Mehdi Razavifar , Alireza Roozbahani , Amir Raoof , Jafar Qajar
{"title":"Impact of ultrasonic waves on physicochemical characteristics of subsurface fluid-rock systems: A review on mechanisms, synergistic effects, and applications","authors":"Mehdi Razavifar , Alireza Roozbahani , Amir Raoof , Jafar Qajar","doi":"10.1016/j.cep.2025.110471","DOIUrl":"10.1016/j.cep.2025.110471","url":null,"abstract":"<div><div>In recent decades, ultrasonic treatment has emerged as an environmentally friendly method for remediating groundwater contamination, enhancing the recovery of subsurface hydrocarbons, and improving the properties of fluid-rock interactions in subsurface systems. This review provides a comprehensive overview of the thermal, mechanical, and chemical mechanisms underlying ultrasonic wave propagation in porous media, with emphasis on its applications in groundwater remediation and enhanced hydrocarbon recovery. We explore ultrasound's capabilities in disintegrating organic and inorganic scales, reducing fluid viscosity, evolving emulsion systems, and improving permeability and wettability in subsurface environments. Particular attention is given to the synergistic effects achieved by combining ultrasound with other physical and chemical methods, such as chemical injection, thermal treatments, and nanofluid-enhanced recovery. Practical implications are discussed, including the stimulation of hydrocarbon-bearing formations, removal of formation damage, enhancement of sweep efficiency, and disruption of biofilms in groundwater systems, based on recent laboratory and field-scale studies. Despite its promise, field-scale implementation remains limited by challenges in modeling wave propagation and optimizing sonication parameters under variable formation conditions. Future research directions are proposed to advance scalable, sustainable ultrasound-based technologies in subsurface engineering.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110471"},"PeriodicalIF":3.9,"publicationDate":"2025-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144724729","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}
Doha Fares, Yazed Abdelaziz, Mingmei Wang, Erqiang Wang
{"title":"Application of dividing wall column technology for liquid petroleum gas fractionation and optimization using whale optimization algorithm and hybrid approaches","authors":"Doha Fares, Yazed Abdelaziz, Mingmei Wang, Erqiang Wang","doi":"10.1016/j.cep.2025.110472","DOIUrl":"10.1016/j.cep.2025.110472","url":null,"abstract":"<div><div>Dividing Wall Columns (DWC) have gained significant attention for their ability to reduce energy consumption and capital costs in chemical separation processes. However, achieving an optimal design remains a complex challenge due to the nonlinear and multivariable nature of DWC systems This study aims on the application of DWC in liquid petroleum gas (LPG) fractionation process, to reduce high energy cost of traditional two-tower process, and compares different optimization algorithms, including the Whale Optimization Algorithm (WOA) and two novel hybrid variants, GA-WOA and GA-PSO. These advanced metaheuristic solvers were benchmarked against traditional algorithms, including Genetic Algorithm (GA) and Particle Swarm Optimization (PSO), through comprehensive comparative analysis. The results demonstrate that the GA-WOA hybrid delivers the best overall performance in solution quality, achieving the lowest Total Annual Cost with reductions of 27 % in condenser duty, over 10 % savings in reboiler duty, and a 14 % decrease in TAC compared to conventional two-column configurations. Among the standalone algorithms, WOA provides the best solution quality. While PSO emerges as the fastest converging algorithm, the GA-WOA hybrid provides the most balanced performance between solution quality and computational efficiency. Among the hybrid approaches, GA-PSO ranks as the second-best performer in terms of solution optimality. These statistically validated findings confirm the economic and energy benefits of DWC technology while establishing WOA hybrids, particularly GA-WOA, as powerful, reliable tools for complex chemical process optimization.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110472"},"PeriodicalIF":3.9,"publicationDate":"2025-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144749791","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":"Recovery of germanium by chlorinated distillation of high content germanium materials enhanced by ultrasonic external field and arsenic removal","authors":"Mingyuan Rao , Qi Zhang , Hongying Xia , Yingjie Xu , Linqing Dai , Libo Zhang","doi":"10.1016/j.cep.2025.110473","DOIUrl":"10.1016/j.cep.2025.110473","url":null,"abstract":"<div><div>Chlorinated distillation is widely recognized as the primary technique for the separation and extraction of germanium from germanium-containing materials. However, challenges such as suboptimal extraction efficiency and the removal of arsenic impurities necessitate further investigation. The integration of ultrasonic external field enhancement technology, commonly referred to as ultrasonic field-enhanced distillation, into the chlorinated distillation process is expected to accelerate metal extraction and improve recovery rates. This research presents findings on the application of ultrasonic external field intensification in the chlorinated distillation of high-content germanium materials (HCGM). At an initial acidity of 9 mol·L⁻¹, the addition of 0.25 g·g⁻¹ of NaOCl, a liquid-to-solid ratio of 7 mL·g⁻¹, and an ultrasonic power of 350 W resulted in a germanium evaporation rate of 96.53 % and an arsenic residual rate of 94.57 %. These rates represent improvements of 5.78 % and 8.28 %, respectively, compared to the conventional process. These enhancements were primarily attributed to the cavitation effects of ultrasound, which facilitate the detachment of inclusions from the material and improve the interaction between the oxidant and the material. This process effectively removes the harmful impurity arsenic from the residual liquid, enabling the selective separation of arsenic while efficiently extracting germanium. The byproduct of the reaction is high-grade lead slag, which can be reintegrated into the lead smelting process for recycling. The resulting high-purity germanium material has undergone treatment that renders it both harmless and resource-efficient.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110473"},"PeriodicalIF":3.9,"publicationDate":"2025-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144771645","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}
Weigang Xu , Hanlin Zhang , Quan Yang , Shijian Zhang , Lin Liu , Ao Wang , Shi Bu
{"title":"Numerical study of condensation heat and mass transfer characteristics of air-steam mixtures in novel grooved corrugated tube","authors":"Weigang Xu , Hanlin Zhang , Quan Yang , Shijian Zhang , Lin Liu , Ao Wang , Shi Bu","doi":"10.1016/j.cep.2025.110465","DOIUrl":"10.1016/j.cep.2025.110465","url":null,"abstract":"<div><div>A Novel Grooved Corrugated Tube (NGCT) was proposed to enhance heat transfer by employing airflow to form tangential vortices in the drainage groove. Numerical simulations of steam condensation revealed the groove's impact on flow fields and liquid film distribution, establishing optimal parameters at groove height is 0.1 times the tube diameter and the angle is 24° Results demonstrate that within the inlet velocity range of 5 to 15 m·s⁻¹, the total heat transfer coefficient increases linearly with velocity, ranging from 85.46 % to 111.09 %. Similarly, increasing the inlet steam quality from 0.6 to 1 results in a linear increase in the overall heat transfer coefficient, ranging from 336.7 % to 440.6 %. The corrugated tube with a drainage groove structure effectively enhances the turbulence intensity of the internal steam, disrupts the non-condensable gas layer, and reduces the formation and accumulation of the liquid film, thereby significantly improving the overall heat transfer efficiency.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110465"},"PeriodicalIF":3.9,"publicationDate":"2025-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144738157","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":"Non-noble metal Co@hollow carbon spheres for highly efficient one-hour phenol conversion to cyclohexanol via temperature-controlled structural engineering","authors":"Luqingshan Xiao, Shuo Ma, Chunli Li, Hao Li","doi":"10.1016/j.cep.2025.110470","DOIUrl":"10.1016/j.cep.2025.110470","url":null,"abstract":"<div><div>Cyclohexanol is an important intermediate in the chemical industry and the synthesis of cyclohexanol from phenol by hydrogenation is a green and efficient process. In this paper, hollow carbon sphere nanoreactors ([email protected], T: temperature) with tunable microenvironment were synthesized by adjusting the pyrolysis temperature using soft template method. The characterization analysis demonstrated that the pyrolysis temperature could adjust the defect density and pore structure of the catalyst. When combined with experimental results and mechanistic studies, hydrogen and phenol were found to diffuse through multistage orifices into the cavities of the catalysts with enhanced mass transfer efficiency, and high defect density and highly dispersed cobalt nanoparticles were found to promote the activation and reaction of hydrogen and phenol. The [email protected]–600 catalyst shows significant catalytic activity at 140 °C for 1 h with 88.9 % phenol conversion and 99.9 % cyclohexanol selectivity. The good reaction activity of [email protected]–600 can be attributed to the catalyst's high defect density (I<sub>D</sub>/I<sub>G</sub>=2.77), substantial metal dispersion (45.67 %), a specific surface area of 588 m²/g, and an average pore size of 3.53 nm. Concurrently, [email protected]–600 demonstrated remarkable universality in catalyzing the hydrogenation of a diverse array of lignin-derived monomers and dimers.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110470"},"PeriodicalIF":3.9,"publicationDate":"2025-07-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144749788","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":"Performance of hydrodynamic cavitation and CoWO4 photocatalyst in the activation of peracetic acid and peroxymonosulfate for cloxacillin removal","authors":"Anvar Asadi , Reza Rezaee , Behzad Shahmoradi , Fatemeh Oughi , Neda Ravankhah","doi":"10.1016/j.cep.2025.110469","DOIUrl":"10.1016/j.cep.2025.110469","url":null,"abstract":"<div><div>This study aimed to explore the performance of a combined approach involving hydrodynamic cavitation (HC) and the cobalt tungstate (CoWO<sub>4</sub>) photocatalyst for the activation of peracetic acid [1] and peroxymonosulfate (PMS), targeting the efficient removal of the antibiotic cloxacillin (CLX) from aqueous environments. The assessment of CLX degradation experiments was conducted by examining various operational parameters. Results indicated that the CLX degradation rate was directly proportional to the PMS concentration, PAA dosage, and cavitation inlet pressure. Under optimal conditions (pH: 7, initial CLX concentration: 10 mg/L, CoWO<sub>4</sub> load: 0.3 g/L, PMS concentration: 0.4 mmol/L, PAA dosage: 200 μmol/L, and cavitation inlet pressure: 4.0 bar), the degradation of CLX reached 95.68 % and 98.93 % after 60 min in the HC+UVC+CoWO<sub>4</sub>+PMS and HC+UVC+CoWO<sub>4</sub>+PAA processes, respectively. A preliminary cost estimation of the treatment processes indicated total expenses of approximately 186.67 USD/m<sup>3</sup> (about 168,004,000 IRR/m<sup>3</sup>) for the HC and CoWO<sub>4</sub> photocatalyst system with PMS activation, and 187.74 USD/m<sup>3</sup> (about 168,972,000 IRR/m<sup>3</sup>) for the HC and CoWO<sub>4</sub> photocatalyst system with PAA activation, demonstrating their economic feasibility for potential industrial applications. Overall, the HC+UVC+CoWO<sub>4</sub>+PMS and HC+UVC+CoWO<sub>4</sub>+PAA approaches provide an efficient and cost-effective strategy of degrading and mineralizing of persistent organic contaminants in aquatic environments.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110469"},"PeriodicalIF":3.8,"publicationDate":"2025-07-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144711345","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}
Taylor Roth, Stefan Mazzadi, Joshua L. Pulsipher, Luis Ricardez-Sandoval
{"title":"Enhancing sustainable agriculture through optimized polyculture hydroponic operating strategies","authors":"Taylor Roth, Stefan Mazzadi, Joshua L. Pulsipher, Luis Ricardez-Sandoval","doi":"10.1016/j.cep.2025.110446","DOIUrl":"10.1016/j.cep.2025.110446","url":null,"abstract":"<div><div>This study develops an optimization framework to determine optimal operating strategies in monoculture and polyculture hydroponic systems considering uncertainty and disturbances. A key novelty of this work is the development of a polyculture hydroponic model incorporating interspecies nutrient interactions and dynamic environmental factors into the optimization problem, offering insights for system management and sustainability. A mechanistic nutrient uptake and growth model captures system dynamics and improves resource efficiency while accounting for parameter uncertainty and external disturbances to enhance system resilience. A case study of hydroponic polyculture soybean and tomato plants demonstrates the benefits of this approach. Results show that hydroponic systems increase yield by over 60% compared to traditional farming. Compared to monoculture hydroponics, polyculture methods reduce nitrogen consumption by 40% and increase annual profit by 3.91% per kilogram of fruit. These findings highlight the importance of nitrogen supply management and demonstrate how computational optimization can advance sustainable agriculture.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110446"},"PeriodicalIF":3.9,"publicationDate":"2025-07-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144749790","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}
Tian-Yu Zhang , Ying Xu , Yu-Chao Ma , Meng Liu , Rong-Hua Wu
{"title":"Flow field analysis-informed optimisation of structural parameters in propulsion agitator design","authors":"Tian-Yu Zhang , Ying Xu , Yu-Chao Ma , Meng Liu , Rong-Hua Wu","doi":"10.1016/j.cep.2025.110467","DOIUrl":"10.1016/j.cep.2025.110467","url":null,"abstract":"<div><div>Propeller-type agitators have broad applications in industrial production. However, there has been limited research on their structural parameter optimisation and flow field performance. In this study, a physical model is established for a propeller-type agitator in practical engineering applications, and its accuracy is validated through physical experiments. The dimensionless structural parameters are optimised to quantitatively characterise the turbulence intensity distribution and mixing effectiveness using evaluation metrics, including the uniformity index and mixing uniformity. Optimisation of the structural parameters is performed using a combined approach integrating computational fluid dynamics (CFD) with the response surface methodology (RSM). The optimisation objectives focus on the impeller blade curvature, diameter, and installation height from the bottom of the tank to achieve optimal mixing performance. The results demonstrate that an appropriate installation height of <em>H<sub>f</sub></em> = 0.335 improves the mixing efficiency without increasing the power consumption. The blade curvature exhibits non-monotonic optimisation characteristics, with an optimal curvature <em>B</em> = 0.908. The optimal configuration is achieved with a blade curvature <em>B</em> = 0.908, diameter ratio <em>D<sub>R</sub></em> = 1.713, and installation height <em>H<sub>f</sub></em> = 0.335, which provide an enhanced mixing performance. The findings of this study establish a theoretical foundation for optimising the design of fluid mixing machinery and provide actionable guidelines for the design and operational refinement of industrial mixing processes.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110467"},"PeriodicalIF":3.9,"publicationDate":"2025-07-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144810153","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}
Jesús E. Lugo-Hinojosa , Sergio A. Martínez-Delgadillo , Juan A. Yáñez-Varela , Alejandro Alonzo Garcia
{"title":"Evaluation of flow patterns in a stirred tank equipped with tubular baffles using CFD numerical models and experimental PIV","authors":"Jesús E. Lugo-Hinojosa , Sergio A. Martínez-Delgadillo , Juan A. Yáñez-Varela , Alejandro Alonzo Garcia","doi":"10.1016/j.cep.2025.110466","DOIUrl":"10.1016/j.cep.2025.110466","url":null,"abstract":"<div><div>Stirred tanks are fundamental to the industry, and the geometry of the baffles has a significant impact on energy consumption and flow characteristics. Recently, tubular baffles (TB) have emerged as a promising alternative to reduce energy consumption in these tanks. The integration of numerical simulations with experimental measurements provides a comprehensive understanding of the hydrodynamics in these systems, allowing for a better understanding of the interaction between the baffle and the impeller. This study analyzes the hydrodynamics of agitated tanks with different tubular baffle arrangements using Computational Fluid Dynamics (CFD) and Particle Image Velocimetry (PIV). PIV was used to evaluate different RANS turbulence models and found that the realizable k-epsilon model adequately predicts the flow behavior both near the impeller and in more remote areas where velocities are lower. CFD results show that the geometry of the tubular baffles modifies the flow patterns in the tank, increasing the flow in the lower part and improving the pumping efficiency by 13 % to 20 %. However, the flow analysis shows that the axial flow in the upper part of the tank is low, creating stagnant zones that double the mixing time in the PBT-4 TB case and increase the mixing energy by 76 %. The PBT-8 TB arrangement was found to reduce this difference to 18 % compared to the flat baffle case.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110466"},"PeriodicalIF":3.9,"publicationDate":"2025-07-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144724730","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}
Xiao-Mei Wang , Qi-Xiang Wu , Muhammad Farhan Amjad , Dong-Hao Zhang , Hai-Kui Zou , Guang-Wen Chu , Bao-Chang Sun
{"title":"Study on desulfurizing and defoaming performance of cocurrent-flow rotating packed bed coupled with cyclone separator","authors":"Xiao-Mei Wang , Qi-Xiang Wu , Muhammad Farhan Amjad , Dong-Hao Zhang , Hai-Kui Zou , Guang-Wen Chu , Bao-Chang Sun","doi":"10.1016/j.cep.2025.110464","DOIUrl":"10.1016/j.cep.2025.110464","url":null,"abstract":"<div><div>High-gravity desulfurization is an effective desulfurization technology. However, to achieve efficient desulfurization under low pressure drop conditions, it is necessary to enhance both the desulfurization efficiency and defoaming performance in a cocurrent-flow configuration. In this work, the cocurrent-flow rotating packed bed (CFRPB) coupled with cyclone separator was proposed. The results demonstrated that the CFRPB coupled with cyclone separator exhibited notable desulfurizing and defoaming efficiencies under low pressure drop, outperforming conventional RPBs. Under the optimal operating conditions, the desulfurizing efficiency, mass-transfer coefficient, liquid content of outlet gas, and defoaming efficiency can reach 98 %, 626 mol/(m<sup>3</sup>·s), 0.2 g/m<sup>3</sup>, and 93 %, respectively. Compared to using a standalone CFRPB, the liquid content of outlet gas decreased by 2.6 g/cm<sup>3</sup>, and the export concentration of SO<sub>2</sub> reduced by 10 %-20 % to a minimum of 10 ppm. Taken together, this novel technology indicates significant application potential in the treatment of industrial sulfur-containing gases.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110464"},"PeriodicalIF":3.8,"publicationDate":"2025-07-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144711441","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}