Chemical Engineering Research & Design最新文献

{"title":"Analogy of electrodialysis mass exchangers to heat exchangers","authors":"Omar A. AlRafee ,&nbsp;Bilal A. Qureshi","doi":"10.1016/j.cherd.2025.09.008","DOIUrl":"10.1016/j.cherd.2025.09.008","url":null,"abstract":"<div><div>Heat exchangers and electrodialysis (ED) systems share a strong analogy. A method similar to <em>ε</em>-NTU is developed for designing ED mass exchangers that can be called <em>ε</em>-MTU (effectiveness-mass transfer units). The effectiveness is defined as the system transport ratio over its maximum possible value. Two different modelling results are shown depending on whether water transport is accounted for (as in a high salinity source) or not (as in brackish water). The equations that relate the MTU, the concentration ratio (CR), and the resistance ratio (ER) to other system parameters such as effectiveness are developed. Finally, the model is tested by comparing its results to both salinity levels. The errors found are ∼0.02 % for the brackish water source (3500 ppm) and ∼0.44 % for the high salinity source (150,000 ppm). Therefore, the <em>ε</em>-MTU model developed can help to design and evaluate ED systems in a robust manner.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"222 ","pages":"Pages 141-154"},"PeriodicalIF":3.9,"publicationDate":"2025-09-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145047061","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}

{"title":"A CFD based approach to the modelling of pressure drop and flow pattern evolution through industrial filter systems","authors":"Joseph D. Bennett ,&nbsp;Mark C.T. Wilson ,&nbsp;Nikil Kapur ,&nbsp;Peter K. Jimack ,&nbsp;Richard P. Maltby ,&nbsp;M. Kieran Looney","doi":"10.1016/j.cherd.2025.08.044","DOIUrl":"10.1016/j.cherd.2025.08.044","url":null,"abstract":"<div><div>A macroscopic CFD approach has been developed to simulate pressure drop and flow pattern evolution in industrial filter systems, specifically for polymer melt filtration in plastic film casting. By coupling filter permeability to local fluid velocity using filter blocking models, the approach avoids direct simulation of particle transport, making it computationally efficient. The model has been validated against a complex real-world filter geometry, accurately capturing pressure drop trends and revealing how flow patterns evolve and filter elements block over time. This approach enables more efficient design and analysis of industrial filtration systems.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"222 ","pages":"Pages 177-190"},"PeriodicalIF":3.9,"publicationDate":"2025-09-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145047060","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}

{"title":"A ZnCl2-based pH-responsive low-melting mixture solvent for extracting psoralen from Ficus carica L. leaves: Insights from experimental and mechanism investigation","authors":"Mengfei Tian ,&nbsp;Mengying Zhang ,&nbsp;Kuiwang Chen ,&nbsp;Jie Liu ,&nbsp;Jiahui Gong ,&nbsp;Wenxue Sun ,&nbsp;Chunying Li ,&nbsp;Chunjian Zhao","doi":"10.1016/j.cherd.2025.09.007","DOIUrl":"10.1016/j.cherd.2025.09.007","url":null,"abstract":"<div><div><em>Ficus carica</em> L. is one of the most ancient fruit crops which is being cultivated in sub-tropical regions worldwide. <em>Ficus carica</em> L. leaves, which are considered agricultural by-products, are frequently discarded, leading to the wastage of biological resources. However, <em>Ficus carica</em> L. leaves are valuable source of psoralen (PSO) that displays multiple bioactive properties beneficial for the treatment of osteoporosis, viruses, bacteria, and inflammation. Therefore, enhancing the efficient isolation of PSO from <em>Ficus carica</em> L. leaves using sustainable solvents has been a focus. In this study, a switchable ZnCl₂-based pH-responsive low-melting mixture solvent (LoMMS-ZnCl₂) for sustainable extraction of PSO from <em>Ficus carica</em> L. leaves was developed. The LoMMS-ZnCl₂ system, consisting of ZnCl₂, DL-menthol, and octanoic acid (OA), demonstrates exceptional performance with an extraction yield of 30.68 mg·g⁻¹ for PSO. After removing ZnCl₂ from the LoMMS-ZnCl₂ system using reverse extraction, the polarity of LoMMS was changed rapidly by pH stimulus, resulting in in-situ separation and enrichment of PSO. The extraction mechanism was further investigated by DFT simulation and nuclear magnetic resonance analysis, revealing that hydrogen bonding, halogen bonding, coordination bonding, and Van der Waals forces are the primary intermolecular interactions between LoMMS-ZnCl₂ and PSO. This strategy highlights the potential of LoMMS-ZnCl₂ for efficient and sustainable extraction of PSO from <em>Ficus carica</em> L. leaves. Furthermore, it also offers a valuable reference for utilizing LoMMS-ZnCl₂ in the extraction of natural bioactive compounds from various plant materials.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"222 ","pages":"Pages 270-285"},"PeriodicalIF":3.9,"publicationDate":"2025-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145099599","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}

{"title":"Study on emergency plugging mechanism after BOP seal failure under UHP blowout conditions in natural gas wells","authors":"Jiajia Jing ,&nbsp;Jilong Zou ,&nbsp;Wei Luo ,&nbsp;Yonggang Deng ,&nbsp;Wenbin Chen ,&nbsp;Feilong Liao","doi":"10.1016/j.cherd.2025.09.003","DOIUrl":"10.1016/j.cherd.2025.09.003","url":null,"abstract":"<div><div>Once a natural gas well blowout occurs, the liquid fluid in the well will be drained in a short time, and the wellhead will rapidly transform into an ultra-high pressure and large displacement blowout environment dominated by natural gas. However, the suspension capacity and motion state of particles in the blowout fluids of natural gas wells and oil wells vary greatly. Therefore, it is of great significance to study whether the particle bridging method can be used for emergency plugging in the case of blowout preventer (BOP) sealing failure in ultra-high pressure (70 MPa) natural gas well blowout conditions. Based on an analysis of the common failure modes of BOPs, this paper establishes a plugging model for BOP. The reliability of the model is verified through a large-scale BOP plugging experimental system, and the mechanism of emergency plugging under gas well blowout conditions is studied using this model. The results show that the plugging efficiency is lower than that of oil wells but remains effective. The \"1/3 bridging rule\" is not applicable to particle bridging plugging under ultra-high pressure and large displacement conditions. Plugging efficiency is negatively correlated with particle size and positively correlated with particle concentration. There is no significant effect of pumping displacement or particle injection volume on plugging efficiency.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"222 ","pages":"Pages 165-176"},"PeriodicalIF":3.9,"publicationDate":"2025-09-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145047059","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}

{"title":"Bubble-assisted multiphase flushing of settled solids in pipelines: Insights from integrated experiments and computational fluid dynamics simulations","authors":"Sadman Shahriar ,&nbsp;Shubham Sharma ,&nbsp;Wenming Zhang ,&nbsp;Xuehua Zhang","doi":"10.1016/j.cherd.2025.08.026","DOIUrl":"10.1016/j.cherd.2025.08.026","url":null,"abstract":"<div><div>Water flushing during slurry transportation in pipelines requires a large amount of water to ensure operational efficiencies and system safety. To develop effective flushing strategy with reduced water consumption, in this study we combined experimental measurements with numerical simulations to correlate removal dynamics of settled sandbeds in horizontal pipelines under clean water and bubble-laden flows. Experiments were conducted in a labscale pipeline under varying solid deposit height, Reynolds number (Re) (12,070-18,020), and particle sizes (45–<span><math><mrow><mn>425</mn><mspace></mspace><mi>μ</mi><mi>m</mi></mrow></math></span>), alongside a novel bubble-assisted approach to enhance flushing efficiency. Key findings reveal that an increase in bed level height prolongs the flushing period, due to the interparticle friction at a dense solid bed in redispersing particles. The flow condition critically governs removal efficiency: increasing Reynolds number from 12,070 to 15,810 boosts particle mobilization and shortens flushing time by more than 50%. However, a trivial improvement occurs at the higher range of Re (15,810-18,020), possibly due to turbulence saturation. Particle size impacts solid mobilization, with fine particles (<span><math><mrow><mo>&lt;</mo><mn>100</mn><mspace></mspace><mi>μ</mi><mi>m</mi></mrow></math></span>) flushing faster than coarse counterparts (<span><math><mrow><mo>&gt;</mo><mn>300</mn><mspace></mspace><mi>μ</mi><mi>m</mi></mrow></math></span>), attributed to their higher surface area-to-volume ratio, amplifying frictional drag. Notably, introducing bubbles as a secondary phase increases the flushing rate by 10%–50%, with micro-nanobubbles (MNBs) (<span><math><mrow><mo>&lt;</mo><mn>100</mn><mspace></mspace><mi>μ</mi><mi>m</mi></mrow></math></span>) demonstrating superior efficacy. This study highlights the potential of bubble-assisted flushing as an effective and clean strategy for reducing water consumption and mitigate downtime in industrial pipeline flushing process.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"222 ","pages":"Pages 86-107"},"PeriodicalIF":3.9,"publicationDate":"2025-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145020925","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}

{"title":"Multi-scale motion characteristics of coarse particles in a swirling flow pneumatic conveying system with the discrete wavelet transform","authors":"Fei Yan ,&nbsp;Mengfei Zhang ,&nbsp;Shihao Cheng ,&nbsp;Yu Zongbing ,&nbsp;Jian Zhang","doi":"10.1016/j.cherd.2025.09.004","DOIUrl":"10.1016/j.cherd.2025.09.004","url":null,"abstract":"<div><div>In order to achieve low-speed operation of pneumatic conveying, this paper proposes a new type of swirling flow blade that promotes particle suspension and acceleration by controlling the generation of swirling. Firstly, the energy-saving efficiency of swirling flow was evaluated in term of the pressure drop and power consumption coefficient, and it is revealed that the optimal conveying velocity and power consumption coefficient are reduced for the swirling flow compared to the conventional axial flow, the maximum reduction rates are 12.99 % and 9.47 %, respectively. Then, to master the particle motion characteristics for swirling flow conveying, the electrical capacitance tomography (ECT) and particle image velocimetry (PIV) were employed to analyze the particle concentration and velocity distributions, the results show that the particle concentration of swirling flow is lower than the conventional axial flow around the bottom of the pipe, and the particle velocity of swirling flow is higher than the conventional axial flow, suggesting that the particles are easily suspended and accelerated for the swirling flow conveying. The core innovation lies in the analysis of the particle velocity field by utilizing one-dimensional discrete wavelet transform (DWT) and continuous wavelet transform (CWT), which reveals the energy-saving mechanism of swirling flow conveying. The results show that using blade enhances large-scale velocity fluctuations and particle suspension, leading to lower center frequencies. It also increases pulsation intensity at pipe bottom, stabilizes small-scale motion at pipe top, and improves spatial correlation.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"222 ","pages":"Pages 235-250"},"PeriodicalIF":3.9,"publicationDate":"2025-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145061226","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}

{"title":"A hybrid stochastic-dynamic framework for reliable alarm generation: Integrating GMM-based probability patterns with temporal evidence fusion","authors":"Xu Weng ,&nbsp;Xiaobin Xu ,&nbsp;Xiping Wang ,&nbsp;Li Yang ,&nbsp;Zhe Zhou","doi":"10.1016/j.cherd.2025.08.043","DOIUrl":"10.1016/j.cherd.2025.08.043","url":null,"abstract":"<div><div>Industrial alarm systems typically utilize critical process variables for anomaly detection. This paper introduces a probabilistic evidence fusion framework that integrates long-term probabilistic trends with short-term temporal dynamics to enhance robust alarm generation. For modeling long-term probabilistic trends, Gaussian mixture models (GMMs) are employed to estimate baseline probability density functions (PDFs) for normal and abnormal states based on historical data. Online samples are then converted into probabilistic evidence via normalized likelihood comparisons against these baseline PDFs. To address short-term characteristics, a temporal evidence combination mechanism is developed, which dynamically fuses current and historical probabilistic evidence using the evidence reasoning (ER) rule. Alarms are subsequently generated based on the fused results. This dual-scale modeling approach effectively captures both persistent stochastic patterns and transient behaviors, thereby ensuring reliable detection across various operational regimes. Numerical simulations and case studies of motor fault detection validate superior performance of the proposed framework in terms of detection accuracy compared to conventional methods, particularly in handling gradual fault progression and transient disturbances.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"222 ","pages":"Pages 73-85"},"PeriodicalIF":3.9,"publicationDate":"2025-09-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145027491","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}

{"title":"Novel integrated EMPC framework for fluid catalytic cracking unit under feedstock uncertainty","authors":"Bin Wei ,&nbsp;Bingrui Zhang ,&nbsp;Liming Che ,&nbsp;Haiqiang Lin ,&nbsp;Hua Zhou","doi":"10.1016/j.cherd.2025.09.001","DOIUrl":"10.1016/j.cherd.2025.09.001","url":null,"abstract":"<div><div>The conventional economic model predictive control (EMPC) framework faces challenges in achieving optimal operation of fluid catalytic cracking units (FCCUs) under feedstock uncertainty. To overcome this limitation, a novel hierarchical EMPC framework integrating a soft sensor for real-time estimation of feedstock properties is proposed in this work. Specifically, an innovative soft sensor is developed, combining oil classification strategy with ensemble learning to accurately predict feedstock properties. This soft sensor is coupled with pseudo-components method to mitigate the effects of feedstock variability, thereby enabling robust dynamic optimization within the economic optimization layer. Simulation results across various feedstock disturbance scenarios demonstrate that the proposed framework outperforms the conventional EMPC approach by rapidly identifying the plant optimum in response to feedstock variations. These validate the proposed framework’s ability to significantly enhance the economic performance of FCCUs under conditions of feedstock uncertainty.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"222 ","pages":"Pages 108-120"},"PeriodicalIF":3.9,"publicationDate":"2025-09-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145020926","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}

{"title":"High-temperature honeycomb molecular sieve catalyst for efficient and safe NOx removal in gas-fired internal combustion engine","authors":"Chenhui Hu ,&nbsp;Kaimin Du ,&nbsp;Zuoxi Zhuo ,&nbsp;Chunhong Liu ,&nbsp;Hongbing Lv ,&nbsp;Wanjue Wang","doi":"10.1016/j.cherd.2025.08.039","DOIUrl":"10.1016/j.cherd.2025.08.039","url":null,"abstract":"<div><div>To address the challenges of efficient and ‌safe denitrification under actual flue gas conditions of internal combustion engine, high-temperature SCR molecular sieve catalyst were prepared and evaluated both in laboratory scale and industrial scale. A comprehensive characterization via TG, XRD, N₂ adsorption-desorption, SEM, and TEM confirmed the robust thermal stability of the molecular sieves catalyst. The molecular sieve catalyst system was commissioned in a 4275 kW distributed natural gas internal combustion engine demonstration facility and successfully passed the 72 h trial running, achieving with over 94 % NO_<em>x</em> conversion efficiency‌ and less than 40 mg/m³ outlet NO_x concentration at a temperature range of ‌440–525 °C. Compared to conventional V-based catalyst, the molecular sieve catalyst not only achieved additional reductions of 2 kg/h NO_<em>x</em> and 38 kg/h CO₂ emissions, along with a nearly 2 % improvement in internal combustion engine efficiency, but also effectively mitigated the risk of system shutdown caused by low cylinder temperatures in exhaust gas purification systems, being considered as a promising catalyst for high-temperature applications, including gas-fired, hydrogen/ammonia-fueled, and biogas internal combustion engines.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"221 ","pages":"Pages 588-597"},"PeriodicalIF":3.9,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144925237","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}

{"title":"Investigation of sheet molding during through air drying of tissue paper: A comparative numerical and experimental study of the solid content","authors":"Kamal Rezk ,&nbsp;Magnus Lestelius ,&nbsp;Agne Swerin ,&nbsp;Mikael Danielsson ,&nbsp;Björn Sjöstrand","doi":"10.1016/j.cherd.2025.08.037","DOIUrl":"10.1016/j.cherd.2025.08.037","url":null,"abstract":"<div><div>Through Air Drying (TAD) technology enhances high-quality tissue-grade paper production by shaping a wet paper web on a structured fabric using vacuum or molding boxes, followed by hot air displacement drying over TAD cylinders. This study uses CFD modeling with COMSOL Multiphysics to understand drying rate during the molding process better. Two-dimensional models of paper sheets estimated solid content over vacuum time. Tissue samples were generated using COMSOL’s interface with MATLAB, enabling a random fiber distribution. Fluid flow and moisture transport were simulated by coupling the Navier-Stokes and advection-diffusion equations, while Darcy’s law with inertial correction described fluid migration within fibers, considering equilibrium between moist air and liquid water. Simulations examined the impact of refining levels and fiber compositions for basis weights from 15 to 30 g/m². Material properties, including porosity and permeability, were calibrated with laboratory tests and validated in pilot experiments. Results showed that increased refining of softwood pulp significantly affects porosity and initial dryness, achieving reasonable agreement between predicted and actual tissue dryness. The calibrated models could be a first step to improve energy efficiency in TAD processes, paving the way for more sustainable tissue-making methods.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"221 ","pages":"Pages 598-609"},"PeriodicalIF":3.9,"publicationDate":"2025-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144925238","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}