Chemical Engineering Research & Design最新文献

{"title":"Structure–property relationships in tertiary amine–functionalized poly(DMAPAA-co-DMAPMA) hydrogels for acetic acid recovery","authors":"Seyed Amin Mirmohammadi,&nbsp;Hirotaka Wakamiya,&nbsp;Takehiko Gotoh,&nbsp;Toshikazu Suenaga,&nbsp;Yutaka Nakashimada,&nbsp;Satoshi Nakai","doi":"10.1016/j.cherd.2026.07.038","DOIUrl":"10.1016/j.cherd.2026.07.038","url":null,"abstract":"<div><div>This study investigates the adsorption and recovery of acetic acid (AA) using tertiary amine-based hydrogels through a three-stage experimental approach. First, hydrogels synthesized from DMAPAA, DMAPAA-Q, DMAPMA, DMAEA, and DMAEM were evaluated to clarify the influence of monomer structure, protonation behavior, and swelling on AA adsorption. Among them, the DMAPAA hydrogel exhibited the highest adsorption capacity at neutral pH. Kinetic analysis showed that adsorption follows a pseudo-second-order model, with an equilibrium capacity of 1.66 mmol/mL-wet gel. To improve desorption performance, DMAPAA–DMAPMA copolymer hydrogels were developed. By optimizing monomer concentration, a molar ratio of 1500:1500 was identified as optimal. This copolymer exhibited a 53% increase in desorption efficiency compared to the DMAPAA hydrogel, while maintaining comparable adsorption capacity. Continuous desorption experiments demonstrated rapid AA release, with more than 60% recovered within 84 min and approximately 96% by 240 min. The copolymer also showed stable performance over ten adsorption–desorption cycles and enabled up to a fourfold increase in AA concentration. Finally, acidity-assisted organic solvent extraction effectively transferred AA into the organic phase, highlighting its suitability as a downstream recovery process. Overall, the results demonstrate that DMAPAA–DMAPMA hydrogels provide an efficient and regenerable platform for AA adsorption and multistage recovery.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"232 ","pages":"Pages 529-543"},"PeriodicalIF":4.0,"publicationDate":"2026-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148637521","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":"Design and formulation of freeze-dried compact-like powders using sub-micron emulsions as a binder","authors":"Shola Mathys,&nbsp;Déborah Gilles,&nbsp;Jacqueline Resende de Azevedo,&nbsp;Karen Kamel,&nbsp;Marie-Alexandrine Bolzinger","doi":"10.1016/j.cherd.2026.07.036","DOIUrl":"10.1016/j.cherd.2026.07.036","url":null,"abstract":"<div><div>This work presents a proof of concept for a novel methodology to produce compact-like powders without relying on conventional mechanical compaction. Sub-micron emulsions (SMEs) were used as a binder to wet a powder mixture, followed by freeze-drying to remove water and form a cohesive product. Different SMEs, containing octyldodecanol, butylene glycol cocoate, butylene glycol dicaprylate/dicaprate and caprylic/capric triglyceride were studied. Lyophilized formulations were then prepared with wetting ratios (sub-micron emulsions-to-powder mixture, SME/PM) ranging from 0.5:1–2:1 using two powder substrates, talc and mica, to assess their effects on visual aspect, pick-up, hardness, mechanical resistance, and residual water content. All freeze-dried powders exhibited excellent cohesion, resisted drop tests, and retained low water content (&lt; 2.5%). The properties (visual aspect, pick-up and hardness) of the compact-like powders were influenced by various parameters, including the wetting ratio, filler and oil types. These results demonstrate that freeze-drying of a powder mixture wetted with SMEs provides a promising alternative to traditional compaction, producing cohesive powders suitable for cosmetic applications.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"232 ","pages":"Pages 706-716"},"PeriodicalIF":4.0,"publicationDate":"2026-08-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148637575","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Optimization design and performance study of a concentric two-stage cyclonic de-liquidizer","authors":"Zicheng Liu,&nbsp;Yanting Zhang,&nbsp;Xiaolong Zhao,&nbsp;Huizhuo Zhang,&nbsp;Guilin Zhang,&nbsp;Yu Yang,&nbsp;Guanxiang Qiao,&nbsp;Zhangcong Huang","doi":"10.1016/j.cherd.2026.06.043","DOIUrl":"10.1016/j.cherd.2026.06.043","url":null,"abstract":"<div><div>To mitigate environmental pollution from venting high-salinity gas wells in Northern Shaanxi, a concentric two-stage cyclonic de-liquidizer was proposed and optimized. Structural parameters were screened via Plackett–Burman design and optimized using steepest ascent and Box–Behnken response surface methodology combined with numerical simulations. The optimal parameters were: two-stage diameter ratio <em>μ= 0.26</em>, secondary swirl chamber aspect ratio <em>n</em>_<em>2</em>= 1.48, primary inlet tangential inclination <em>γ</em>_<em>1</em>= 35°, and overflow pipe insertion depth <em>h</em> = 1425 mm. The optimized separator achieved a peak separation efficiency of 99.88% under inlet flow rates of 5 × 10⁴∼30 × 10⁴ m³/d and liquid volume fractions of 0.01∼1%. Efficiency increased significantly with flow rate up to a critical limit of 25 × 10⁴ m³/d and remained stable under inlet pressures of 1∼6 MPa. An optimal operating window of 20 × 10⁴∼25 × 10⁴ m3/d with liquid fraction below 0.2% is recommended, requiring 4∼6 MPa driving pressure, consistently yielding &gt; 98% efficiency. This study provides a theoretical basis and design guidance for high-salinity gas well venting pretreatment.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"231 ","pages":"Pages 576-594"},"PeriodicalIF":4.0,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148452791","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":"Assessing the synergies between textile sludge and low-density polyethylene (LDPE) Co-pyrolysis: Experimental insights and machine learning","authors":"Arslan Khan,&nbsp;Asif Hussain Khoja,&nbsp;Erum Pervaiz,&nbsp;Waheed Miran,&nbsp;Dagmar Juchelková,&nbsp;Salman Raza Naqvi,&nbsp;Imtiaz Ali","doi":"10.1016/j.cherd.2026.06.007","DOIUrl":"10.1016/j.cherd.2026.06.007","url":null,"abstract":"<div><div>Co-pyrolysis leverages complementary properties of diverse feedstock to improve conversion efficiency, offering a sustainable route for integrated waste management and energy production. This study investigates reaction kinetics, synergistic interactions, product analysis, and machine learning prediction for co-pyrolyzing textile sludge (TS) with low-density polyethylene (LDPE) at mass ratios of 25%TS:75%LDPE, 50%TS:50%LDPE, and 75%TS:25%LDPE. Thermogravimetric analysis was performed from room temperature to 1000 °C at 2.5, 5, 7.5, and 10 °C/min. Model-free methods like linear differential Friedman, linear integral Kissinger-Akahira-Sunose (KAS), and Ozawa-Flynn-Wall (OFW) were used to evaluate kinetic parameters. Average <em>E</em>_<em>a</em> (Friedman) was 262.61 kJ/mol for 25%TS:75%LDPE, 178.34 kJ/mol for 50%TS:50%LDPE and 267.80 kJ/mol for 75%TS:25%LDPE. Furthermore, positive synergistic interactions were most significant between 450–600 °C with the dominant peaks at 500 °C for all blended samples. Fixed-bed co-pyrolysis of the optimum blend (50%TS:50%LDPE) at 500 °C produced 22% pyro-oil, 34% biochar, and 44% gaseous products. Moreover, obtained pyro-oil comprises of hydrocarbons and long-chain aliphatic derivatives, N-containing heterocycles and amines, carboxylic and phenolic acids, ethers and acetal, phthalates, and the carbohydrate derivatives. Furthermore, machine learning models like Artificial neural networks (ANNs), Classification &amp; regression trees (C&amp;RT), and support vector machine (SVM) were developed to predict <em>E</em>_<em>a</em>. ANN performed best for 50%TS:50%LDPE and 75%TS:25%LDPE (R² = 0.999 and 0.997) while C&amp;RT excelled for 25%TS:75%LDPE (R² = 0.988). Findings demonstrate pronounced synergistic interactions and integrated kinetic and machine learning prediction strategy for converting diverse waste into energy.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"231 ","pages":"Pages 251-267"},"PeriodicalIF":4.0,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148452859","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Performance optimization of CO2 hydrogenation to methanol in the fixed-bed reactor with fractal fins","authors":"Zilong Xu,&nbsp;Zhe Li,&nbsp;Guiyao Hu,&nbsp;Lixiang Wan,&nbsp;Wenda Xu,&nbsp;Jiyong Kuang,&nbsp;Baoqing Liu","doi":"10.1016/j.cherd.2026.06.014","DOIUrl":"10.1016/j.cherd.2026.06.014","url":null,"abstract":"<div><div>CO₂ hydrogenation to methanol has attracted considerable attention as a promising pathway toward sustainable development. This study introduced a novel fixed-bed reactor featuring a fractal-fin cooling structure, providing an effective strategy to overcome heat-transfer limitations. A computational fluid dynamics model incorporating detailed reaction kinetics was rigorously developed to investigate the performance characteristics of the reactor. Furthermore, a multi-objective optimization framework integrating response surface methodology with the non-dominated sorting genetic algorithm-II was established. The results indicated that, compared with the adiabatic reactor, the reactor with finned-tube cooling effectively increased methanol yield by 29%. Increasing the fin number and the fractal angle progressively enhanced the reactor’s heat transfer capability, resulting in a higher methanol mole concentration and a lower CO mole concentration. Additionally, as the inlet temperature increased, CO₂ conversion gradually rose and eventually stabilized, while methanol selectivity continuously declined. A higher temperature difference along the finned-tube wall was found to improve methanol selectivity. The operating parameters of the reactor were optimized to maximize both methanol selectivity and CO₂ conversion, and the Pareto-optimal solution set exhibited significant improvements in both metrics compared with the base-case conditions.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"231 ","pages":"Pages 317-331"},"PeriodicalIF":4.0,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148452860","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":"Collaborative regulation of a dust control and two–stage dust collection system for different cutting zones","authors":"Jun Wu,&nbsp;Xiaoyan Gong,&nbsp;Tao Song,&nbsp;Jiangming Ding,&nbsp;Zhongde Huang,&nbsp;Haoran Fu,&nbsp;Xinyu Wang,&nbsp;Xiaoze Pei","doi":"10.1016/j.cherd.2026.06.015","DOIUrl":"10.1016/j.cherd.2026.06.015","url":null,"abstract":"<div><div>With the advancement of full-face rapid excavation technology in coal mine roadways, dust generation has increased sharply, intensifying explosion risks and occupational health hazards. Conventional ventilation-volume control cannot meet the requirements of precise dust control under different cutting zones. To address this, a dust control and two-stage dust collection collaborative regulation system was developed, and differentiated collaborative regulation strategies were proposed for different cutting zones. The system integrates airflow regulation, first-stage near-source dust collection, and second-stage residual dust interception. Taking a fully mechanized excavation face in a northern Shaanxi coal mine as the case study, an airflow-dust coupled numerical model was established using the Euler–Lagrange approach and the Realizable k–ε turbulence model, and validated using field measurements. Based on simulated dust concentration distributions under different regulation parameters, a bi-objective optimization model was constructed using the response surface method, with dust concentration at the driver's position and average dust concentration in the breathing zone on the return-air side as the objective functions. The model was solved with the NSGA-II algorithm to obtain optimized collaborative regulation strategies. An experimental platform for the system was designed to verify model accuracy and dust reduction performance. The maximum relative errors of dust concentrations at the driver's position and in the breathing zone on the return-air side were 8.15% and 9.04%, respectively. After applying the optimized regulation strategies, the average dust concentration at the driver's position decreased by 59.74%, and that in the breathing zone on the return-air side decreased by 61.45%.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"231 ","pages":"Pages 268-283"},"PeriodicalIF":4.0,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148452864","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":"Green hydrogen-assisted decarbonization of coal-to-ammonia process: Process integration, system analysis and techno-economic assessment","authors":"Yuan Li,&nbsp;Wei Zhou,&nbsp;Dongliang Chen,&nbsp;Chao Ren,&nbsp;Qiwang Hou,&nbsp;Zhonglin Zhang,&nbsp;Xiaogang Hao,&nbsp;Xiao Du,&nbsp;Guoqing Guan","doi":"10.1016/j.cherd.2026.06.023","DOIUrl":"10.1016/j.cherd.2026.06.023","url":null,"abstract":"<div><div>A green hydrogen-assisted route for decarbonizing coal-to-ammonia production was proposed by integrating alkaline water electrolysis with a conventional coal-based ammonia process. A system-level framework combining Aspen Plus simulation, heat integration, exergy analysis, and techno-economic assessment was established to evaluate the performance of the integrated system. The results show that green hydrogen addition reshapes the hydrogen-carbon balance of the process and reduces the dependence on the gasification-shift pathway. A preferred green hydrogen coupling ratio of 35–40% was identified as a compromise between carbon mitigation and economic performance. Under this condition, the hydrogen and nitrogen utilization efficiencies increase from 34.50% to 57.78% and from 67.78% to 70.82%, respectively. After pinch-based heat integration, the cold and hot utility demands are reduced by 29.1% and 41.5%, respectively, while the overall energy and exergy efficiencies reach 51.06% and 40.7%. A screening-level cradle-to-gate GWP assessment further shows that the proposed process has an estimated GWP of approximately 3.12 t CO₂-eq/t NH₃ under the 35% green hydrogen coupling and low-carbon heat supply assumptions. The total capital investment is estimated at 4.88 billion CNY, with an ammonia production cost of 2400–2480 CNY/t NH₃, an internal rate of return of 6.88%, and a discounted payback period of 10.23 years. Under the baseline assumptions of this study, one-factor sensitivity analysis indicates that the proposed process becomes economically more competitive when the electricity price decreases below 0.18 CNY/kWh or the carbon price increases above 150 CNY/t CO₂; these thresholds should be interpreted as conditional values rather than general break-even points.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"231 ","pages":"Pages 464-483"},"PeriodicalIF":4.0,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148452768","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":"The improvement effect and mechanism of surfactants on the fluidity of coal tar","authors":"Lei Zhang,&nbsp;Xiaodiao Dai,&nbsp;Lei Zhang,&nbsp;Ruikang Song,&nbsp;Haocheng Zhao,&nbsp;Bei Wang,&nbsp;Yongping Liang,&nbsp;Junfeng Ren,&nbsp;Shizhe Gao","doi":"10.1016/j.cherd.2026.06.027","DOIUrl":"10.1016/j.cherd.2026.06.027","url":null,"abstract":"<div><div>During in-situ underground coal pyrolysis, the tar generated ascends from the high-temperature zone toward the surface and cools naturally. This cooling induces a sharp viscosity increase that blocks the extraction channel, impeding engineering implementation. To address this obstruction, this study systematically evaluates the viscosity-reduction performance of five chemical agents—sodium dodecyl sulfate (SDS), sodium dodecyl benzene sulfonate (SDBS), anhydrous betaine (BA), polyvinyl alcohol (PVA), and Tween 80—at 30 °C, simulating extraction conditions. Reduction ratios are measured across 1–9 wt% dosage. Contact angle, surface tension, and polarized-light microscopy reveal the underlying mechanisms. Results identify BA as the optimal agent, delivering a maximum viscosity reduction of 34.13% at 5 wt% dosage, representing a 2.2-fold improvement over simple water dilution (15.73%). This value is comparable to the ∼30% reduction reported for heavy oils using similar nonionic surfactants. Its superior performance originates from a marked decrease in oil–water interfacial tension and the formation of uniformly dispersed, near-spherical oil droplets. PVA, in contrast, increases system viscosity because of incompatibility with the tar. This work presents the first systematic comparison of anionic, zwitterionic, and nonionic surfactants for tar viscosity reduction under in-situ pyrolysis extraction conditions. The findings provide directly transferable guidance for field agent selection and dosage optimization.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"231 ","pages":"Pages 392-400"},"PeriodicalIF":4.0,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148452863","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":"Meshed metal wire for enhanced heat transfer inside a packed bed reactor: A simulation and experimental verification study","authors":"Shiyi Li,&nbsp;Yiming He,&nbsp;Xixi Luo,&nbsp;Min Sheng,&nbsp;Yunfei Gao","doi":"10.1016/j.cherd.2026.06.009","DOIUrl":"10.1016/j.cherd.2026.06.009","url":null,"abstract":"<div><div>Fixed-bed reactors often face inefficient heat transfer due to the low thermal conductivity of conventional catalyst packings, leading to temperature gradients and hotspots. This study proposes integrating meshed Al metal wire with alumina catalysts to enhance heat transfer in fixed-bed reactors. Simulations and experiments were conducted for four configurations: empty, loosely packed alumina bed, densely packed alumina bed, and alumina + meshed metal wire. The results show that the meshed metal wire (thermal conductivity 238 W/(m·K)) significantly improves temperature uniformity, reducing the temperature standard deviation to 19.62 °C, which is 75.4% lower than densely packed alumina alone. It also enhances convective flow while maintaining a manageable pressure drop (0.30 Pa), and the overall heat transfer coefficient remains consistently higher than that of catalyst-only configurations over the investigated Re range. A transient simulation under reactive conditions further verifies that the meshed metal wire can effectively dissipate reaction heat and suppress temperature accumulation. This low-cost, easy-to-manufacture meshed metal wire design offers a practical solution to optimize heat management in fixed-bed reactors, suitable for high thermal demand reactions like Fischer–Tropsch synthesis.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"231 ","pages":"Pages 401-411"},"PeriodicalIF":4.0,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148452866","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":"Driver–system coupling in packed bed aerodynamics: How flow driver characteristics affect packed bed experimental data","authors":"Maxim Nikitin,&nbsp;Dmitry Pashchenko","doi":"10.1016/j.cherd.2026.06.012","DOIUrl":"10.1016/j.cherd.2026.06.012","url":null,"abstract":"<div><div>In experimental, numerical, and analytical studies of packed beds, the operating point (superficial velocity, dry pressure drop) is often imposed. In reality, it is dynamically set by coupling between the bed’s hydraulic resistance and the finite-capacity flow driver’s (e.g., blower) performance curve. Ignoring this coupling risks data misinterpretation and flawed model validation. This study investigates blower-system coupling for gaseous flow (<span><math><mrow><mi>R</mi><msub><mrow><mi>e</mi></mrow><mrow><mi>p</mi></mrow></msub><mo>=</mo><mn>39</mn><mo>÷</mo><mn>10099</mn></mrow></math></span>) through randomly packed beds of spherical particles with specific particle diameters <span><math><mrow><mi>D</mi><mo>/</mo><msub><mrow><mi>D</mi></mrow><mrow><mi>p</mi></mrow></msub><mo>=</mo><mn>2</mn><mo>.</mo><mn>38</mn><mo>÷</mo><mn>6</mn><mo>.</mo><mn>67</mn></mrow></math></span>. The coupling effect manifests as data constraints imposed by the driver’s performance envelope, specifically its choking and surge limits. A Flow Driver Envelope Screening Method (FDESM) with univariate and bivariate algorithms is introduced to detect outliers from extreme operating regimes and identify invalid data points. The method is applied to experimental datasets and compared to standard filtering using the Forchheimer-type friction factor correlation. Results indicate that a substantial portion of experimental data (up to 50% in some tests) falls within abnormal driver regimes, making it unsuitable for validating decoupled models. The FDESM successfully reconstructs the operating field, linking bed design, driver characteristics, and power-supply frequency. The analysis reveals that the measured loss coefficient combines bed resistance and the driver’s internal losses. Consequently, conventional numerical and analytical models with fixed-velocity boundary conditions predict idealized operating points but fail to capture real system stability defined by the driver’s curve. This work underscores that accurate packed-bed characterization and model validation should account for driver–system coupling. The FDESM provides a framework for data screening, ensuring robust experimental analysis and reliable scale-up.</div></div>","PeriodicalId":10019,"journal":{"name":"Chemical Engineering Research & Design","volume":"231 ","pages":"Pages 307-316"},"PeriodicalIF":4.0,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148452868","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}