Jinxu Hao , Xianda Sun , Baibin Ma , Wanzhen Huang , Yuandong Yang , Xiaohan Ren
{"title":"A cation-exchange membrane direct formate-CO2 fuel cell: Enabling simultaneous hydrogen production and CO2 utilization","authors":"Jinxu Hao , Xianda Sun , Baibin Ma , Wanzhen Huang , Yuandong Yang , Xiaohan Ren","doi":"10.1016/j.fuproc.2025.108346","DOIUrl":"10.1016/j.fuproc.2025.108346","url":null,"abstract":"<div><div>The carbon-neutral and carbon-negative energy utilization technologies have long been people pursued to realize the strategic objective of carbon neutrality. Herein, we propose a cation-exchange membrane (CEM) direct formate-CO<sub>2</sub> fuel cell that possesses the capability of simultaneously generating electricity and producing hydrogen, as well as continuously transforming carbon dioxide into pure sodium bicarbonate. Using the CO<sub>2</sub>-derived formate fuel, the roof-of-concept CEM direct formate-CO<sub>2</sub> fuel cell exhibits a peak power density of 38 mW cm<sup>−2</sup> at 80 °C without the assistance of additional electrolyte. The fairly stable constant-current discharge curve along with the detected hydrogen and pure sodium bicarbonate prove the conceptual feasibility of this electricity‑hydrogen-bicarbonate co-production device. By adding alkaline electrolyte to the anode, we achieved a higher peak power density of 63 mW cm<sup>−2</sup> at the corresponding hydrogen production rate of 0.57 mL min<sup>−1</sup> cm<sup>−2</sup>. More interestingly, the concentrations of pure NaHCO<sub>3</sub> solution can be controlled by adjusting the cathode water flow rate and fuel cell discharge current density. This work presents a theoretically feasible avenue for coupling hydrogen production and CO<sub>2</sub> utilization.</div></div>","PeriodicalId":326,"journal":{"name":"Fuel Processing Technology","volume":"278 ","pages":"Article 108346"},"PeriodicalIF":7.7,"publicationDate":"2025-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145227249","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Mansuur Husein , Liang Cheng , Francis Kwaku Attiogbe , Abdallah Abdelfattah , Hany S. El-Mesery , Emmanuel Nkudede
{"title":"Optimization of advanced biogas production via the DiCOM bioprocess utilizing the biogas test plant BTP2: Insights from multifactorial analysis","authors":"Mansuur Husein , Liang Cheng , Francis Kwaku Attiogbe , Abdallah Abdelfattah , Hany S. El-Mesery , Emmanuel Nkudede","doi":"10.1016/j.fuproc.2025.108343","DOIUrl":"10.1016/j.fuproc.2025.108343","url":null,"abstract":"<div><div>This study introduces an innovative optimization of the DiCOM bioprocess, which integrates aerobic composting and anaerobic digestion, utilizing the Biogas Test Plant BTP2 configured as a continuous stirred-tank reactor (CSTR). The research seeks to enhance biogas production from sewage sludge by examining the effects of key operational parameters, including temperature, pH, inoculum-to-substrate ratio, and stirrer speed. This investigation is pioneering in its use of a DiCOM-CSTR configuration, distinguishing it from previous studies that focused on fixed-bed or sequential systems. This approach facilitates continuous operation and enhances process control. A multifactorial experimental design was employed, utilizing Box-Behnken Design (BBD) and Response Surface Methodology (RSM), along with Principal Component Analysis (PCA), to evaluate the combined impacts of critical parameters such as temperature, pH, inoculum-to-substrate ratio (ISR), and stirrer speed. Under optimized conditions, a thermophilic temperature of 65 °C, neutral pH (7.0–7.5), ISR of 0.63, and controlled stirring speed of 100 rpm contributed to achieving a methane yield of up to 64.2 % and hydrogen sulfide concentrations as low as 3.9 ppm. The results surpass previously reported values, confirming the effectiveness of the proposed configuration and methodological approach. The integrated PCA-RSM framework provided enhanced multivariate insight into parameter interactions and process dynamics. Future studies should deepen the understanding of microbial community dynamics, assess the long-term operational stability of the DiCOM process, and evaluate its adaptability across diverse organic waste streams. This study not only advances the design and optimization of DiCOM systems but also offers a scalable approach for sustainable energy recovery from organic waste.</div></div>","PeriodicalId":326,"journal":{"name":"Fuel Processing Technology","volume":"278 ","pages":"Article 108343"},"PeriodicalIF":7.7,"publicationDate":"2025-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145227252","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Ke Huang , Xin Zhang , Xiaozhen Li , Renxin Liu , Ke Wu
{"title":"Exploration on physicochemical properties and combustion behaviors of hydrochar from co-hydrothermal carbonization of swine manure and tea waste","authors":"Ke Huang , Xin Zhang , Xiaozhen Li , Renxin Liu , Ke Wu","doi":"10.1016/j.fuproc.2025.108345","DOIUrl":"10.1016/j.fuproc.2025.108345","url":null,"abstract":"<div><div>Co-hydrothermal carbonization (co-HTC) of animal manure and lignocellulosic biomass is recognized as an innovative approach to improve the quality of hydrochar derived from the HTC of animal manure. This study explored the effects of mass mixing ratio and temperature on the physicochemical properties and combustion behaviors of hydrochar from co-HTC of swine manure (SM) and tea waste (TW). The synergistic effect between SM and TW promoted the deoxygenation of SM and the aromatization of hydrochar. Compared to hydrochar from HTC of SM, the carbon content and higher heating value increased considerably, reaching the maximum of 48.64 % and 19.94 MJ/kg, respectively. Less lamellar structure and numerous microspheres were observed on the surface of hydrochar produced at 250 °C with 1/1 mass ratio. Additionally, the combustion performance of hydrochars from co-HTC were improved, as indicated by increases in the comprehensive combustion index and combustion stability index. Kinetic analysis showed that the activation energy of hydrochar increased with the increasing TW proportion and temperature. These findings provided valuable insights into the co-HTC of SM and TW, supporting the effective upgrading of animal manure and lignocellulosic biomass.</div></div>","PeriodicalId":326,"journal":{"name":"Fuel Processing Technology","volume":"278 ","pages":"Article 108345"},"PeriodicalIF":7.7,"publicationDate":"2025-09-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145155933","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yadi Jia , Pinjing He , Fan Lü , Wei Peng , Hua Zhang , Khamphe Phoungthong
{"title":"Upcycling of EVA resin from photovoltaics into supercapacitor material and combustible gas by autogenic pressure pyrolysis","authors":"Yadi Jia , Pinjing He , Fan Lü , Wei Peng , Hua Zhang , Khamphe Phoungthong","doi":"10.1016/j.fuproc.2025.108344","DOIUrl":"10.1016/j.fuproc.2025.108344","url":null,"abstract":"<div><div>In response to the growing challenge of photovoltaic waste management, developing sustainable and value-added treatment strategies is imperative. In this study, ethylene-vinyl acetate (EVA) resins sourced from waste photovoltaic modules and virgin materials were utilized for the production of hierarchical porous carbon (HPC) and methane-rich combustible gas via autogenic pressure pyrolysis coupled with KOH activation. Temperature-dependent pyrolysis revealed that 700 °C was the optimal condition, yielding pyrolysis gas with a high methane content (43.39 vol%) and producing graphitized carbon spheres. Subsequent KOH activation generated HPC with a large specific surface area of 765.4 m<sup>2</sup>/g. When applied as a supercapacitor electrode in 6 mol/L KOH electrolyte, the HPC exhibited a high specific capacitance of 152 F/g at 0.2 A/g. Additionally, EVA resins with higher vinyl acetate content and melt index (MI) produced greater amounts of methane and pyrolytic carbon, while the resins with lower MI values showed enhanced reactivity toward chemical activation. This work offers a green and efficient route for the high-value recycling of EVA in PV waste and contributes to the sustainable synthesis of advanced HPC materials for energy storage applications.</div></div>","PeriodicalId":326,"journal":{"name":"Fuel Processing Technology","volume":"278 ","pages":"Article 108344"},"PeriodicalIF":7.7,"publicationDate":"2025-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145155935","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Stefan Schwarz , Georg Daurer , Joshua Slawatycki , Matthias Urban , René Prieler , Christian Gaber , Martin Demuth , Christoph Hochenauer
{"title":"Comparative chemiluminescence investigation of OH* radicals in laminar and turbulent multi-fuel air- and oxy-fuel flames on semi-industrial and laboratory scale including NOX-formation","authors":"Stefan Schwarz , Georg Daurer , Joshua Slawatycki , Matthias Urban , René Prieler , Christian Gaber , Martin Demuth , Christoph Hochenauer","doi":"10.1016/j.fuproc.2025.108342","DOIUrl":"10.1016/j.fuproc.2025.108342","url":null,"abstract":"<div><div>Chemiluminescence emitted by the de-excitation of excited hydroxyl radicals (OH*), allows for several insights into combustion processes. The presented study investigates air- and oxy-fuel combustion of natural gas with hydrogen enrichment up to 100%, using both small-scale laminar flames and turbulent high-impulse flames (50–100 kW). The obtained results from the laminar 1 kW flames from the laboratory burner are then used, to interpret the influence of turbulence and chemistry influence from an industrial scale multi-fuel multi-oxidizer burner. The measurements performed for the laboratory burner were also compared to simulations. Experimental data were compared to 1D simulations, showing good agreement in trends. However, in turbulent flames, turbulence effects far exceeded those of combustion chemistry. While laminar flames exhibited the highest chemiluminescence intensity in CH<sub>4</sub>-air combustion in both experiments and simulations, the maximum in turbulent combustion experiments occurred in oxy-fuel combustion, with hydrogen and natural gas performing similarly. Oxy-fuel flames showed similar chemiluminescence intensities, increased by 2 orders of magnitude, compared to turbulent air-fuel combustion. Additionally, the changes in flame shape and reaction zone size for hydrogen-enrichment in air-fuel combustion were investigated in terms of NO<sub>X</sub> formation, where OH* imaging proved its potential for emission reduction.</div></div>","PeriodicalId":326,"journal":{"name":"Fuel Processing Technology","volume":"278 ","pages":"Article 108342"},"PeriodicalIF":7.7,"publicationDate":"2025-09-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145155932","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Analysis of configurations for coupling an active magnetic regenerator with heat exchangers for hydrogen liquefaction","authors":"Angelica Liponi , Mathieu Tenda , Rasmus Bjørk , Umberto Desideri","doi":"10.1016/j.fuproc.2025.108337","DOIUrl":"10.1016/j.fuproc.2025.108337","url":null,"abstract":"<div><div>This paper presents a study of four different configurations for performing the heat exchange between helium—supplied by an active magnetic regenerator (AMR)—and hydrogen in the 82–20 K range for hydrogen liquefaction. We evaluate helium mass flow requirements and analyse the configurations considering both technical and exergetic aspects. Results show a strong influence of the temperature difference of helium at the AMR cold end on the required helium mass flow rate, which ranges from 35 to over 75 times the liquid hydrogen mass flow rate. The exergy efficiency of the cooling stage, not including AMR losses, ranges between 33 % and 49 %. The use of a single AMR causes significant temperature differences between helium and hydrogen in the heat exchangers leading to large exergy losses (representing over 95 % of the overall losses). We finally show that this issue can be overcome using multiple AMR in parallel with increasing cold-end temperatures.</div></div>","PeriodicalId":326,"journal":{"name":"Fuel Processing Technology","volume":"278 ","pages":"Article 108337"},"PeriodicalIF":7.7,"publicationDate":"2025-09-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145155934","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Krutarth Pandit, Ishani Karki Kudva, Shekhar G. Shinde, Christian Boose, Liang-Shih Fan
{"title":"Techno-economic assessment of biomass-to-liquid fuel production via chemical looping in comparison to conventional pathways","authors":"Krutarth Pandit, Ishani Karki Kudva, Shekhar G. Shinde, Christian Boose, Liang-Shih Fan","doi":"10.1016/j.fuproc.2025.108341","DOIUrl":"10.1016/j.fuproc.2025.108341","url":null,"abstract":"<div><div>Rising liquid fuel demand is increasing CO₂ emissions, making renewable biomass technologies vital for a low-carbon future. This study presents a chemical looping-based biomass conversion process integrated with Fischer-Tropsch synthesis (CLFT) for liquid fuel production and evaluates its techno-economic performance against two established biomass-based pathways: biomass gasification to liquid fuels (GFT) and biomass pyrolysis to liquid fuels (PHP). A minimum fuel selling price (MFSP) analysis, conducted using a discounted cash flow approach, estimates MFSP values of $3.59/GGE for CLFT, $5.26/GGE for GFT, and $4.54/GGE for PHP. The energy efficiencies of CLFT, GFT, and PHP are at 37.7 %, 37.3 %, and 46.4 %, respectively, while their carbon conversion efficiencies are 32.3 %, 30.5 %, and 40.4 %. Sensitivity analyses reveal that feedstock cost exerts the greatest influence on MFSP, followed by the internal rate of return and capital expenditures. Additionally, a 50 % increase in plant capacity (from the baseline 2000 dry tons/day of biomass) results in only an 11 % reduction in MFSP, whereas a 50 % decrease in plant size leads to a 17 % increase in MFSP. These findings highlight CLFT's economic and technical advantages, reinforcing its promise as a cost-effective, sustainable fuel generation alternative.</div></div>","PeriodicalId":326,"journal":{"name":"Fuel Processing Technology","volume":"278 ","pages":"Article 108341"},"PeriodicalIF":7.7,"publicationDate":"2025-09-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106655","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Experimental investigation and machine learning-based estimation of oxyhydrogen (HHO) gas production using KOH electrolyte in a flat plate electrolyser","authors":"Mohammad Amin Adoul , Balaji Subramanian , Naveen Venkatesh Sridharan , Ramin Karim , Ravdeep Kour","doi":"10.1016/j.fuproc.2025.108339","DOIUrl":"10.1016/j.fuproc.2025.108339","url":null,"abstract":"<div><div>Hydrogen gas has gained significant attention as a cleaner alternative to fossil fuels offering a sustainable energy solution. This study explores the production efficiency of oxyhydrogen (HHO) gas using a flat plate electrolyser with potassium hydroxide (KOH) as the electrolyte. Machine learning regression models were employed to estimate hydrogen generation rates and system efficiency based on key operational parameters that includes voltage, current and electrolyte concentration. A set of gradient-boosting algorithms was evaluated utilizing raw experimental data to predict (i) hydrogen output in liters per minute (LPM) and (ii) system efficiency. The results indicate that Categorical Boosting (CatBoost) excelled in forecasting system efficiency (R<sup>2</sup> = 0.9748, RMSE = 1.6567 on testing data) and predicting HHO gas generation rate (R<sup>2</sup> = 0.9936, RMSE = 0.0090). The experimental results show that with the increase in KOH concentration there is increase in production of Hydrogen. Maximum efficiency was noted with 0.5 N of KOH with the peak efficiency of 99.8 % because of its optimal conductivity and power consumption. It can also be absorbed that higher concentration such 0.75 N and 1 N have shown significant improvement in hydrogen production. Experimental findings further revealed that moderate operating conditions maximize hydrogen production with efficiency varying as a function of applied current and electrolyte concentration. This study highlights the advantages of integrating machine learning models with electrolysis-based hydrogen production offering a scalable and data-driven approach to optimizing energy efficiency. The results underscore the potential of KOH-based electrolysis for sustainable hydrogen generation and reinforce the role of predictive modeling in enhancing system performance.</div></div>","PeriodicalId":326,"journal":{"name":"Fuel Processing Technology","volume":"278 ","pages":"Article 108339"},"PeriodicalIF":7.7,"publicationDate":"2025-09-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106656","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Co-Zn bimetallic oxide & hydroxyfluoride nanowires: highly active catalyst for catalytic transfer hydrogenation of furfural","authors":"Chenyu Wang , Xiao Tan , Wei Feng , Peijun Ji","doi":"10.1016/j.fuproc.2025.108330","DOIUrl":"10.1016/j.fuproc.2025.108330","url":null,"abstract":"<div><div>Co-Zn bimetallic hydroxyfluoride nanorods (CoZnF) were synthesized at room temperature in an aqueous solution. After calcination at 330 °C in air, CoZnF was partially decomposed to form Co<img>Zn bimetallic oxide & hydroxyfluoride (CoZnO&CoZnF) nanowires. The higher electronegativity of fluorine compared to oxygen reduces the valence electron density of oxygen in CoZnF, thereby weakening the metal‑oxygen bonds, and generating abundant oxygen vacancy sites in CoZnO&CoZnF. Electron transfer between cobalt and zinc maintains cobalt in the Co(II) oxidation state. Catalytic results demonstrate the potential of CoZnO&CoZnF for selective hydrogenation of furfural to furfuryl alcohol (FA). Lewis acid-base pairs (Co<sup>2+</sup>/Zn<sup>2+</sup>-O<sup>2−</sup>) and oxygen vacancy sites act as active sites for catalytic transfer hydrogenation (CTH). The nanowire structure and highly accessible active sites enhance catalytic activity. CoZnO&CoZnF exhibits an excellent catalytic activity, achieving 98.1 % yield of furfuryl alcohol (FA) with a selectivity of 99.2 %. Mechanistic insights from <sup>1</sup>HNMR analysis and kinetic studies elucidate the reaction pathway, including activation energy determination.</div></div>","PeriodicalId":326,"journal":{"name":"Fuel Processing Technology","volume":"278 ","pages":"Article 108330"},"PeriodicalIF":7.7,"publicationDate":"2025-09-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106199","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Machine learning-driven modeling framework for steam co-gasification applications","authors":"Usman Khan Jadoon, Ismael Díaz, Manuel Rodríguez","doi":"10.1016/j.fuproc.2025.108340","DOIUrl":"10.1016/j.fuproc.2025.108340","url":null,"abstract":"<div><div>Steam co-gasification of biomass and plastic waste is a promising route for syngas production and waste valorization. However, accurately predicting syngas composition remains challenging due to inherent complexity and nonlinearity of the process. This study presents a comprehensive comparative analysis between conventional process simulators-based models (Aspen Plus), namely the thermodynamic equilibrium (TEM), restricted thermodynamic (RTM), and kinetic (KM) modeling approaches, and machine learning (ML) models for the prediction of the syngas composition. Using 208 experimental data points compiled from 20 published studies covering various feedstocks and gasification conditions in bubbling fluidized bed gasifiers (BFBG), the performance of the models was evaluated after extensive data preprocessing. Among several ML algorithms evaluated, the neural network (NN) delivered the lowest average root mean square error in syngas mol fraction predictions (0.0174), outperforming RTM (0.0966), KM (0.1378), and TEM (0.1470). To explore input–output relationships beyond interpolation, a conditional generative adversarial network (cGAN) generated synthetic data, which served as the basis for sensitivity and interpretability analyses. The NN, acting as a surrogate model, was paired with SHapley Additive exPlanations (SHAP) and Partial Dependence Plots (PDP) to quantify the effects and nonlinear interactions of key features on syngas yields providing actionable insights for process optimization.</div></div>","PeriodicalId":326,"journal":{"name":"Fuel Processing Technology","volume":"278 ","pages":"Article 108340"},"PeriodicalIF":7.7,"publicationDate":"2025-09-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145106654","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}