Chemical Engineering Journal Advances最新文献

{"title":"Gas–liquid mass-transfer modeling in industrial-scale bioreactors: A standardized framework and critical assessment","authors":"Víctor Puig-I-Laborda ,&nbsp;Johan Le Nepvou De Carfort ,&nbsp;Ulrich Krühne ,&nbsp;Krist V. Gernaey ,&nbsp;John M. Kavanagh ,&nbsp;David F. Fletcher ,&nbsp;Lars K. Nielsen","doi":"10.1016/j.ceja.2025.100982","DOIUrl":"10.1016/j.ceja.2025.100982","url":null,"abstract":"<div><div>Gas transfer often limits large-scale bioprocesses, demanding robust models for design, scale-up, and scale-down. This study establishes a standardized computational framework for gas–liquid mass-transfer modeling in industrial-scale bioreactors, integrating and evaluating the main sub-models governing <span><math><mrow><msub><mrow><mi>k</mi></mrow><mrow><mi>L</mi></mrow></msub><mi>a</mi></mrow></math></span> prediction — bubble dynamics, interfacial area, drag laws, and turbulence closures — within CFD simulations of a 134<!--> <!-->m³ bubble column and a 96<!--> <!-->m³ Rushton-impeller stirred tank. A systematic sensitivity analysis reveals that bubble size modeling (including pressure and coalescence corrections) and drag law selection are the dominant parameters controlling gas holdup and interfacial area, while <span><math><msub><mrow><mi>k</mi></mrow><mrow><mi>L</mi></mrow></msub></math></span> correlations and bubble-induced turbulence models exert secondary but non-negligible influence on local extremes of <span><math><mrow><msub><mrow><mi>k</mi></mrow><mrow><mi>L</mi></mrow></msub><mi>a</mi></mrow></math></span>. Among tested formulations, the Grace–Simonnet drag law, hybrid (Higbie–Lamont–Scott) <span><math><msub><mrow><mi>k</mi></mrow><mrow><mi>L</mi></mrow></msub></math></span> approach, and variable single-bubble-size model offered the best trade-off between physical realism and computational cost. The results are consolidated into a decision chart that ranks sub-model relevance and guides model selection based on reactor type and turbulence regime. This framework provides decision-ready guidance for reliable, scale-consistent CFD modeling of gas–liquid mass transfer in large-scale bioreactors.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"25 ","pages":"Article 100982"},"PeriodicalIF":7.1,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145938922","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Development of aerobic micro granular sludge in a sequencing batch airlift reactor for simultaneous removal of COD, NH4+, PO43-, and SO42-","authors":"Kunnath Saidalavi Shameem ,&nbsp;Pothanamkandathil Chacko Sabumon","doi":"10.1016/j.ceja.2025.101006","DOIUrl":"10.1016/j.ceja.2025.101006","url":null,"abstract":"<div><div>This study investigates the long-term effectiveness of an automated Sequencing Batch Airlift Reactor (SBAR) in simultaneous removal of COD, NH₄⁺, PO₄³, and SO₄²⁻ by developing aerobic micro granular sludge. For this an automated SBAR (3 L capacity) with pH and DO controls, operated for 8 h (short) followed by 16 h (long) cycles; was employed using synthetic wastewater over a year. This study operated in six different phases with durations of 23, 27, 73, 125, 67, and 52 days, respectively within a temperature range of 31.5 ± 3.5 °C. During the entire phases, influent concentrations were maintained approximately at NH₄⁺-<em>N</em> = 50 mg/L, COD = 480 mg/L, and SO₄²⁻-<em>S</em> = 35 mg/L, while PO₄³⁻-P was maintained at 10 mg/L for Phases I–IV and then decreased to 5 mg/L for Phases V–VI. Sludge was not wasted during the entire operation from SBAR and thus maintained a very high solids retention time (SRT) to promote the growth of slow growing bacteria like anammox and achieved zero sludge discharge. In the stabilized conditions in the final phase, the SBAR performed well for an average simultaneous removal of COD (96.67 ± 1.17%), NH₄⁺-N (91.70 ± 3.66%), TN (83.21 ± 3.61%), PO₄³⁻-P (91.37 ± 1.55%) and SO₄²⁻-S (70.73 ± 4.13%). Batch studies and microbial identification studies carried out using biomass drawn from SBAR showed that mixed culture involving anammox, autotrophic nitrification, heterotrophic denitrification, thiobacillus denitrification, and heterotrophic nitrification and aerobic denitrification (HN-AD) played significant roles in nitrogen removal. Enhanced phosphate removal was achieved by P binding to loosely bound extracellular polymeric substances in addition to the enhanced biological phosphorus removal. Overall, these findings highlight the effectiveness in cultivating majorly aerobic micro granular sludge and sustainability of the SBAR in simultaneous removal of COD, NH₄⁺, PO₄³⁻, and SO₄²⁻. The developed process could be a good choice for decentralized wastewater treatment systems, particularly in resource-constrained regions and contributes to achieving United Nations Sustainable Development Goal #6.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"25 ","pages":"Article 101006"},"PeriodicalIF":7.1,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145938847","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Improving fouling resistance of polyvinylidene fluoride membrane with mono-hydroxyl poly(dimethylsiloxane) (PDMS-OH) grafted silica nanoparticles","authors":"Muayad Al-Shaeli ,&nbsp;Raed A. Al-Juboori ,&nbsp;Huanting Wang ,&nbsp;Bradley Ladewig ,&nbsp;Qusay F. Alsalhy ,&nbsp;Jianhua Zhang","doi":"10.1016/j.ceja.2025.100991","DOIUrl":"10.1016/j.ceja.2025.100991","url":null,"abstract":"<div><div>In this study, mono‑hydroxyl polydimethylsiloxane (CH₃-PDMS-OH) was successfully grafted onto silica (SiO₂) nanoparticles via Steglich esterification process to produce surface-functionalized PDMS-g-SiO₂ nanomaterials. These nanoparticles were then introduced into polyvinylidene fluoride (PVDF) matrices through non-induced phase inversion (NIPS) to fabricate mixed matrix ultrafiltration membranes with different nanoparticle loadings (0, 1.6, 3.2, 6.3, and 11.8 wt %). The PDMS-g-SiO₂ incorporation resulted in membranes with slightly reduced porosity and hydrophobicity compared to pristine PVDF yet exhibited markedly improved antifouling performance. Although pure water flux decreased slightly due to the addition of nanoparticles, the rejection rate of Bovine serum albumin (BSA) improved substantially because of optimized pore structure and surface chemistry. In contrast, membranes containing unmodified SiO₂ showed higher initial flux but suffered from severe irreversible fouling. The modified PVDF membranes showed a flux recovery ratio of up to 97 % and significantly reduced protein adsorption (19.9 µg/cm²) relative to pristine PVDF (62 µg/cm²), confirming the formation of a low-energy, fouling-resistant surface. High flux recovery was sustained over four fouling/cleaning cycles with both BSA and humic acid (HA), and its durability was further demonstrated through 15 days of long-term testing. This study establishes a new hybrid design approach that combines the hydrophobic flexibility of PDMS with the hydrophilic stability of SiO₂, offering a durable and effective route for developing antifouling PVDF membranes for wastewater treatment applications.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"25 ","pages":"Article 100991"},"PeriodicalIF":7.1,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145938846","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Nanogels crosslinked with a novel selenocystine-based linker for triple-stimuli-responsive drug delivery","authors":"Marcin Mackiewicz ,&nbsp;Serife Dagdelen ,&nbsp;Jan Romanski ,&nbsp;Marcin Karbarz","doi":"10.1016/j.ceja.2025.100959","DOIUrl":"10.1016/j.ceja.2025.100959","url":null,"abstract":"<div><div>A first-in-class, water-processable nanogel was obtained by surfactant-free semi-batch precipitation polymerisation of poly(N-isopropylacrylamide) (pNIPA) cross-linked with the new selenium linker N,N′-bis(acryloyl)selenocystine (BISeSe). Unlike conventional disulfide, diselenide or acid-cleavable linkers, BISeSe delivers (1) carboxyl groups that impart pH-responsiveness and (2) Se-Se bonds that undergo glutathione reduction, thus merging two key intracellular triggers in a single, predominantly aqueous, surfactant-free polymerisation process that avoids organic solvents during nanogel formation and requires no post-synthetic modifications. The process yields highly monodisperse spheres (60 ± 6 nm, TEM; PDI= 0.05, DLS) with an overall yield of 82 %. Doxorubicin (DOX) is electrostatically loaded at 25 wt % with 81 % efficiency. At pH 7.4 without GSH, nanogels release only 13.9 % of DOX after 12 h, whereas at pH 5.0 with 10 mM GSH they discharge 84 % in the same period, following an erosion-dominated Korsmeyer-Peppas profile (<em>n</em> = 0.53). Blank carriers retain ≥ 80 % viability in MCF-7 and MCF-10A cells, while DOX-loaded gels are 1.6-fold more potent than free DOX against MCF-7 and ∼60-fold less toxic to MCF-10A (IC₅₀ 0.08 vs 9.65 µM). This water-based polymerisation route provides a scalable and cleaner alternative to conventional organic-phase syntheses, offering a promising platform for selective drug-delivery systems.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"25 ","pages":"Article 100959"},"PeriodicalIF":7.1,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145623446","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Mitigating ammonia emissions for a sustainable livestock farming by advances in membrane technology and modelling tools","authors":"Paula Calvo-de Diego,&nbsp;María Cruz García-González,&nbsp;Mercedes Sánchez-Báscones,&nbsp;Beatriz Molinuevo-Salces","doi":"10.1016/j.ceja.2025.100983","DOIUrl":"10.1016/j.ceja.2025.100983","url":null,"abstract":"<div><div>With the agricultural sector contributing to 93 % of total ammonia emissions, the development of mitigation technologies is imperative for livestock farming. This study compared the nitrogen recovery performance of two novel gas-permeable membrane configurations: System 1 (S1), with external gas flow, and System 2 (S2), with internal gas flow. The influence of initial N concentration and exposure time on N recovery rates was investigated. The results established the markedly superior performance of S2, which achieved a N recovery rate of 237 g m⁻² d⁻¹, outperforming the 154 g m⁻² d⁻¹ rate of S1. This peak rate represents a 7-fold increase when compared to previous results. Mathematical models derived from regression analysis were developed for S1 and S2 and indicating that the theoretical maximum performance of S2 was 1.8-fold higher than that of S1 (Maximum N recovery rates of 155.65 and 281.2 g N m⁻² d⁻¹ for S1 and S2, respectively). The enhanced efficiency of S2 is ascribed to its internal flow configuration, which promotes a superior nitrogen mass transfer rate across the membrane. This design demonstrated greater robustness in managing high nitrogen loads, positioning it as a highly promising technology for practical implementation in livestock operations.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"25 ","pages":"Article 100983"},"PeriodicalIF":7.1,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145748330","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Electrospun polyacrylonitrile/bio-based polyurethane composite membranes filled with ZIF-8 and MXene as durable, thermally stable, and high-ionic-conductivity separators for aqueous zinc-ion batteries","authors":"Nattapon Tanalue ,&nbsp;Chutiwat Likitaporn ,&nbsp;Peerawat Prathumrat ,&nbsp;Wanwisa Limphirat ,&nbsp;Tawan Wongsalam ,&nbsp;Manunya Okhawilai ,&nbsp;Pranut Potiyaraj","doi":"10.1016/j.ceja.2026.101035","DOIUrl":"10.1016/j.ceja.2026.101035","url":null,"abstract":"<div><div>Aqueous zinc-ion batteries (AZIBs) are promising energy storage systems owing to their safety and low cost. However, internal short circuit failure caused by uncontrolled zinc plating is a major challenge. Here, we developed a dual-filler co-modified polyacrylonitrile (PAN)/bio-based polyurethane (PU) nanofibrous separator in which MXene was incorporated together with zeolitic imidazolate framework-8 (ZIF-8) into an electrospun 75/25 PAN/PU matrix. The concurrent presence of ZIF-8 and MXene establishes a multi-interfacial ion-regulation mechanism that homogenizes zinc ion flux and suppresses localized zinc deposition, enabling cooperative ion-transport modulation over using single-filler modification. The optimized 10%ZIF-8/MXene/PAN/PU membrane exhibited high electrolyte uptake of 2273 ± 31%, porosity of 99.4 ± 0.1%, ionic conductivity of 10.55 mS cm⁻¹, and a zinc ion transference number of 0.63, facilitating uniform ion transport and reduced polarization. In zinc||zinc symmetric cells, the membrane maintained stable charge-discharge profiles for over 500 hrs. Systematic studies further revealed that electrospinning parameters and filler content critically influenced fiber morphology, porosity, and electrochemical performance, highlighting the significance of design optimization. Notably, the dual-filler strategy enabled improving electrochemical characteristics, directly demonstrating that the observed performance enhancement originated from the co-modification effect of ZIF-8 and MXene. These results provide a new co-regulation design concept for high-safety separators that enhance the performance, reliability, and durability of AZIBs.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"25 ","pages":"Article 101035"},"PeriodicalIF":7.1,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145973192","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Injectable hydrogel adhesives for surgery: Design, cross-linking strategies, and applications","authors":"Tongyue Zhang ,&nbsp;Zheng Zou ,&nbsp;Haoyi Su ,&nbsp;Xuyao Liu ,&nbsp;Shaoxiong Lu ,&nbsp;Yuting Zhu ,&nbsp;Tieshi Luowu ,&nbsp;Huaiyuan Sun ,&nbsp;Ben Zhang ,&nbsp;Qiang Zhang","doi":"10.1016/j.ceja.2026.101032","DOIUrl":"10.1016/j.ceja.2026.101032","url":null,"abstract":"<div><div>Sutures and anastomoses are widely used for surgical closure; however, owing to their high technical requirements, operation complexity, and limitations of the methods themselves, both closure methods can result in incomplete sealing, causing secondary tissue damage. In recent years, non-invasive hydrogels have demonstrated considerable potential as medical adhesives for applications such as tissue regeneration, wound closure, and wound repair, owing to their superior biological properties and ease of operation. Among them, injectable hydrogel adhesives have attracted increasing attention in the surgical field for their handling convenience and ability to provide complete wound coverage. However, to date, no comprehensive reviews of their use in surgery have been reported. Consequently, we review progress in the design of injectable hydrogels over the past decade, including their design principles, cross-linking strategies, and evaluation methods. We also highlight their application in different surgical fields—including neurosurgery, ophthalmology, cardiothoracic surgery, general surgery, urology, plastic surgery, and orthopedic surgery. In this review, we aim to provide meaningful insights into the design of next-generation hydrogel adhesives for wound closure and tissue regeneration.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"25 ","pages":"Article 101032"},"PeriodicalIF":7.1,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145973193","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Solvent-regulated synthesis of S-scheme BiOBr/TiO2 heterojunctions: Mechanism and pathway analysis for efficient photocatalytic degradation of sodium pentachlorophenate","authors":"Ruyi Xu ,&nbsp;Xinquan Wang ,&nbsp;Nannan Wu ,&nbsp;Zhenzhen Liu ,&nbsp;Shanshan Di ,&nbsp;Huiyu Zhao ,&nbsp;Zhiwei Wang ,&nbsp;Chengbo Gu ,&nbsp;Peipei Qi","doi":"10.1016/j.ceja.2026.101043","DOIUrl":"10.1016/j.ceja.2026.101043","url":null,"abstract":"<div><div>In this study, a high-performance S-scheme heterojunction BiOBr/TiO₂ photocatalyst composite was obtained within 1 h through adjusting the key factors of one-step solvothermal method for degradation of sodium pentachlorophenate (PCP-Na). Particluarly, ethylene glycol proportion in solvent significantly influenced the morphology and crystalline phase of BiOBr/TiO₂ composite. The optimized composite featured a unique mulberry-like structure composed of densely arranged microspheres, which enhanced its specific surface area and provided abundant active sites. Compared to pure BiOBr and TiO₂, the BiOBr/TiO₂ composite exhibited a broader visible-light absorption range, more efficient charge separation and transfer, and a stronger photocurrent response. Under visible light irradiation, BiOBr/TiO₂ degraded 93.09 % of PCP-Na within 120 min, which was approximately 15 times higher than that of pure TiO₂. Mechanistic investigations indicated that ·O₂⁻ and h⁺were the primary active species involved in the photocatalytic process. The main degradation pathways invloved dechlorination and single-electron coupling reaction. Moreover, the composite exhibited high degradation efficiency for PCP-Na in real water sample under visible light and maintained good stability.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"25 ","pages":"Article 101043"},"PeriodicalIF":7.1,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146034400","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A deep learning framework for predicting and optimizing flow fields in reactive flows","authors":"Mohsen Gharib ,&nbsp;Farideh Hoseinian Maleki ,&nbsp;Philip Rößger ,&nbsp;Martin Gräbner ,&nbsp;Andreas Richter","doi":"10.1016/j.ceja.2025.100966","DOIUrl":"10.1016/j.ceja.2025.100966","url":null,"abstract":"<div><div>Computational Fluid Dynamics (CFD) is widely used for solving and optimizing the flow fields of different systems and applications. However, running CFD simulations, especially for reactive flow systems, can be very time consuming and memory intensive, which limits e.g. design space exploration in the optimization tasks. In this work, a data-driven modeling methodology has been developed to predict 2D flow distributions in a chemical reactor. The primary objective was establishing correlations between global boundary conditions (including process and geometrical parameters), and the resulting CFD flow field distributions. A convolutional autoencoder was used to compress and reduce the data dimensions efficiently. Simultaneously, a multilayer perceptron served as the mapping mechanism that linked the global boundary conditions to the compressed data. The methodology developed in this work provides a very successful demonstration of its ability to map both geometric and process parameters to flow fields. The results showed a prediction accuracy of approximately 94%–97% for the CFD cases, indicating a very high prediction quality. Besides this, the prediction time was less than a second, which is significantly lower compared to the computational effort required for CFD simulations. To demonstrate the practical applicability of this approach, an interactive tool was developed to enable real-time visualization of predicted flow fields. This tool represents a foundational step towards applying digital twins and integrating such models into industrial practice.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"25 ","pages":"Article 100966"},"PeriodicalIF":7.1,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145623445","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Morphological evolution and recovery of high-purity ZnO from zinc roasting dust via pyrometallurgical reduction","authors":"Seon Ho Sim ,&nbsp;Ki Min Roh ,&nbsp;Tae Jun Park","doi":"10.1016/j.ceja.2025.100974","DOIUrl":"10.1016/j.ceja.2025.100974","url":null,"abstract":"<div><div>Zinc oxide (ZnO) is a versatile functional material with widespread applications in ceramics, coatings, catalysts, and optoelectronics, where high-purity ZnO is required. In this study, zinc roaster fume dust, a major metallurgical byproduct, was utilized as an alternative feedstock to produce ZnO through a dry reduction–reoxidation process. The reduction conditions, such as the reduction temperature (1100–1400 °C), reductant content (10–20 wt% coke with respect to the feedstock), and reaction time (30–90 min), were systematically explored to maximize ZnO recovery. The best-performing condition was 1150 °C for 60 min with 15 wt% coke, yielding ZnO of ∼99.5 wt% purity, as verified by inductively coupled plasma optical emission spectrometry and X-ray diffraction. Morphological characterization of the recovered ZnO powder revealed a distinct temperature-dependent phase transition; at ≤1150 °C, hexagonal prismatic crystals dominated due to anisotropic growth along [0001], whereas at higher temperatures spherical particles prevailed, consistent with supersaturation-driven nucleation of Zn vapor followed by rapid reoxidation. The particle-size distribution narrowed with increasing temperature, while agglomeration above ∼1300 °C broadened the mean size, indicating an upper thermal limit for uniform powders. these results demonstrate that dry reduction–reoxidation offers an effective and environmentally benign pathway to recover industrial-grade, high-purity ZnO from zinc fume dust while enabling morphology control via thermally tunable nucleation–growth regimes.</div></div>","PeriodicalId":9749,"journal":{"name":"Chemical Engineering Journal Advances","volume":"25 ","pages":"Article 100974"},"PeriodicalIF":7.1,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145747812","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}