{"title":"CO2 electroreduction in a bubble-plate electrolyzer: A new route to scale up","authors":"Qing Hu, Yujing Liu, Zhihang Wei, Linjie Chao, Lin Luo, Zhenmin Cheng","doi":"10.1002/aic.18875","DOIUrl":"https://doi.org/10.1002/aic.18875","url":null,"abstract":"CO<sub>2</sub> electroreduction (CO<sub>2</sub>ER) provides a promising pathway for carbon utilization, but achieving high single-pass conversion is hindered by mass transfer limitations and the scalability constraints of conventional reactor designs. This work introduces a novel bubble-plate electrolyzer (BPE) that incorporates cobalt phthalocyanine (CoPc) catalysts immobilized on carbon paper substrates. This design creates abundant dynamic triple-phase interfaces, enhancing mass transfer and reaction kinetics. A gas-facing catalyst configuration optimizes bubble-catalyst interactions, resulting in exceptional catalytic performance and enabling scalable reactor design. A multi-layer BPE architecture achieves a remarkable single-pass CO<sub>2</sub> conversion of 28.74%, a substantial increase from the single-layer 6.11%, while maintaining excellent kinetic similarity and operational simplicity. Mechanistic studies reveal that a synergistic interplay between current density and CO<sub>2</sub> concentration governs CO<sub>2</sub> reduction within the BPE, where the unique gas flow configuration optimizes reactant residence time. This innovative BPE design provides a compelling strategy for practical and scalable carbon conversion technologies.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"43 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2025-04-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143885372","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 : 2025-04-29DOI: 10.1002/aic.18879
Yingjie Fei, Youguang Ma, Huai Z. Li
{"title":"Initial drop coalescence at a liquid–liquid interface","authors":"Yingjie Fei, Youguang Ma, Huai Z. Li","doi":"10.1002/aic.18879","DOIUrl":"https://doi.org/10.1002/aic.18879","url":null,"abstract":"The initial coalescence of drops with bulk liquid in various outer fluids was investigated, focusing on the effect of outer fluid's viscosity. The inner fluids included both Newtonian and non-Newtonian liquids. A micro-particle image velocimetry (micro-PIV) system with 0.2 ms temporal and 5.2 μm spatial resolution quantified the flow field and mapped the viscosity distribution within the coalescing non-Newtonian drops. The temporary evolution of the liquid bridge width was tracked using both an electrical method with 0.8 μs resolution and an optical method with 10 μm resolution. In air, the rescaled bridge width <i>Φ</i> followed classical regimes with normalized time <i>τ</i>, exhibiting a viscous regime (<i>Φ</i> ~ <i>τ</i>) followed by an inertial regime (<i>Φ</i> ~ <i>τ</i><sup>1/2</sup>). In viscous outer fluids, both regimes are present, but a prolonged crossover regime was observed. An empirical fitting <i>Φ</i> ~ <i>τ</i> ln<i>τ</i> is found to satisfactorily describe the whole coalescence.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"37 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2025-04-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143885371","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 : 2025-04-28DOI: 10.1002/aic.18848
Xuemei Xuan, Wenjie Lan, Pinxi Cai, Shan Jing, Shaowei Li
{"title":"Study on the dynamic interfacial tension during mass-transfer process using a novel interface probe method","authors":"Xuemei Xuan, Wenjie Lan, Pinxi Cai, Shan Jing, Shaowei Li","doi":"10.1002/aic.18848","DOIUrl":"https://doi.org/10.1002/aic.18848","url":null,"abstract":"Dynamic interfacial tension (DIFT) is a key parameter in two-phase flow-coupling mass transfer process. The variation in solute concentration is a critical factor influencing (DIFT) during mass transfer process. However, existing studies rarely achieve the simultaneous determination of DIFT and solute concentrations. This poses challenges for conducting in-depth investigations and making accurate predictions regarding DIFT. In this study, a new interface probe method was developed to simultaneously measure the solute concentration and DIFT. The effects of solute concentration and mass-transfer flux on DIFT were investigated. The results demonstrated that DIFT was not only influenced by solute concentrations, but also correlated with the mass-transfer flux. Based on the experimental results, a predictive model is established that correlates the DIFT with solute concentration and mass-transfer flux. This model shows wide applicability to the experimental results reported in both our present and previous studies. In the future, this model will be a theoretical basis for prediction of flow behavior in liquid–liquid flow coupling with mass transfer.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"7 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2025-04-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143880231","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 : 2025-04-22DOI: 10.1002/aic.18866
Qiang Liu, Yi Wei, Lintao Xu, Yongan Yang, Jingnan Wang, Xi Wang
{"title":"Interpretable machine learning-assisted high-throughput screening of highly active nitrogen fixation dual-atom catalysts","authors":"Qiang Liu, Yi Wei, Lintao Xu, Yongan Yang, Jingnan Wang, Xi Wang","doi":"10.1002/aic.18866","DOIUrl":"https://doi.org/10.1002/aic.18866","url":null,"abstract":"Machine learning (ML) has addressed the traditional challenges of large data processing in density functional theory (DFT) calculations. However, understanding the relationship between fundamental descriptors and catalytic performance and identifying key drivers of catalytic activity remain challenging. Here, we present a cost-effective, high-throughput, and interpretable ML method to accurately identify nitrogen reduction reaction (NRR) performance determinants. Initially, 378 M<sub>1</sub>M<sub>2</sub>@TiO<sub>2</sub> catalysts are screened, yielding 33 promising candidates through high-throughput techniques. Subsequently, ML models (primarily XGBoost) predict free energy changes of key NRR intermediates. Shapley Additive Explanations (SHAP) analysis identifies two critical features: the M<sub>1</sub><span></span>N<span></span>N bond angle (M<sub>1</sub>NN) and the M<sub>2</sub><span></span>N bond length. Four catalysts exhibiting energy changes below 0.3 eV in the potential-determining step are identified as promising candidates. Combined SHAP analysis and electronic structure calculations confirm the inherent activity of NRR catalysts, highlighting the importance of fundamental properties in modulating active sites for superior NRR performance.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"17 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2025-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143857871","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 : 2025-04-21DOI: 10.1002/aic.18864
Xue Su, Zheng-Qing Huang, Chun-Ran Chang
{"title":"Self-adaptive copper pairs on CuO(111) boosting ammonia catalytic combustion","authors":"Xue Su, Zheng-Qing Huang, Chun-Ran Chang","doi":"10.1002/aic.18864","DOIUrl":"https://doi.org/10.1002/aic.18864","url":null,"abstract":"Copper oxides exhibit outstanding performance in ammonia catalytic combustion, but a limited understanding of reaction mechanisms and the nature of active sites under operating conditions hinders further catalyst optimization. Utilizing density functional theory-based microkinetic simulations, we herein establish a comprehensive reaction mechanism on CuO(111), which enables the successful prediction of the experimental light-off temperature and identifies the self-adaptive copper pairs as key active sites. The NH<sub>2</sub> coupling over the copper pairs is the critical step for N<sub>2</sub> formation, which, along with H<sub>2</sub>O production, governs the overall reaction rate. Interestingly, the copper atom pairs can adjust their atomic distance ranging from 2.42 to 2.90 Å and their oxidation states between Cu<sup>I</sup> and Cu<sup>II</sup> in response to the adsorbed intermediates, thereby facilitating the catalytic cycle and specifically inhibiting NH<sub>2</sub> dehydrogenation. Moreover, reducing copper pair distance through surface compressive strain can further lower the activation energies of rate-determining steps and enhance the reactivity.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"18 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2025-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143853669","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 : 2025-04-21DOI: 10.1002/aic.18849
Yuzhe Zhang, Lu Chen, Xiaoqing Yan, Wenkai Teng, Honghui Ou, He Li, Qizhong Huang, Huagui Hu, Guidong Yang
{"title":"Dual-reaction pathway engineering via anode-driven methanol oxidation for efficient electrocatalytic ammonia production","authors":"Yuzhe Zhang, Lu Chen, Xiaoqing Yan, Wenkai Teng, Honghui Ou, He Li, Qizhong Huang, Huagui Hu, Guidong Yang","doi":"10.1002/aic.18849","DOIUrl":"https://doi.org/10.1002/aic.18849","url":null,"abstract":"Replacing the anodic oxygen evolution reaction with selective methanol oxidation to formic acid offers a promising route to enhance paired electrochemical ammonia synthesis. However, the inherent kinetic and thermodynamic disparities between the cathodic reduction reaction and anodic oxidation reaction present significant challenges in achieving optimal electrochemical system performance. Herein, we propose a dual-reaction strategy employing bifunctional Au/CoOOH nanocomposite catalysts, achieving simultaneous NH<sub>3</sub> production (34.15 g) and formic acid synthesis (69.65 g) after 24 h at 2.6 V cell voltage. Density functional theory (DFT) calculations further reveal that loading in Co-based catalysts and its hybridization with Au nanoparticles can effectively tune the electronic configuration of the Co-O sites to poison their strong adsorption capacity of intermediate products, lowering the reaction energy barrier to alter the reaction pathway. This work provides an atomic-level design principle for coupled electrochemical systems, demonstrating better reaction efficiency, while co-producing high-value chemicals for scalable green ammonia synthesis.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"49 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2025-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143857872","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":"Volcanic relationship between Co-carbon layer interaction strength and catalytic activity for olefin hydroformylation","authors":"Jiamei Wei, Peng Gao, Shen Wang, Yue Ma, Dong Cao, Daojian Cheng","doi":"10.1002/aic.18869","DOIUrl":"https://doi.org/10.1002/aic.18869","url":null,"abstract":"Metal-support interaction (MSI) is of great significance for designing the supported metal catalysts with high catalytic activity and selectivity. In this work, the MSI between Co and the carbon layer in armored cobalt nanoparticle catalysts (Co@xC) is effectively regulated based on the channel confinement strategy. Notably, a direct volcanic relationship could be obtained between the MSI strength of catalysts and the reaction rate constant. The Co@2.5C catalyst with suitable MSI strength achieves complete 1-hexene conversion (100%) and the yield of heptanal is 17,161 mol kg<sub>Co</sub><sup>−1</sup> h<sup>−1</sup> during the 1-hexene hydroformylation reaction. Further <i>in situ</i>/<i>ex situ</i> characterizations combined with theoretical calculations confirm the appropriate MSI accelerates the electron transfer from the carbon atom to the Co site, thereby enhancing the adsorption of 1-hexene species and boosting the reaction kinetics (the first-order reaction rate constant is 0.017 min<sup>−1</sup>). The volcanic structure-activity relationship in this work exhibits guiding significance for the development of industrial catalysts.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"30 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2025-04-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143849409","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 : 2025-04-19DOI: 10.1002/aic.18871
Qiushi Xu, Zifeng Li, Xiaoping Guan, Ning Yang, Raffaella Ocone
{"title":"Identification of volatile cloudy zone in a liquid-injected fluidized bed by CFD–DEM simulation","authors":"Qiushi Xu, Zifeng Li, Xiaoping Guan, Ning Yang, Raffaella Ocone","doi":"10.1002/aic.18871","DOIUrl":"https://doi.org/10.1002/aic.18871","url":null,"abstract":"In liqud-injected fluidized bed processes, such as ethylene polymerization, it is crucial to quantitatively identify the cloudy zone consisting of gas bubbles, droplets, and wet particles. While various experimental methods exist for measuring relevant parameters, a comprehensive understanding of the characteristics of the cloudy zone remains challenging. This study introduces a particle-based method to identify the cloudy zone using CFD–DEM simulations, focusing on heat and mass transfer during liquid evaporation and particle-droplet collisions. Image analysis of simulation results reveals a horseshoe-shaped cloudy zone and elucidates the life cycle of wet particles, transitioning from dry to wet and back to dry. The investigation identifies five distinct stages characterized by changes in evaporation rate, temperature, and liquid mass during the core-annular flow of wet particles. Importantly, the temperature gap between dry and wet particles diminishes as thermal energy transfer during droplet-particle collisions weakens at higher liquid injection rates.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"266 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2025-04-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143849410","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 : 2025-04-19DOI: 10.1002/aic.18800
Yuxin Chen, Haolan Tao, Honglai Liu, Liqing He, Cheng Lian
{"title":"Constructing micro-rheological model for lithium-ion battery electrode slurry for coating window prediction","authors":"Yuxin Chen, Haolan Tao, Honglai Liu, Liqing He, Cheng Lian","doi":"10.1002/aic.18800","DOIUrl":"https://doi.org/10.1002/aic.18800","url":null,"abstract":"The composition of lithium-ion battery electrode slurry determines its rheological properties, which have a significant impact on defect control during the coating process and the final electrode microstructure. Due to the complexity of slurry composition, it is difficult to determine the quantitative relationship between the formulation and rheological properties through experimental analysis. Herein, a shear rheological model based on the microscopic properties of electrode slurry was proposed, and the predicted viscosities based on slurry compositions were consistent with experimental measurements. Furthermore, the coating performance of electrode slurries was evaluated by combining a two-dimensional phase-field model and an analytical model, and the relationship between slurry viscosity and stable coating window was analyzed. Our work provides theoretical guidance for the formulation design of electrode slurry and the optimization of the coating process, which has practical significance for improving the manufacturing of lithium-ion batteries.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"40 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2025-04-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143849411","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":"Three-dimensional computational fluid dynamics study of liquid flow characteristics and flooding behaviors in corrugated packing","authors":"Shiji Xu, Cong Gao, Yuxin Zhang, Kehan Wang, Hongkang Zhao, Qunsheng Li, Jiaxing Xue","doi":"10.1002/aic.18870","DOIUrl":"https://doi.org/10.1002/aic.18870","url":null,"abstract":"Fluid flow behavior in packed columns is complex, with notable differences between the constant liquid hold-up region and the flooding region. This study numerically investigates the gas–liquid flow behavior for various contact angle (CA) and liquid load (<i>L</i>) conditions in both regions, using the volume of fluid-continuum surface force model. In the constant liquid hold-up region, CA and <i>L</i> significantly affect the liquid flow pattern, liquid hold-up, wetting rate, interfacial area ratio, pressure drop, and axial and radial distributions of liquid. In the flooding region, the dynamics of flooding evolution, critical conditions, and triggering mechanisms are analyzed under different CAs, considering the packing geometry, liquid hold-up, pressure drop, and interfacial area ratio. The results show that liquid accumulation at the bottom of the packing, caused by edge effects, is a key factor triggering flooding.","PeriodicalId":120,"journal":{"name":"AIChE Journal","volume":"108 1","pages":""},"PeriodicalIF":3.7,"publicationDate":"2025-04-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143846834","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}