyakarn Treeratanaphitak , Jeff Gostick

The performance of Polysulfide Bromide Flow Batteries (PBS) is depended on the design of the electrodes, which plays a crucial role in ensuring optimal electrolyte distribution and conductivity. These factors are essential for facilitating efficient electrochemical kinetics. This study introduces a novel approach to electrode fabrication using polyacrylonitrile/graphene composites through 3D printing, which enhances structural uniformity and electrical conductivity. The incorporation of reduced graphene oxide, with an electrical conductivity of 23 S/m, into polyacrylonitrile-based electrodes substantially improves their electrical conductivity. Unlike traditional techniques that produce randomly oriented fibers, 3D printing offers precise control over electrode architecture. This enables uniform electrolyte flow, improved mass transfer, and increased electrolyte diffusion across the electrode surface. The precise architectural design ensures that the electrolyte's retention time is aligned with its inert properties and optimizing the electrochemical process. One of the two 3D-printed electrode designs exhibited a diffusion coefficient of 73.85 × 10^-13 m²/s. This research not only overcomes the limitations of traditional electrode fabrication techniques but also highlights the potential of advanced 3D printing technologies in the creation of next-generation flow battery electrodes. The findings from this study could pave the way for the development of more efficient, durable, and scalable energy storage systems.

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引用次数: 0

Generation of high-viscosity heavy oil droplets: Insights from image analysis and numerical simulation

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-02-15 DOI: 10.1016/j.cep.2025.110232

Yaohua Huang , Huatong Zhu , Dongyue Peng , Zhixin Liao , Hao Lu , Qiang Yang

To understand the behavior of high-viscosity heavy oil droplets generated in mass transfer systems, a method was established to measure the microdroplet formation via image analysis, with measurement errors controlled within 10 %. N-dodecane–dimethicone solutions with different viscosities and ethanol–deionized water solutions were employed as dispersed and continuous phases, respectively. The study identifies three stages of microdroplet formation: shrinkage, expansion, and fracture. The pressure and velocity fields during the fracture stage are simulated using a numerical simulation method. The fracture stages of droplets are categorized into three morphologies: fluctuating fracture, equilibrium fracture, and hysteretic fracture, which can be predicted using the Re number and We number. Increasing the viscosity of the dispersed phase increases the droplet formation time. The volume of produced droplets increases as the n-dodecane content in the dispersed phase increases. Finally, the droplet size decreases with an increase in the microdroplet formation time and a decrease in the nozzle size. Experimental results reveal the formation of high-viscosity heavy oil droplets in strong mass transfer solvents and offer prospects for developing micro-reaction technology for heavy crude oil refining.

{"title":"Generation of high-viscosity heavy oil droplets: Insights from image analysis and numerical simulation","authors":"Yaohua Huang , Huatong Zhu , Dongyue Peng , Zhixin Liao , Hao Lu , Qiang Yang","doi":"10.1016/j.cep.2025.110232","DOIUrl":"10.1016/j.cep.2025.110232","url":null,"abstract":"<div><div>To understand the behavior of high-viscosity heavy oil droplets generated in mass transfer systems, a method was established to measure the microdroplet formation via image analysis, with measurement errors controlled within 10 %. N-dodecane–dimethicone solutions with different viscosities and ethanol–deionized water solutions were employed as dispersed and continuous phases, respectively. The study identifies three stages of microdroplet formation: shrinkage, expansion, and fracture. The pressure and velocity fields during the fracture stage are simulated using a numerical simulation method. The fracture stages of droplets are categorized into three morphologies: fluctuating fracture, equilibrium fracture, and hysteretic fracture, which can be predicted using the <em>Re</em> number and <em>We</em> number. Increasing the viscosity of the dispersed phase increases the droplet formation time. The volume of produced droplets increases as the n-dodecane content in the dispersed phase increases. Finally, the droplet size decreases with an increase in the microdroplet formation time and a decrease in the nozzle size. Experimental results reveal the formation of high-viscosity heavy oil droplets in strong mass transfer solvents and offer prospects for developing micro-reaction technology for heavy crude oil refining.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"211 ","pages":"Article 110232"},"PeriodicalIF":3.8,"publicationDate":"2025-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143529729","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Process modeling, simulation and thermodynamic analysis of a novel process integrating coal gasification, smelting reduction and methanol synthesis for ironmaking and methanol co-production

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-02-14 DOI: 10.1016/j.cep.2025.110231

Hao Cheng , Guoqiang Cao , Zhongren Ba , Donghai Hu , Yongbin Wang , Guorong Zhu , Chunyu Li , Jiantao Zhao , Yitian Fang

A novel process integrating coal gasification, smelting reduction, and methanol synthesis process has been proposed and designed to produce both high-quality hot metal and methanol. This process comprises eight key units: Coal Gasification Pre-reduction, Smelting Reduction, Water Gas Shift, Acid Gas Removal, CO₂ Compression and Storage, Gas and Steam Turbine, Methanol Synthesis, and Distillation. The innovative aspect of this process lies in the partial recycling of H₂ rich clean syngas which is generated from the WGS and AGR stages. Key operational parameters based on the feed of coal is 100 tones/h, such as the ore/coal ratio, oxygen/coal ratio, circulation ratio (CR), and oxygen replenishment (OR) were optimized at values of 1.4, 0.8, 0.5, and 10 tons/h, respectively, enabling the co-production of 100 tons of hot metal and 55 tons of methanol. Thermodynamic analysis indicates that the energy consumption, energy efficiency, and exergy efficiency of the CGSRMS system per unit of product (1 t-Fe and 0.55 t-CH₃OH) are 10.47 GJ, 73.06 %, and 72.12 %, respectively. CO₂ emissions are significantly reduced to 0.91 t/h per unit of product, representing a 51.81 % decrease compared to conventional processes with same production outputs.

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引用次数: 0

Environmental life-cycle assessment and green principles in process intensification: A review of novel catalysts from solid waste

IF 3.8 3区工程技术 Q3 ENERGY & FUELS

Chemical Engineering and Processing - Process Intensification

Pub Date : 2025-02-13 DOI: 10.1016/j.cep.2025.110208

A.V.S.L. Sai Bharadwaj , Ripsa Rani Nayak , J Koteswararao , Chinnam Sampath , Baburao Gaddala , Bharat Govind Pawar , Navneet Kumar Gupta

The development of novel catalysts from solid waste has become a key strategy in sustainable research. This review focuses on the environmental life-cycle assessment (LCA) of waste-derived catalysts, highlighting their role in process intensification and alignment with green chemistry principles. LCA is crucial for evaluating the environmental, socioeconomic, and design implications of catalyst production from waste materials. The continuous disposal of solid waste contributes to rising energy demands, environmental degradation, and human health risks, which underscores the need for efficient, green solutions. This review examines the evolution of waste-derived heterogeneous catalysts, emphasizing their significance in the circular economy and sustainable practices. The impact of analytical and physico-chemical properties on both conventional and intensified processes is explored, with reaction time and temperature identified as critical parameters in catalyst synthesis. Conventional catalyst production, often involving high temperatures (>600 to <900°C) and long reaction times (4–5 hours), is energy intensive. However, process intensification, reducing these conditions to <100°C and <100 minutes, offers a sustainable alternative by minimizing energy consumption while maintaining catalyst performance. This review also compares various analytical techniques, such as X-ray diffraction, scanning electron microscopy, and density functional theory, to assess the effectiveness of catalysts produced through intensified methods. The findings suggest that intensified synthesis processes yield results comparable to traditional methods, demonstrating their potential to reduce energy demand and promote sustainability in catalyst production from solid waste.

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引用次数: 0