Chemical Engineering and Processing - Process Intensification最新文献

{"title":"Numerical investigations of liquid–liquid extraction through a coiled tube integrated with an extraction outlet","authors":"Almoatasem-Bellah K. Abdelnaeem ,&nbsp;Dominique Thévenin ,&nbsp;Katharina Zähringer ,&nbsp;Abouelmagd Abdelsamie ,&nbsp;Michael Mansour","doi":"10.1016/j.cep.2025.110310","DOIUrl":"10.1016/j.cep.2025.110310","url":null,"abstract":"<div><div>This study numerically investigates the extraction of two immiscible liquids through coiled tubes integrated with an extraction outlet. Assuming a fully mixed initial state, representing the worst-case scenario, the research explores optimal conditions for achieving pure extraction of each liquid through different outlets. Two laminar Reynolds numbers of 225 and 563, along with seven different outlet split ratios, were analyzed for horizontal-axis coiled tubes. The effects of geometrical parameters and flow conditions on extraction efficiency were examined. For an inlet amine volume fraction of 50%, the results indicate that optimal extraction occurs at a split ratio of 0.5, with enhanced performance at Re = 563 compared to Re = 225. Sharp-edged, constant-diameter extraction tubes outperformed rounded and nozzle-type configurations while reducing the extraction tube diameter diminished the efficiency. Furthermore, an extraction at a coil angle of 675° (2 turns minus 45°) provided better efficiency compared to 765° (2 turns plus 45°). It is therefore recommended to operate near Re = 563, utilize a straight extraction tube with the same diameter as the coiled tube, and employ a sharp-edged connection at a coil angle of 675°. The extraction split ratio should align with the inlet rate of the lighter phase.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110310"},"PeriodicalIF":3.8,"publicationDate":"2025-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143868059","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":"Process intensification and economic evaluation of adiponitrile production based on hybrid modeling","authors":"Wenwen Cong,&nbsp;Xiaolin Hou,&nbsp;Rui Xiao,&nbsp;Jiaojiao Zhang,&nbsp;Yuying Zhang,&nbsp;Siliang Jiao","doi":"10.1016/j.cep.2025.110325","DOIUrl":"10.1016/j.cep.2025.110325","url":null,"abstract":"<div><div>Adiponitrile (ADN) is a crucial chemical used to produce Nylon 66, with potential applications in civilian clothing, specialized equipment, and new energy vehicles. This paper outlines a method for producing adiponitrile from 1,3-butadiene hydrocyanation and enhances it using process simulation and machine learning (ML). The system is optimized for energy savings and assessed economically. An artificial neural network (ANN) model is developed to predict ADN product molar flow and system energy consumption. The Non-dominated Sorting Genetic Algorithm II (NSGA-II) algorithm is used to optimize two goals: increasing ADN yield and reducing system energy consumption. The prediction results show that the coefficient of determination (<em>R</em>²) for both system energy consumption and ADN product flow is greater than 0.989, with the Mean Absolute Percentage Error (<em>MAPE</em>) value less than 0.01. The optimization results indicate a 2.31 % reduction in system energy consumption and a 1.85 % increase in ADN product flow.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110325"},"PeriodicalIF":3.8,"publicationDate":"2025-04-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143855251","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 open-source framework for the multi-objective optimization of passive micromixer based on RSM and MOEA/D","authors":"Zhen Li ,&nbsp;Jiarun Lou ,&nbsp;Weiwei Li ,&nbsp;Renhao Wang ,&nbsp;Quanliang Dong ,&nbsp;Xiangyao Xue ,&nbsp;Shuai Shao","doi":"10.1016/j.cep.2025.110316","DOIUrl":"10.1016/j.cep.2025.110316","url":null,"abstract":"<div><div>Balancing the mixing index, pressure drop and mixing energy consumption is crucial for enhancing the performance of passive micromixers. In this paper, a T-shaped micromixer scheme integrating cylindrical obstacles and contraction-expansion parts is proposed and the geometric parameters are studied in order to achieve multi-objective optimization. The geometry of the micromixer is optimized by selecting three design variables (<em>L₁, L₂</em> and <em>D_cy</em>), where <em>L₁</em> and <em>L₂</em> are used to adjust the changes in the cross section of the flow channel and <em>D_cy</em> controls the diameter of the cylindrical obstacle. For different Reynolds numbers (0.1 and 100), COMSOL simulation and Box-Behnken experiment design are used to evaluate the effects of each design variable on the mixing evaluation indicators. The findings indicate that <em>L₂</em> exerts the most substantial influence on the performance of the micromixer. It can effectively modify the width of the flow channel, thereby optimizing the fluid velocity and concentration gradient, and consequently having a significant impact on mixing evaluation indicators. Regarding multi-objective optimization, the decomposition based multi-objective evolutionary algorithm (MOEA/D) is used to construct the Pareto optimal solution. This algorithm offers a balanced scheme between different mixing evaluation indicators. The experimental results demonstrate that the optimized micromixer can not only enhances the mixing index but also remarkably reduces the pressure drop. It can achieve a complete mixing effect while reducing the pressure drop by nearly 41% compared to the passive micromixer using two-layer serpentine crossing channels when <em>Re</em> = 100, which is especially suitable for microfluidic applications such as biochemical detection. Furthermore, this study makes the MATLAB program source code used in the calculation process publicly available, which provides a strong support for the subsequent research and application.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110316"},"PeriodicalIF":3.8,"publicationDate":"2025-04-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143860577","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":"Optimization and Control of Continuous Biodiesel Production Processes: A Review","authors":"Dr. Aparna Gautam","doi":"10.1016/j.cep.2025.110323","DOIUrl":"10.1016/j.cep.2025.110323","url":null,"abstract":"<div><div>Biodiesel is an eco-friendly, low-toxicity biofuel that reduces greenhouse gas emissions, making it a promising alternative to fossil fuels. Biodiesel production requires the transesterification of lipids with alcohol, a process heavily dependent on efficient catalyst and optimized reactor design. Batch-type reactors present challenges such as extended residence time, high operating expenses, significant energy consumption with limited production efficiency. To address these issues, scientists are currently concentrating on continuous flow biodiesel production methods.</div><div>Current studies on biodiesel production have concentrated on utilizing process intensification methods to tackle major challenges. These methods involves novel reactor configurations and combined reaction/separation procedure that boost the reaction speeds, decrease the alcohol-to-oil ratio, <em>in-situ</em> product separation, and minimize energy usage. With the help of these advancements, continuous production in scalable units has become feasible, leading to the successful commercialization of various technologies. Building on these advancements, this review examines two decades of research on continuous biodiesel production, exploring process simulation, optimization, and control aspects. It further delves into strategies for process intensification, scale-up methodologies, and techno-economic analysis, offering a comprehensive understanding of the field's progress and future potential.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110323"},"PeriodicalIF":3.8,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143860579","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":"Study on gas-solid flow characteristics of loop seal surge in circulating fluidized bed boiler","authors":"Xin Shen ,&nbsp;Xiaoqian Li ,&nbsp;Hairui Yang ,&nbsp;Yan Jin","doi":"10.1016/j.cep.2025.110322","DOIUrl":"10.1016/j.cep.2025.110322","url":null,"abstract":"<div><div>During the operation of a 350 MWe supercritical circulating fluidized bed (CFB) boiler, a low-frequency surge in the loop seal can lead to cracks in the castable material of the internal insulation layer, thereby impacting normal and safe boiler operation. Using the computational particle fluid dynamics (CPFD) method, the effect of a low-frequency loop seal surge on the gas-solid flow of a 350 MWe supercritical CFB boiler was studied in this paper. The causes, parameters and elimination conditions of the loop seal surge were analysed. The results show that when the loop seal is under a surge condition, the pressure drop gradient is greater than the critical material sealing value of 3526 Pa/m, and the material flow in the downcomer is not smooth. The volume fraction of material particles in the loop seal is low, which cannot effectively seal the material. When the primary fluidized air, supply air, and recycle air are controlled within a reasonable range, the loop seal surge can be effectively prevented. The acceptable range for primary fluidized air is 14.5 m/s to 16.0 m/s; for supply air, it is 0.05 m/s to 0.10 m/s; and for recycle air, it is 1.0 m/s to 1.5 m/s.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110322"},"PeriodicalIF":3.8,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143860575","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":"Creating resilient networks of microreactors: A graph theory approach","authors":"Jaxyn Kirian ,&nbsp;Michael Abeiku Daniels ,&nbsp;Krista Harris ,&nbsp;Agnieszka Truszkowska","doi":"10.1016/j.cep.2025.110306","DOIUrl":"10.1016/j.cep.2025.110306","url":null,"abstract":"<div><div>The practical integration of numerous microreactors into networks is still a challenge that hinders the use of microtechnology on a commercial scale. One major difficulty is achieving uniform flow rates inside all interconnected microreactors. In this work, we construct microreactor networks using topologies inspired by the classical graph theory and study them with the flow network model. We propose methodology for creating, modeling, and quantifying the performance of the networks with up to 58 devices. We study the flow uniformity inside the microreactor networks, their response to malfunctioning, and their recovery from various levels of damage. We found that all investigated network topologies had acceptable performance, even after sustaining considerable damage, and identified designs that outperformed the others in various aspects. We also showed that repairing a heavily malfunctioning network is not trivial for any topology, including simple ones. Finally, we confirmed select findings with three-dimensional direct numerical simulations.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110306"},"PeriodicalIF":3.8,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143843625","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":"Deep purification of trace fine particles in hydrogenated oil by microchannel separator","authors":"Pengcheng Tao ,&nbsp;Aosong Wei ,&nbsp;Li Dai ,&nbsp;Zhuofan Deng ,&nbsp;Dingliang Xu ,&nbsp;Cao Heng ,&nbsp;Xiafei Wu ,&nbsp;Wenjie Lv ,&nbsp;Hualin Wang","doi":"10.1016/j.cep.2025.110321","DOIUrl":"10.1016/j.cep.2025.110321","url":null,"abstract":"<div><div>The purification of hydrogenated oil using diatomaceous earth filtration separators has the high economic costs and material consumption. Previously, our team had achieved some industrial advantages by treating hydrogenated oils with microchannel separators; however there is still room for deep purification of micron-sized particulate pollutants.</div><div>In this study, a pilot-scale microchannel separator with a capacity of 1 m³/h was used for the deep purification of hydrogenated oil following the industrial-scale microchannel separator to enhance the its separation precision. Two separation media with equivalent diameters were used. The pilot microchannel separator was filled with a finer separating medium with an equivalent diameter of 0.3 ∼ 0.6 mm, which achieved an average turbidity reduction of 13.3 %. Moreover, the total particle number exhibited an average decrease of 43.4 %. The deep purification treatment extended the operation cycle of the downstream diatomite filter to 1.7 times its original duration. Using the microchannel separator, a projected reduction of 15 tons/year in solid waste discharge is anticipated for a petroleum resin process with a treatment capacity of 40 m³/h. This translates to an annual cost saving of 27 %.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110321"},"PeriodicalIF":3.8,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143833811","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":"Efficiency and multi-objective optimization of gas-liquid-phase mass transfer in high-viscosity fluids within heart-shaped microchannels","authors":"Feiyu Gao ,&nbsp;Jinli Guo ,&nbsp;Wei Zhang ,&nbsp;Yaqi Hou ,&nbsp;Jiahua Hu","doi":"10.1016/j.cep.2025.110319","DOIUrl":"10.1016/j.cep.2025.110319","url":null,"abstract":"<div><div>Microchannels are widely utilized in the microchemical industry due to their highly efficient and enhanced mass transfer properties. However, when processing high-viscosity fluids, the flow pressure drop in microchannels significantly increases, posing challenges for system performance. To address this, it is crucial to control both mass transfer and pressure drop in gas-liquid two-phase systems in microchannels under high-viscosity conditions. This study investigates the mass transfer and flow behavior of high-viscosity fluids in heart-shaped microchannels (Advanced Flow Reactor, AFR). Experimental visualization techniques are employed to explore the effects of bubble size distribution, gas content, and pressure drop on the gas-liquid two-phase flow and its mass transfer characteristics in high-viscosity systems. A predictive model for the pressure drop in these heart-shaped microchannels is also developed. Air and high-viscosity glycerol-water solution (viscosity range of 50–320 mPa·s) are selected as the gas-liquid two-phase system. The experimental operating conditions are optimized using the enhanced multi-objective NSGA-II algorithm to identify a set of critical process parameters that balance low pressure drop with high mass transfer coefficient. The results demonstrate that compared to the liquid-phase volumetric mass transfer coefficients (<em>K_la</em>) at the lowest gas-phase flow rate for each viscosity, the increase in <em>K_la</em> is 53 %–122.7 % for viscosities ranging from 50 to 150 mPa·s. This improvement is accompanied by a 70 %–100 % increase in gas-phase flow rate and a corresponding 30 %–58 % rise in pressure drop. Optimization results indicate under ideal experimental conditions, mass transfer efficiency is enhanced, and pressure drop loss is reduced by an average of 53 %, despite a small reduction in the mass transfer coefficient. This suggests that an optimal design can effectively balance mass transfer efficiency with pressure drop reduction, offering practical solutions for high-viscosity gas-liquid two-phase systems. The findings provide a theoretical foundation for optimizing microchannel operating parameters in high-viscosity systems and achieving multi-objective optimization with low pressure drop and high mass transfer efficiency.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110319"},"PeriodicalIF":3.8,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143850771","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":"Prediction of bend-pipeline erosion field based on CFD and reduced order method","authors":"Lijing Mu ,&nbsp;Shengxuan He ,&nbsp;Sheng Chen ,&nbsp;Xizhong Chen ,&nbsp;Jinhai Shi ,&nbsp;Yongmin Zhang ,&nbsp;Cenfan Liu","doi":"10.1016/j.cep.2025.110320","DOIUrl":"10.1016/j.cep.2025.110320","url":null,"abstract":"<div><div>In this paper the accuracy and efficiency of the Reduced Order Model (ROM), a machine learning algorithm, for predicting hydrodynamic behavior and erosion wear phenomena in a gas-solid two-phase flow pipeline system were investigated by performing a comprehensive comparison between ROM predictions and Computational Fluid Dynamics (CFD) results. Firstly, the accuracy of CFD simulation results among three erosion models, Oka, Vieira and DNV erosion models, was validated by comparison with experimental data. The Oka model was found to be more precise in predicting the erosion phenomena of the multiphase flow in pipeline. Secondly, the rational and efficiency of ROM predictions were examined, which the tendencies of hydrodynamic multiphase flow behaviors and erosion wear phenomena were discerned in agreement with CFD results. Furthermore, it is found that ROM predictions could save computational time by more than three orders of magnitude compared to the CFD method. Thirdly, the influence of design points and mode number on static pressure and erosion rate distribution was studied to enhance the accuracy of ROM predictions. Then, for a comprehensive validation of ROM predictions, four operating conditions with different gas inlet velocities and particle mass fluxes were analyzed. The result indicates that ROM predictions, under the recommended selection of design points and mode number, demonstrate a relatively good correspondence with CFD results both quantitatively and qualitatively. Finally, ROM predictions were utilized on a 135-degree industry pipe, enabling prompt and precise prediction of both the erosion position and erosion rate for the gas-particle industrial elbow pipe by conducting a comparison with the industrial measurement data.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110320"},"PeriodicalIF":3.8,"publicationDate":"2025-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143829817","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":"Determining residence time distributions in oscillatory baffled reactors: A comparison between experiments and CFD-simulations","authors":"Matthias Adams ,&nbsp;Georgios D. Stefanidis ,&nbsp;Tom Van Gerven","doi":"10.1016/j.cep.2025.110297","DOIUrl":"10.1016/j.cep.2025.110297","url":null,"abstract":"<div><div>Oscillatory flow reactors are a process intensification technology that aims at enabling plug flow-like operation for inherently slow processes. However, the plug flow regime is usually challenging to obtain in practice. To that end, this work focuses on simulating residence time distributions in oscillatory baffled reactors with for the first time an experimental validation of the simulated results. Four different physical models are implemented to simulate residence time distributions: 2D-axisymmetric laminar, 2D-axisymmetric turbulent <span><math><mi>κ</mi></math></span>-<span><math><mi>ϵ</mi></math></span>, 3D laminar and 3D turbulent <span><math><mi>κ</mi></math></span>-<span><math><mi>ϵ</mi></math></span>. Different flow conditions are tested ranging between 50 and 250 for the net Reynolds number and 50 and 300 for the oscillatory Reynolds number. The comparison between experiments and simulations is done qualitatively and quantitatively. The quantitative parameters include: the mean residence time, the root mean square error and the number of ideal tanks in series. The results show that in almost all tested flow conditions 3D laminar physics are necessary to predict the experimental residence time distribution. However, for the tested flow parameters, literature advises in general to use 2D-axisymmetric laminar physics to model local flow patterns. This demonstrates the need for new guidelines to model global parameters in oscillatory baffled reactors and the importance of experimental validation.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110297"},"PeriodicalIF":3.8,"publicationDate":"2025-04-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143833896","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}