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 : 2025-12-30DOI: 10.1016/j.cep.2025.110684
Maria Cecilia Pacco-Huamaní , Michele Greque de Morais , Vilásia Guimarães Martins , Jorge Alberto Vieira Costa
Açaí seed and purple corn cobs were subjected to three bioactive compound extraction methods: agitation (AE), ultrasound-assisted extraction (UAE), and a combination of mechanical agitation and ultrasound (UAE+A). In each technique, green solvents, such as water and 30 % ethanol, were used individually. This study aimed to evaluate and compare the efficiency of the extraction methods and solvents in terms of total phenolic content (TPC), total flavonoid content (TFC), total anthocyanin content (TAC), antioxidant capacity, color, and antimicrobial activity. For both raw materials, the extraction efficiency followed the order UAE+A > UAE > AE. Following this trend, açaí seeds exhibited phenolic content of 3819.12–14877.99 mg GAE/100 g d.w., flavonoids of 533.15–957.13 mg QE/100 g d.w., and anthocyanins of 67.63–235.24 mg C3G/100 g d.w. In contrast, purple corn cobs presented phenolics of 3203.48–8255.30 mg GAE/100 g d.w, flavonoids of 1014.24–1628.10 mg QE/100 g d.w., and anthocyanins of 442.34–2247.35 mg C3G/100 g d.w. Antioxidant activities followed the same trend (AE < UAE < UAE+A) in DPPH, ABTS, and FRAP assays. Both extracts exhibited darker coloration when obtained by UAE+A. Regarding antimicrobial activity, the açaí seed extract obtained via UAE+A showed higher inhibition against Staphylococcus aureus, whereas the purple corn cob extract exhibited greater inhibition against Escherichia coli. These results demonstrate the potential of açaí seed and purple corn cob agro-industrial residues as sustainable sources of bioactive compounds with possible applications in the food, nutraceutical, and cosmetic industries, and confirm UAE+A as an efficient method for their recovery.
Açaí种子和紫玉米芯采用搅拌（AE）、超声辅助提取（UAE）、机械搅拌与超声联合提取（UAE+ a）三种生物活性化合物提取方法。在每种技术中，分别使用绿色溶剂，如水和30%乙醇。从总酚含量（TPC）、总黄酮含量（TFC）、总花青素含量（TAC）、抗氧化能力、颜色和抗菌活性等方面对不同提取方法和溶剂的提取效率进行了评价和比较。两种原料的萃取效率依次为UAE+A >； UAE >； AE。这一趋势后,巴西莓种子表现出GAE酚醛含量3819.12 - -14877.99毫克/ 100 g d.w。类黄酮533.15 - -957.13毫克QE / 100 g d.w。,和花青素C3G 67.63 - -235.24毫克/ 100 g d.w。相比之下,紫色的玉米穗轴了酚醛树脂的d.w GAE 3203.48 - -8255.30毫克/ 100克、类黄酮1014.24 - -1628.10毫克QE / 100 g d.w。,和花青素C3G 442.34 - -2247.35毫克/ 100 g d.w。抗氧化活动遵循相同的趋势(AE & lt;阿联酋& lt;阿联酋+ A)在DPPH, abt和收紧化验。当用UAE+A提取时，两种提取物的颜色都较深。在抗菌活性方面，通过UAE+A获得的açaí种子提取物对金黄色葡萄球菌有较高的抑制作用，而紫色玉米芯提取物对大肠杆菌有较强的抑制作用。这些结果证明了açaí种子和紫玉米芯农业工业残留物作为生物活性化合物的可持续来源的潜力，在食品、营养保健和化妆品工业中有可能应用，并证实了UAE+A是一种有效的回收方法。
{"title":"Sustainable green extraction of bioactive compounds from açaí seeds and purple corn cobs using agitation and ultrasound-assisted","authors":"Maria Cecilia Pacco-Huamaní , Michele Greque de Morais , Vilásia Guimarães Martins , Jorge Alberto Vieira Costa","doi":"10.1016/j.cep.2025.110684","DOIUrl":"10.1016/j.cep.2025.110684","url":null,"abstract":"<div><div>Açaí seed and purple corn cobs were subjected to three bioactive compound extraction methods: agitation (AE), ultrasound-assisted extraction (UAE), and a combination of mechanical agitation and ultrasound (UAE+A). In each technique, green solvents, such as water and 30 % ethanol, were used individually. This study aimed to evaluate and compare the efficiency of the extraction methods and solvents in terms of total phenolic content (TPC), total flavonoid content (TFC), total anthocyanin content (TAC), antioxidant capacity, color, and antimicrobial activity. For both raw materials, the extraction efficiency followed the order UAE+A > UAE > AE. Following this trend, açaí seeds exhibited phenolic content of 3819.12–14877.99 mg GAE/100 g d.w., flavonoids of 533.15–957.13 mg QE/100 g d.w., and anthocyanins of 67.63–235.24 mg C3G/100 g d.w. In contrast, purple corn cobs presented phenolics of 3203.48–8255.30 mg GAE/100 g d.w, flavonoids of 1014.24–1628.10 mg QE/100 g d.w., and anthocyanins of 442.34–2247.35 mg C3G/100 g d.w. Antioxidant activities followed the same trend (AE < UAE < UAE+A) in DPPH, ABTS, and FRAP assays. Both extracts exhibited darker coloration when obtained by UAE+A. Regarding antimicrobial activity, the açaí seed extract obtained via UAE+A showed higher inhibition against <em>Staphylococcus aureus</em>, whereas the purple corn cob extract exhibited greater inhibition against <em>Escherichia coli</em>. These results demonstrate the potential of açaí seed and purple corn cob agro-industrial residues as sustainable sources of bioactive compounds with possible applications in the food, nutraceutical, and cosmetic industries, and confirm UAE+A as an efficient method for their recovery.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110684"},"PeriodicalIF":3.9,"publicationDate":"2025-12-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146074183","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}
Pub Date : 2025-12-26DOI: 10.1016/j.cep.2025.110682
Zhenyue Zhang , Yu Li , Ningjie Sun , Zhancheng Guo , Ru’an Chi , Zhe Wang , Yuan Li , Bolin Sun
The addition of Mg in Zn-Al-Mg coating exacerbates the suspended dross, and the suspended dross removal is benefit to achieve defect-free coatings and cost saving on cleaning dross. The Fe-containing phase was the dominant inclusion particles in Zn-Al-Mg galvanized liquid and precipitated in quantity below 550 °C in theory. The supergravity-induced filtration with Al2O3 ceramic foam filter (Al2O3 CFF) was able to efficiently remove the Fe-containing phase. Under the condition of 450 °C for temperature, 50 for gravity coefficient and the Al2O3 CFF with porosity of 170 ppi and thickness of 20 mm, the removal ratio of Fe (RFe), loss percentage of Al (LAl), loss percentage of Mg (LMg) and the yield of zinc (YZn) reached 97 %, 40 %, 16 % and 88 %, respectively. And further the continuously supergravity-induced filtration for purification of Zn-Al-Mg galvanized liquid was achieved.
{"title":"Efficient method to filter Zn-Al-Mg galvanized liquid by using supergravity technology","authors":"Zhenyue Zhang , Yu Li , Ningjie Sun , Zhancheng Guo , Ru’an Chi , Zhe Wang , Yuan Li , Bolin Sun","doi":"10.1016/j.cep.2025.110682","DOIUrl":"10.1016/j.cep.2025.110682","url":null,"abstract":"<div><div>The addition of Mg in Zn-Al-Mg coating exacerbates the suspended dross, and the suspended dross removal is benefit to achieve defect-free coatings and cost saving on cleaning dross. The Fe-containing phase was the dominant inclusion particles in Zn-Al-Mg galvanized liquid and precipitated in quantity below 550 °C in theory. The supergravity-induced filtration with Al<sub>2</sub>O<sub>3</sub> ceramic foam filter (Al<sub>2</sub>O<sub>3</sub> CFF) was able to efficiently remove the Fe-containing phase. Under the condition of 450 °C for temperature, 50 for gravity coefficient and the Al<sub>2</sub>O<sub>3</sub> CFF with porosity of 170 ppi and thickness of 20 mm, the removal ratio of Fe (<em>R<sub>Fe</sub></em>), loss percentage of Al (<em>L<sub>Al</sub></em>), loss percentage of Mg (<em>L<sub>Mg</sub></em>) and the yield of zinc (<em>Y<sub>Zn</sub></em>) reached 97 %, 40 %, 16 % and 88 %, respectively. And further the continuously supergravity-induced filtration for purification of Zn-Al-Mg galvanized liquid was achieved.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110682"},"PeriodicalIF":3.9,"publicationDate":"2025-12-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145923516","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}
The efficient separation of olefin/paraffin mixtures is a key challenge in the petrochemical industry. Conventional extractive distillation processes often suffer from high extractant circulation rates and excessive energy consumption, making the development of new extractants with superior performance crucial for reducing process costs and enhancing separation efficiency. This study addresses the separation challenge of the n-pentane/1-pentene system. It systematically evaluates extractant selection and the extractive distillation process by integrating thermodynamic modeling, experimental measurements, and process simulation. First, the extraction performance of six commonly used organic solvents was simulated and compared using Aspen Plus software. Based on relative volatility analysis, N,N-dimethylformamide (DMF) was selected as the baseline extractant. Building on this, the COSMO-RS theoretical model was employed to predict the solubility and selectivity of various ionic liquids (ILs). Eventually, 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide ([EMIM][NTF₂])—with a selectivity of 3.01—was chosen as a co-extractant to be used in combination with DMF. Subsequently, liquid-liquid equilibrium (LLE) experiments were conducted for two ternary systems: n-pentane–1-pentene–[EMIM][NTF₂] and n-pentane–DMF–[EMIM][NTF₂]. The experimental data were correlated using the NRTL activity coefficient model to obtain reliable binary interaction parameters, and the model accuracy was verified by comparing predicted values with experimental results. Based on the obtained thermodynamic parameters, the extractive distillation processes using the pure DMF solvent system and the DMF-[EMIM][NTF₂] mixed solvent system were simulated in Aspen Plus, followed by a comparative analysis of their energy consumption. The results show that compared with the conventional DMF process, the mixed solvent system reduces the total reboiler heat load by 11.81% and the condenser heat load by 23.92%, while significantly decreasing the extractant circulation rate from 600 kg/h to 310 kg/h. These findings provide important theoretical guidance and experimental evidence for the separation of olefin/paraffin mixtures.
{"title":"Ionic liquid enhanced extractive distillation for the separation of n-pentane/1-pentene","authors":"Haoyang Xu, Mingcheng Zheng, Xiaoping Chen, Hui Tian","doi":"10.1016/j.cep.2025.110678","DOIUrl":"10.1016/j.cep.2025.110678","url":null,"abstract":"<div><div>The efficient separation of olefin/paraffin mixtures is a key challenge in the petrochemical industry. Conventional extractive distillation processes often suffer from high extractant circulation rates and excessive energy consumption, making the development of new extractants with superior performance crucial for reducing process costs and enhancing separation efficiency. This study addresses the separation challenge of the n-pentane/1-pentene system. It systematically evaluates extractant selection and the extractive distillation process by integrating thermodynamic modeling, experimental measurements, and process simulation. First, the extraction performance of six commonly used organic solvents was simulated and compared using Aspen Plus software. Based on relative volatility analysis, N,N-dimethylformamide (DMF) was selected as the baseline extractant. Building on this, the COSMO-RS theoretical model was employed to predict the solubility and selectivity of various ionic liquids (ILs). Eventually, 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide ([EMIM][NTF₂])—with a selectivity of 3.01—was chosen as a co-extractant to be used in combination with DMF. Subsequently, liquid-liquid equilibrium (LLE) experiments were conducted for two ternary systems: n-pentane–1-pentene–[EMIM][NTF₂] and n-pentane–DMF–[EMIM][NTF₂]. The experimental data were correlated using the NRTL activity coefficient model to obtain reliable binary interaction parameters, and the model accuracy was verified by comparing predicted values with experimental results. Based on the obtained thermodynamic parameters, the extractive distillation processes using the pure DMF solvent system and the DMF-[EMIM][NTF₂] mixed solvent system were simulated in Aspen Plus, followed by a comparative analysis of their energy consumption. The results show that compared with the conventional DMF process, the mixed solvent system reduces the total reboiler heat load by 11.81% and the condenser heat load by 23.92%, while significantly decreasing the extractant circulation rate from 600 kg/h to 310 kg/h. These findings provide important theoretical guidance and experimental evidence for the separation of olefin/paraffin mixtures.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"220 ","pages":"Article 110678"},"PeriodicalIF":3.9,"publicationDate":"2025-12-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145881304","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 : 2025-12-24DOI: 10.1016/j.cep.2025.110679
Kouadio Jean Eric-Parfait Kouamé , Ebenezer Ola Falade , Yanyun Zhu , Yunyun Zheng , Ishtiaq Ahmad , Bingge Liu , Ibourahema Coulibaly , Xingqian Ye
Hemicellulose-rich insoluble dietary fibers (IDFs) derived from distillers’ grains of wheat, sorghum, and corn offer considerable potential as health-promoting ingredients. However, their properties depend on extraction and modification methods. This study compared conventional (ultrasound-UAE, microwave-MAE, and alkali-assisted-AK) and intensified hybrid methods, focusing on microwave–alkaline (MK) and ultrasound–microwave–alkaline (UMK) treatments and their enzymatic variants (MMK and MUMK). These integrated strategies combined mechanical, thermal, and biochemical actions to optimize fiber architecture and functionality. Intensified processes enhanced porosity, hydrophilicity, and surface reactivity, leading to superior hydration, adsorption, and probiotic performance. MUMK showed the highest water-holding capacity (4.95 g/g; +101 % vs DGs) and functionality (GFI = 78 %), while UMK exhibited the greatest cholesterol adsorption (36.07 mg/g) and pH stability (pH7/pH2 = 2.46). Biologically, intensified treatments improved Lactobacillus acidophilus growth and adhesion, with MK showing the best fermentation efficiency (AUC = 41.11 OD·h) and MMK reaching 85.96 % adhesion. These findings demonstrate that coupling mechanical disruption, alkaline hydrolysis, and enzymatic depolymerization enhances reactive sites and probiotic–fiber interactions. Overall, MK, UMK, MMK, and MUMK effectively convert distillers’ grains into multifunctional IDFs with balanced hydration, lipid-binding, and probiotic-supporting properties, providing a sustainable valorization route aligned with SDG 12 (Responsible Consumption and Production).
{"title":"Sustainable valorization of distillers’ grains: Intensified extraction and modification strategies for functional fiber development","authors":"Kouadio Jean Eric-Parfait Kouamé , Ebenezer Ola Falade , Yanyun Zhu , Yunyun Zheng , Ishtiaq Ahmad , Bingge Liu , Ibourahema Coulibaly , Xingqian Ye","doi":"10.1016/j.cep.2025.110679","DOIUrl":"10.1016/j.cep.2025.110679","url":null,"abstract":"<div><div>Hemicellulose-rich insoluble dietary fibers (IDFs) derived from distillers’ grains of wheat, sorghum, and corn offer considerable potential as health-promoting ingredients. However, their properties depend on extraction and modification methods. This study compared conventional (ultrasound-UAE, microwave-MAE, and alkali-assisted-AK) and intensified hybrid methods, focusing on microwave–alkaline (MK) and ultrasound–microwave–alkaline (UMK) treatments and their enzymatic variants (MMK and MUMK). These integrated strategies combined mechanical, thermal, and biochemical actions to optimize fiber architecture and functionality. Intensified processes enhanced porosity, hydrophilicity, and surface reactivity, leading to superior hydration, adsorption, and probiotic performance. MUMK showed the highest water-holding capacity (4.95 g/g; +101 % vs DGs) and functionality (GFI = 78 %), while UMK exhibited the greatest cholesterol adsorption (36.07 mg/g) and pH stability (pH7/pH2 = 2.46). Biologically, intensified treatments improved <em>Lactobacillus acidophilus</em> growth and adhesion, with MK showing the best fermentation efficiency (AUC = 41.11 OD·h) and MMK reaching 85.96 % adhesion. These findings demonstrate that coupling mechanical disruption, alkaline hydrolysis, and enzymatic depolymerization enhances reactive sites and probiotic–fiber interactions. Overall, MK, UMK, MMK, and MUMK effectively convert distillers’ grains into multifunctional IDFs with balanced hydration, lipid-binding, and probiotic-supporting properties, providing a sustainable valorization route aligned with SDG 12 (Responsible Consumption and Production).</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"220 ","pages":"Article 110679"},"PeriodicalIF":3.9,"publicationDate":"2025-12-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145837815","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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