Chemical Engineering and Processing - Process Intensification最新文献

{"title":"Re-evaluating 2-heptanol as solvent for the extraction of 2,3-butanediol from water","authors":"William Graf von Westarp,&nbsp;Janik Hense,&nbsp;Moritz Haas,&nbsp;Andreas Jupke","doi":"10.1016/j.cep.2025.110591","DOIUrl":"10.1016/j.cep.2025.110591","url":null,"abstract":"<div><div>The performance of an extraction-distillation process for separating 2,3-butanediol from H₂O was evaluated in a recent study, finding high efficeincy when using 2-heptanol as solvent for extraction. Since the study was based on liquid-liquid equilibrium (LLE) data mainly derived from molecular simulations, the aim of this communication was to consolidate the database by providing experimental phase equilibrium data and to re-evaluate 2-heptanol as solvent. Based on LLE experiments, a solvent-to-feed ratio (S/F) of 3.175 was required to recover 95 % of 2,3-BDO in a counter-current extraction column. This S/F is 21.9 times higher than the estimation derived from the data based on molecular simulations. The high S/F results in a strong dilution of 2,3-BDO in the extract. Experimental investigation of the boiling point data of the 2,3-BDO – 2-heptanol system for subsequent distillation revealed the presence of a temperature minimum azeotrope at low 2,3-BDO concentrations, which limits the feasibility of the overall process. Since the use of 2-heptanol as solvent is oftentimes referred to in the community of diol separation, the results presented in the work at hand are relevant to a broad readership.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"219 ","pages":"Article 110591"},"PeriodicalIF":3.9,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145322470","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 investigation of conservation of fluid oscillation in a continuous oscillatory baffled reactor","authors":"Qi Feng Chan,&nbsp;Alexander Riddell,&nbsp;Calum Selman,&nbsp;Jianyu Wang,&nbsp;Rohen Prinsloo,&nbsp;Xiong-Wei Ni","doi":"10.1016/j.cep.2025.110621","DOIUrl":"10.1016/j.cep.2025.110621","url":null,"abstract":"<div><div>Continuous oscillatory baffled reactors (COBRs) have been utilised in organic synthesis and crystallisation, however, no validation work has yet been conducted to determine if the fluid displacement caused by the oscillation at the start of the COBR is conserved at the end of the COBR. This work reports, <em>for the first time</em>, both experimental measurements and theoretical evaluations of the displacement. The experimental validation involves physically measuring the fluid displacement using a laser distance sensor located at the end of the COBR. Surprisingly, the measured displacement values at some operating conditions differ from the initial settings. The theoretical evaluation entails the determination of power dissipation across the COBR using the pressure measurements at four locations along the COBR. The model evaluated displacements agree well with the experimental measurements at all operational conditions, validating the methodologies used in this work.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"219 ","pages":"Article 110621"},"PeriodicalIF":3.9,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145516399","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":"Research on the treatment of neodymium iron boron (NdFeB) waste by flash reduction melting method","authors":"Lei Guo,&nbsp;Haojie Zheng,&nbsp;Kaidi Mu,&nbsp;Zhancheng Guo","doi":"10.1016/j.cep.2025.110639","DOIUrl":"10.1016/j.cep.2025.110639","url":null,"abstract":"<div><div>Neodymium iron boron (NdFeB) is a third-generation rare earth permanent magnet material, and its production process generates waste containing approximately 30 % rare earth elements. If not recycled, this waste of rare earth resources will also have an impact on the environment. This paper presents a method for treating NdFeB waste through flash reduction melting. The separation of slag and iron can be effectively achieved through the combined process of pre-reduction and flash melting, along with grinding and magnetic separation of the particles. Particles smaller than 30 μm achieve effective separation of slag and iron via flash reduction melting combined with grinding and magnetic separation, whereas particles larger than 30 μm require pre-reduction treatment. This study also examines the effects of particle size and pre-reduction on flash reduction melting and develops a process route for the flash reduction treatment of NdFeB waste. After the two-step process, the metallization rate of the particles exceeds 95 %, yielding spherical metallic iron powder and rare earth slag following grinding and magnetic separation. The Nd content in the rare earth slag reaches up to 62 %, while the iron content in the iron powder can reach 95 %.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"219 ","pages":"Article 110639"},"PeriodicalIF":3.9,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145681269","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":"Influence of sonication-dilution sequence on ZnO nanorod growth from aqueous precursors","authors":"Anna Drabczyk ,&nbsp;Wojciech Bulowski ,&nbsp;Grzegorz Putynkowski ,&nbsp;Jakub Cyganek ,&nbsp;Patryk Kasza ,&nbsp;Katarzyna Bucka ,&nbsp;Robert P. Socha","doi":"10.1016/j.cep.2025.110653","DOIUrl":"10.1016/j.cep.2025.110653","url":null,"abstract":"<div><div>Zinc oxide (ZnO) is a wide-bandgap semiconductor that exhibits excellent optical, electrical, piezoelectric, and photocatalytic properties. Its one-dimensional nanostructures, particularly nanorods, are of great interest for applications in optoelectronics, sensors, solar cells and transparent electrodes. The performance of such devices strongly depends on nanorod morphology, which is highly sensitive to synthesis conditions. Although low-temperature, solution-based methods for ZnO nanorod fabrication are widely accessible, achieving reproducible control over their alignment, density and aspect ratio remains challenging. In particular, the impact of precursor suspension processing – especially the sequence of physicochemical steps such as sonication and dilution – has been largely overlooked, despite its critical role in determining dispersion quality and nanorod formation. This study addresses this gap by systematically investigating how the order of suspension processing steps affects the structural and functional characteristics of ZnO nanorods synthesized via an aqueous route. Two sequences – (i) dilution followed by sonication and (ii) sonication followed by dilution – were compared using rheological measurements, dynamic light scattering (DLS), scanning electron microscopy (SEM), UV-Vis spectroscopy and contact angle analysis. The results showed that performing sonication before dilution significantly improved suspension homogeneity, reduced viscosity, and enhanced nanorod growth. Nanorod height increased with heating temperature, while diameter showed no consistent trend. Wettability and optical haze were also strongly influenced by synthesis conditions. By identifying a simple and effective way to control precursor dispersion, this work solves a practical problem in ZnO nanorod synthesis and provides a strategy for enhancing the reproducibility of morphology-dependent properties.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"219 ","pages":"Article 110653"},"PeriodicalIF":3.9,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145733514","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":"Modeling and performance assessment of innovative hybrid electro-disinfection processes for Escherichia coli inactivation in water","authors":"Murat Solak ,&nbsp;Rüya Tekin Karaköse","doi":"10.1016/j.cep.2025.110594","DOIUrl":"10.1016/j.cep.2025.110594","url":null,"abstract":"<div><div>Pathogenic strains of <em>Escherichia coli</em> (<em>E. coli</em>) represent a major public health concern when transmitted through contaminated water, making their effective elimination a global priority. This study investigates a hybrid electro-disinfection system for <em>E. coli</em> inactivation that combines electrocoagulation (EC) and electrooxidation (EO) in a single reactor. Microbial inactivation kinetics were evaluated under varying hybrid electrode configurations (Al/SS/TiPbO₂ and Al/SS/TiIrO₂) and current densities (0.625, 1.25 and 1.875 mA/cm²). Inactivation behavior was described using a variety of kinetic models. Data were analyzed using GInaFiT (Geeraerd and Van Impe Inactivation Fitting Tool), and the model performance was assessed through statistical indicators (R²<em>,</em> AICc<em>,</em> BIC) alongside biological interpretability. Residual Al (Aluminium) and Pb (Lead) concentrations remained below WHO (World Health Organization), EPA (Environmental Protection Agency), and EU (European Union) limits, ensuring water safety. Strong correlations between OD₆₀₀ and microbial reduction validated optical density as a rapid monitoring tool. Integration of solar panels further enhanced energy efficiency. Overall, it was determined that the hybrid EC–EO system is a quick, efficient, and environmentally friendly disinfection method for the well-suited for off-grid and decentralized applications.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"219 ","pages":"Article 110594"},"PeriodicalIF":3.9,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145359792","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":"Turbulent collisions of inertial particles considering particle-particle interactions","authors":"Junwen Wang ,&nbsp;Fang Zhang ,&nbsp;Wei Cui ,&nbsp;Jichao Lin ,&nbsp;Jianchun Wang ,&nbsp;Songying Chen ,&nbsp;Guichao Wang","doi":"10.1016/j.cep.2025.110622","DOIUrl":"10.1016/j.cep.2025.110622","url":null,"abstract":"<div><div>By comparing the one-way coupled point-particle method with an interaction-inclusive point-particle model, the differences were analyzed in the radial distribution function, radial relative velocity, and dynamic collision kernel under various turbulent kinetic energy dissipation rates and Stokes numbers. The findings reveal that considering inter-particle interactions leads to a more dispersed particle distribution, resulting in a lower and smoother radial distribution function compared to the one-way coupled approach. The dynamic collision kernel was found to be larger when inter-particle interactions were included, as more collision events were generated by these interactions.</div><div>The effects of particle size and density on collision statistics were investigated using the interaction-inclusive point-particle model. The results indicate that when the particle radius is 25 μm, the radial distribution function and dynamic collision kernel are maximized, while the radial relative velocity decreases as particle radius decreases. Notably, for all three particle sizes, the radial relative velocity reaches its peak at a Stokes number of approximately 1.5. The collision statistics were compared for three different particle densities under varying turbulence intensities, which indicates that the radial distribution function attains its highest value at a Stokes number of approximately 1.5, with the peak value for 5 g/cm³ particles exceeding that of 3 g/cm³ and 8 g/cm³ particles.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"219 ","pages":"Article 110622"},"PeriodicalIF":3.9,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145614441","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":"A dynamic PCA and transformers coupled reduced-order model for transient solid-liquid flows in stirred tanks","authors":"Yu Jiang ,&nbsp;Edmond Byrne ,&nbsp;Xizhong Chen ,&nbsp;Jarka Glassey","doi":"10.1016/j.cep.2025.110605","DOIUrl":"10.1016/j.cep.2025.110605","url":null,"abstract":"<div><div>Solid-liquid mixing in stirred tanks is critical in industries such as pharmaceuticals and chemicals, where uniform mixing enhances product quality and operational efficiency. In this study, a reduced-order model (ROM) based on dynamic Principal Component Analysis (DPCA) and Transformer coupled approach was developed to predict transient solid-liquid mixing dynamics in stirred tanks. The model leverages DPCA to decompose the system’s spatial dynamics and captures the temporal evolution with a Transformer network. The results showed that DPCA significantly reduced the dimensionality of the system, while the Transformer model captured the temporal dynamics effectively. The DPCA decomposition revealed flow structures with cylindrical symmetry, particularly around the impellers, which are crucial for understanding mixing efficiency. This work demonstrates the feasibility of combining DPCA and Transformer networks for real-time, and optimization of industrial mixing processes, offering a significant reduction in computational costs while maintaining predictive accuracy.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"219 ","pages":"Article 110605"},"PeriodicalIF":3.9,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145413212","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":"Intensified recovery of vanadium via ultrasonic-assisted hydrolysis","authors":"Hao Peng,&nbsp;Teng Liu,&nbsp;Qiuyan Wu,&nbsp;Wenjing Pan,&nbsp;Jingjing Wang,&nbsp;Bing Li","doi":"10.1016/j.cep.2025.110647","DOIUrl":"10.1016/j.cep.2025.110647","url":null,"abstract":"<div><div>This study examined the hydrolysis process of vanadium solutions, enhanced by ultrasonic technology, focusing on the effects of key variables such as pH, initial vanadium concentration, reaction time, and reaction temperature. The results indicated that hydrolysis was an effective method for vanadium recovery, significantly improved by ultrasound technology. A precipitation efficiency of 99.75 % was achieved under the optimal conditions: initial vanadium concentration of 10 g/L, a pH of 1.8, reaction temperature of 60 °C, reaction time of 60 min and stirring rate at 400 rpm. The XRD and SEM analyses confirmed that the hydrolyzed product was HNaV₆O₁₆·4H₂O, exhibiting a hydrangea-like morphology. Kinetic analysis of crystallization, based on the Avrami model, revealed an Avrami exponent of <em>n</em> = 2.6 ± 0.3 across various temperatures, suggesting that the precipitation mechanism was independent of temperature. It was also determined that the ultrasonic-assisted hydrolysis-precipitation process followed an interface-controlled growth mechanism for three-dimensional crystals, characterized by a decreasing nucleation rate.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"219 ","pages":"Article 110647"},"PeriodicalIF":3.9,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145681266","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":"Ultrasound-assisted upcycling of thermal transfer ink ribbons into purified terephthalic acid and carbon black","authors":"Lokesh Mekala ,&nbsp;Kathula Naresh ,&nbsp;Vikas Choudhary ,&nbsp;Radha Kumari Muktham ,&nbsp;Alka kumari ,&nbsp;Vineet Aniya","doi":"10.1016/j.cep.2025.110619","DOIUrl":"10.1016/j.cep.2025.110619","url":null,"abstract":"<div><div>In the present study, the recycling of waste generated from thermal-sensitive transfer ink ribbons (TTR) is investigated to produce purified Terephthalic acid (TPA) and Carbon black (CB). Utilizing an ultrasound-assisted method, the process depolymerizes the Polyethylene Terephthalate (PET Film) in the ribbons into TPA via NaOH-catalyzed hydrolysis. From the preliminary solvent system screening, DCM-Methanol showed the highest yield and purity of TPA among xylene, chloroform, acetone, and tetrahydrofuran, combined with methanol and ethanol. A three-level Box-Behnken design (BBD) is adopted to optimize the alkaline hydrolysis reaction conditions (solvent weight ratio, catalyst wt.%, and time) to achieve maximum yield and purity. The experimental data closely matched predicted outcomes, producing significant quadratic models with high R² values (&gt;0.99). The maximum yield (94.9 %) and purity (99.7 %) of TPA are observed at DCM-Methanol wt. ratio of 70:30, catalyst 5 wt.%, and reaction time of 12.5 min at 45 °C, and a solid-liquid ratio of 1:10. The CHNS analysis of recovered carbon black from TTR showed, before purification, 79.37 % and after purification, 88.03 % C content. Further, the evaluation of the energy economy factor and environmental energy impact factor of the proposed investigation demonstrated the ability of the method to turn TTR waste into valuable resources.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"219 ","pages":"Article 110619"},"PeriodicalIF":3.9,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145517086","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":"Extractive middle-wall dividing wall column with ionic liquid entrainer for enhanced ternary azeotrope separation","authors":"Hengyan Zhou ,&nbsp;Qingjun Zhang ,&nbsp;Guoqiang Huang ,&nbsp;Mingxin Hou ,&nbsp;Wenyu Xiang ,&nbsp;Chunjiang Liu","doi":"10.1016/j.cep.2025.110613","DOIUrl":"10.1016/j.cep.2025.110613","url":null,"abstract":"<div><div>Conventional extractive distillation for ternary azeotrope separation suffers from excessive entrainer consumption, high energy demand, and capital costs. Process intensifications, such as heat-integrated distillation and top-wall dividing wall columns, have emerged to mitigate these limitations. However, these methods fail to address the fundamental challenge of coupling multiple extraction processes. To overcome this limitation, this study proposes an extractive middle-wall dividing wall column process (E-MDWC). The E-MDWC integrates two extractive processes, with the entrainer fed above the dividing wall, altering flow patterns and enhancing the mass-energy transfer in the column. This not only enhances separation efficiency but also reduces operating costs. In this paper, the COSMO-SAC model was employed to screen [BMIM][OAc] as the optimal entrainer for separating acetonitrile-ethanol-water azeotropes. The E-MDWC process was optimized using the NSGA-II to minimize the total annual cost (TAC) and CO₂ emissions. Compared to the conventional ternary extractive distillation process and the extractive top-wall dividing wall column process, the E-MDWC achieves reductions in TAC by 13.06 % and 9.43 %, and in CO₂ emissions by 10.45 % and 7.53 %, respectively, highlighting its superior performance. This study highlights the potential of E-MDWC as an advanced, economical, and sustainable solution for separating complex ternary azeotropes, particularly when utilizing low-volatility entrainers.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"219 ","pages":"Article 110613"},"PeriodicalIF":3.9,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145517088","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}