AIChE JournalPub Date : 2025-01-03DOI: 10.1002/aic.18723
Stepan Sibirtsev, Lukas Thiel, Andrey Kirsanov, Andreas Jupke
{"title":"Droplet contact numbers and contact probabilities in liquid-liquid dense-packed zones","authors":"Stepan Sibirtsev, Lukas Thiel, Andrey Kirsanov, Andreas Jupke","doi":"10.1002/aic.18723","DOIUrl":"https://doi.org/10.1002/aic.18723","url":null,"abstract":"Dense-packed zones (DPZs) are crucial in designing equipment for liquid-liquid phase separation processes, as the DPZ height affects apparatus size. This article presents an open-access simulation approach to determine droplet contact numbers and probabilities, which are vital for modeling the deformation and coalescence of polydisperse droplets in a DPZ. The simulation is applied to three technical cases to assess how droplet size distribution (DSD) shapes impact contact numbers and probabilities. Sensitivity analysis reveals that broader DSDs and larger droplet classes lead to higher contact numbers. In contrast, contact probability is primarily determined by droplet class diameter and its number probability within the DSD, showing an almost linear relationship. These results highlight the significance of DSD shape and droplet class diameter in predicting droplet contact numbers and probabilities in DPZs, providing valuable insights for future modeling of liquid-liquid phase separation.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"18 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2025-01-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142917652","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}
AIChE JournalPub Date : 2025-01-02DOI: 10.1002/aic.18715
Shuyuan Fan, Xiaodong Hong, Zuwei Liao, Congjing Ren, Yao Yang, Jingdai Wang, Yongrong Yang
{"title":"Adaptive sampling Bayesian algorithm for constrained black-box optimization problems","authors":"Shuyuan Fan, Xiaodong Hong, Zuwei Liao, Congjing Ren, Yao Yang, Jingdai Wang, Yongrong Yang","doi":"10.1002/aic.18715","DOIUrl":"https://doi.org/10.1002/aic.18715","url":null,"abstract":"Constrained black-box optimization (CBBO) has become increasingly popular in process optimization. Algorithms often encounter difficulties in balancing feasibility and optimality, with some even failing to find feasible solutions. This article introduces an adaptive sampling Bayesian optimization algorithm (ASBO) to solve CBBO problems effectively. The developed infill sampling criterion introduces an adaptive acquisition function to facilitate multistage optimization. The three stages consist of exploring feasible solutions, balancing feasibility and optimality, and optimizing. Furthermore, a hybrid method is proposed for complex problems. A gradient-based optimizer (GBO) aids in constructing the posterior distribution, thereby enhancing the identification of feasible regions. Additionally, four auxiliary strategies are developed to enhance stability and accelerate convergence in simulation-based optimization. The effectiveness of the proposed algorithm is validated through three benchmark problems and two process optimization cases. Comparative analysis against state-of-the-art algorithms demonstrates better iteration efficiency of ASBO algorithms.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"34 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2025-01-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142917653","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":"An electro-metathesis membrane reactor for directly producing LiOH with purity exceeding 99.5%","authors":"Xiao Liu, Guangzhong Cao, Songhui Wang, Weixiang Shan, Tianle Gu, Zhaoming Liu, Chenxiao Jiang, Tongwen Xu","doi":"10.1002/aic.18705","DOIUrl":"https://doi.org/10.1002/aic.18705","url":null,"abstract":"Producing battery-grade lithium hydroxide (LiOH) from lithium salts is essential for high-performance lithium-ion batteries. Traditional causticization methods, which involve metathesis reactions between lithium salts (such as Li<sub>2</sub>CO<sub>3</sub>, Li<sub>2</sub>SO<sub>4</sub>, or LiCl) and bases (such as Ca(OH)<sub>2</sub>, NaOH, or Ba(OH)<sub>2</sub>), often result in low concentrations of LiOH and significant lithium loss dragged by CaCO<sub>3</sub>/Na<sub>2</sub>SO<sub>4</sub>/BaSO<sub>4</sub> as solid waste. To address these challenges, we developed the “electro-metathesis” membrane reactor, which integrates the metathesis reaction with an electro-membrane system based on ion-distillation technology. This technology enhances the causticization process by regulating ion migration through ion exchange membranes and blocking impurity ions stage by stage, improving lithium recovery to 84.4% and achieving high-purity (99.6%) LiOH products. Furthermore, the process cost is 3.32 $/kg LiOH, which is lower than traditional causticization processes. This research highlights the advantages of the “electro-metathesis” membrane reactor in process efficiency, product quality, and cost management, showing strong potential for industrial applications.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"44 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2024-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142905571","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}
AIChE JournalPub Date : 2024-12-30DOI: 10.1002/aic.18720
Bin Wu, Lin Chen, Yanchun Fan, Huidong Zheng, Fuweng Zhang
{"title":"Experimental study and numerical simulation of liquid–liquid dispersions in micro-impinging jet mixers","authors":"Bin Wu, Lin Chen, Yanchun Fan, Huidong Zheng, Fuweng Zhang","doi":"10.1002/aic.18720","DOIUrl":"https://doi.org/10.1002/aic.18720","url":null,"abstract":"This study investigates the turbulent two-phase dispersion of toluene-water in micro-impinging jet (MIJ) mixers using both experimental and numerical methods. We employ computational fluid dynamics combined with the population balance model (CFD-PBM) to predict the mean droplet size (<i>d</i><sub>32</sub>) and droplet size distribution (DSD). The numerical predictions align well with the experimental results. The liquid–liquid dispersion in the MIJ mixer is a two-step process, each step governed by the velocity ratio (<i>r</i>) and Reynolds number (<i>Re</i><sub>j</sub>), respectively. By increasing the volume flow rate (<i>Q</i>) and <i>r</i>, or by reducing the diameter of the outlet orifice of mixing chamber (<i>D</i><sub>o</sub>), the dispersion process can be intensified. This leads to the production of smaller droplets with a narrow DSD within a millisecond timeframe. Additionally, we propose a correlation for <i>d</i><sub>32</sub> that accurately describes the two-step dispersion process of the mixer, providing a reliable guide for the design and optimization of liquid–liquid systems.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"36 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2024-12-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142902127","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}
AIChE JournalPub Date : 2024-12-28DOI: 10.1002/aic.18726
Dong Lin, Xiuhui Zheng, Ze Zong, Yang Xu, Qiuming He, Zhe Ma, De Chen, Chaohe Yang, Xiang Feng
{"title":"Confined water accelerated alkene epoxidation inside channels of Ti-beta zeolite","authors":"Dong Lin, Xiuhui Zheng, Ze Zong, Yang Xu, Qiuming He, Zhe Ma, De Chen, Chaohe Yang, Xiang Feng","doi":"10.1002/aic.18726","DOIUrl":"https://doi.org/10.1002/aic.18726","url":null,"abstract":"Comprehensive mechanistic explorations and profound understandings of the interactions between water molecules and active intermediates harbors tremendous significance in the field of zeolite catalysis. Herein, we envision a strategy to accelerate alkene epoxidation reactions (e.g., 1-pentene, 1-hexene, cyclohexene, cyclooctene) with preformed H<sub>2</sub>O<sub>2</sub> inside confined channels of Ti-beta by water molecules. Combined with <i>in situ</i> UV–vis, kinetic experiments, and DFT calculations, it is found that keen control of water molecules could effectively enhance H<sub>2</sub>O<sub>2</sub> adsorption and stabilize crucial oxygen intermediates (Ti-OOH) by hydrogen bonding interactions. As a result, the yields of corresponding epoxides increased up to 20.5%. However, excessive water clusters construct a dense and robust hydrogen-bond network, blocking the activation of reactants and further epoxidation over Ti sites. This finding not only sheds new light on the mechanism of water-accelerated reaction, but also opens up new opportunities to enhance the efficiency of industrial epoxidation reactions involving H<sub>2</sub>O<sub>2</sub>.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"114 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2024-12-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142888552","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}
AIChE JournalPub Date : 2024-12-26DOI: 10.1002/aic.18707
Dalia N. Dorantes-Landa, Alberto Hernandez-Aguirre, Luis Ricardez-Sandoval, Sergio Huerta-Ochoa, Carlos O. Castillo-Araiza
{"title":"A systematic approach to defining a unit cell for fluid dynamics in packed beds with low tube-to-particle diameter ratio","authors":"Dalia N. Dorantes-Landa, Alberto Hernandez-Aguirre, Luis Ricardez-Sandoval, Sergio Huerta-Ochoa, Carlos O. Castillo-Araiza","doi":"10.1002/aic.18707","DOIUrl":"https://doi.org/10.1002/aic.18707","url":null,"abstract":"This work develops an approach to identify the suitable representative volume (unit cell) that captures fluid dynamics in beds packed with spheres or cylinders with a <i>d</i><sub>t</sub>/<i>d</i><sub>p</sub> ≤ 10, by describing radial void fraction and velocity profiles at particle Reynolds numbers between 5 and 100. Rigid-body simulations were used to construct synthetic packings, while velocity profiles were obtained from particle-resolved simulations. This methodology, rooted in the similitude of fluid dynamics between beds of different lengths, determines the minimum length (or number of particles in a bed) required for the unit cell to accurately describe the void fraction and velocity profiles. Defining such a unit cell for fluid dynamics not only reduces computational effort but also opens avenues for its use in multiscale techniques to develop reliable pseudo-continuous models, which is currently the bottleneck in the design and optimization of wall-cooled packed-bed reactors in industrial scenarios.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"14 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2024-12-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142887182","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":"Bipolar membrane electrodialysis with isolation chamber enables high-purity LiOH production with ordinary membranes","authors":"Duyi He, Weicheng Fu, Zihao Wang, Junying Yan, Huangying Wang, Ruirui Li, Baoying Wang, Xiaochun Chen, Yaoming Wang, Tongwen Xu","doi":"10.1002/aic.18674","DOIUrl":"https://doi.org/10.1002/aic.18674","url":null,"abstract":"Currently, bipolar membrane electrodialysis (BMED) is recognized as an eco-friendly technique to recycle lithium from waste lithium-ion batteries. However, the application of ordinary bipolar membranes has the disadvantage of unsatisfactory product purity due to undesired ion leakage. Herein, we proposed isolation chamber bipolar membrane electrodialysis (ICBMED) to inhibit coion migration, thereby increasing the purity of the regenerated acid and alkali. The experimental results indicate that 97.7%–99.3% of the LiOH generated by the ICBMED using domestic membranes was generated, which is much greater than the 85.7%–94.4% obtained without an isolation chamber. The total cost of the ICBMED for LiOH production with inexpensive domestic membranes was 1.65$/kg-LiOH (US) at 400 A/m<sup>2</sup>, which is lower than the cost of 1.91$/kg-LiOH (US) for flagship membranes with identical product quality. BMED with an isolation chamber provides a viable solution for acid–base production by balancing product quality and cost.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"202 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2024-12-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142880176","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":"Channel–molecule attraction mediated molecule transport in confined nanochannels of COF membranes for nanofiltration","authors":"Ruilong Li, Yongjian Yang, Jingjing Chen, Chongchong Chen, Wenpeng Li, Xiaoli Wu, Jingtao Wang","doi":"10.1002/aic.18719","DOIUrl":"https://doi.org/10.1002/aic.18719","url":null,"abstract":"Porous membranes, a type of material widely used in nanofiltration, are confronted with the limitation that the influence of channel–molecule interactions on transport behaviors has yet been investigated in detail. Herein, covalent organic framework membranes with adjustable pore sizes (⁓ 2.5 nm and ⁓ 1.2 nm) and chemical groups (−F, −OH, and −CO−) were prepared by interfacial polymerization. We demonstrate that strong channel–molecule attraction induces the formation of stable solvent layers along nanochannel walls, which protect central molecules from the attraction of chemical groups. Significantly, stable solvent layers permit fast transport of ethanol (245.6 L m<sup>−2</sup> h<sup>−1</sup> bar<sup>−1</sup>) with reactive black (RB) rejection of 96%. Likely, for membranes with weak channel–molecule attraction, no solvent layers are formed and molecules also transport smoothly. Interestingly, membranes that exhibit moderate channel–molecule attraction exert metastable solvent layers, thus displaying high transport resistance. This hindrance effect on molecule transport becomes more pronounced in smaller nanochannels.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"65 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2024-12-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142880175","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}
AIChE JournalPub Date : 2024-12-24DOI: 10.1002/aic.18714
Yan Zhang, Hai Liu, Ruoyu Hu, Yan Zhou, Shuai Wang, Jianguang Qi, Yinglong Wang, Zhaoyou Zhu, Guoxuan Li
{"title":"Extraction of valuable metals from waste Li-ion batteries by deep eutectic solvent: Experimental and mechanism analysis","authors":"Yan Zhang, Hai Liu, Ruoyu Hu, Yan Zhou, Shuai Wang, Jianguang Qi, Yinglong Wang, Zhaoyou Zhu, Guoxuan Li","doi":"10.1002/aic.18714","DOIUrl":"https://doi.org/10.1002/aic.18714","url":null,"abstract":"A novel phospho-based hydrophobic deep eutectic solvents (HDESs) is proposed to selectively extract valuable metals from waste lithium-ion batteries (LIBs). Under the optimized extraction conditions, the single-stage extraction efficiency of HDES [TOP][Lid] for Co<sup>2+</sup> and Ni<sup>2+</sup> were 98.5% and 83.9%, and HDES [TBP][Lid] for Co<sup>2+</sup> and Ni<sup>2+</sup> were 96.0% and 82.9%, and Li<sup>+</sup> was enriched in the extract. FT-IR, <sup>1</sup>H NMR, and ESP analysis confirmed the hydrogen bond between HBD and HBA. The metal ion extraction mechanism by HDESs was analyzed based on quantum chemistry (QC) and molecular dynamics (MD). The extraction mechanism at the molecular level is that electrostatic and coordination interactions between transition metal ions and HDESs dominate the extraction of metal ions (Co<sup>2+</sup> and Ni<sup>2+</sup>). The interaction intensity with HDESs was stronger than that between Li<sup>+</sup> and HDESs.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"25 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2024-12-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142880240","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":"Carbon-zero co-production of hydrogen and chemicals boosted by directional hydrogen spillover via terminated interface","authors":"Xuanlin Guo, Huifang Wu, Yang Zhao, Lirong Zheng, Qian Wang, Dianqing Li, Junting Feng","doi":"10.1002/aic.18713","DOIUrl":"https://doi.org/10.1002/aic.18713","url":null,"abstract":"Acceptorless dehydrogenation of biomass-alcohol provides an appealing route for co-producing green H<sub>2</sub> and high-value chemicals. However, the sluggish H species binding step severely inhibits reaction equilibrium and cause C-C cleavage. Herein, we propose a unique directional H spillover strategy driven by controlling electron transport direction via constructing Au-O-Cu-O-Mg/Al interfacial structure, to allow H species transfer from O-H dehydrogenation Cu<sup>2+</sup> site to C-H dehydrogenation Au site to promote H<sub>2</sub> formation. The structure that each Cu precisely terminated by Mg/Al is inherited from layered double hydroxides with orderly dispersed atom arrangement. Comprehensive studies substantiate that the unreducible Mg<sup>2+</sup>/Al<sup>3+</sup> blocks electron transfer toward support, whereas Au-O-Cu electronic interaction drives H spillover from the support to Au. The Au/CuMgAl catalyst demonstrated unprecedentedly high glycerol dehydrogenation activity, showing 3–10 times turnover frequency (1.18 × 10<sup>4</sup> h<sup>−1</sup>) than other biomass-derived H<sub>2</sub> formation system, co-producing lactic acid with selectivity up to 98.8%.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"2 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2024-12-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142874865","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}