Chemical Engineering and Processing - Process Intensification最新文献

{"title":"Low-cost reinforcement learning framework to optimize micromixer structures and parameters","authors":"Quanjiang Li ,&nbsp;Tao Bu ,&nbsp;Zhuang Zhang ,&nbsp;Jingtao Wang","doi":"10.1016/j.cep.2026.110727","DOIUrl":"10.1016/j.cep.2026.110727","url":null,"abstract":"<div><div>Micromixers play a crucial role in microfluidic technology. Given the complexity, challenges, and time-consuming nature of their design processes, automating the design and optimization of micromixers is of paramount importance. This study proposes a low-overhead sequential decision-making reinforcement learning framework that addresses the issue of interoperability between various inversion algorithms and finite element simulations, thereby enabling the dynamic optimization of micromixer geometries. The framework integrates ezdxf, Mph, COMSOL, and a custom-designed reward function to facilitate both the geometric and parametric design. The custom-designed reward function enhances the interaction between the reinforcement learning agent and the integrated framework, guiding the decision-making process towards optimal objectives. The effectiveness of the framework was validated through a case involving a parameter space of size 10,800. With mixing index and Mixing Energy Cost as the optimization objectives, the RL process converged after 178 agent–environment interactions, reducing the interaction count by approximately 44.03% relative to genetic algorithms. Furthermore, this framework can be easily adapted, with minimal modifications, for application to other finite element analysis problems.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"222 ","pages":"Article 110727"},"PeriodicalIF":3.9,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146102463","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":"Synergistic process integration of microwave-assisted acid and thermomechanical pretreatments for intensified saccharification of industrial hemp hurds","authors":"El Hage Maria ,&nbsp;Nouviaire Armelle ,&nbsp;Debs Espérance ,&nbsp;Louka Nicolas ,&nbsp;Conforto Egle ,&nbsp;Maugard Thierry ,&nbsp;Maache-Rezzoug Zoulikha ,&nbsp;Rezzoug Sid-Ahmed","doi":"10.1016/j.cep.2026.110741","DOIUrl":"10.1016/j.cep.2026.110741","url":null,"abstract":"<div><div>This study investigates a chemical process intensification strategy to overcome the recalcitrance of industrial hemp hurds (IHH) for bioethanol production. A two-step sequential approach was developed, coupling Microwave-Assisted Acid Pretreatment (MAAP) with thermomechanical Intensification of Vaporization by Decompression to Vacuum (IVDV). First, MAAP was optimized using a Box–Behnken design (BBD) to evaluate the effects of H₂SO₄ concentration (0.3–1.7 %), microwave power (300–900 W), and exposure time (8–24 min) on sugar yields. Under optimal conditions (1 % H₂SO₄, 900 W, 8 min), MAAP induced partial hemicellulose solubilization (27 %) and 12.5 % increase in A_BET surface area (0.951 m²/g) compared to raw IHH, achieving an Overall Reducing Sugar (ORS) yield of 48.8 %. To enhance saccharification, the process was intensified by integrating IVDV step (0.7 MPa for 5 to 15 min). This sequential strategy (30-min MAAP followed by 5-min IVDV) revealed a strong synergistic process integration, elevating the ORS yield to 84.6 %, a 33 % improvement over IVDV and 160 % over MAAP. The synergy arises from coupling of MAAP-induced chemical weakening with IVDV-driven thermomechanical disruption, which increased the specific surface area by 22 % higher than IVDV-only and 73 % higher than MAAP-only. The results demonstrate that this combination effectively deconstructs biomass, offering a promising route for sustainable biorefineries</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"222 ","pages":"Article 110741"},"PeriodicalIF":3.9,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146186706","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 in co-production of plant and bacterial cellulose from citrus waste: A review","authors":"Hanieh Ghorbani jafarbigloo,&nbsp;Alireza Chackoshian Khorasani","doi":"10.1016/j.cep.2026.110730","DOIUrl":"10.1016/j.cep.2026.110730","url":null,"abstract":"<div><div>Bacterial cellulose (BC) offers remarkable properties such as biodegradability and biocompatibility, but its commercialization remains challenging due to high costs. A promising solution involves converting such as citrus waste (CW), into BC alongside other value-added products, enhancing sustainability and reducing expenses. While CW has been studied for plant cellulose extraction and limited BC production, existing reviews focus on pectin, polyphenols, or biofuels, neglecting combined plant cellulose and BC valorization. This review analyzes plant cellulose and BC production from CW, proposing an integrated approach. It evaluates physical, chemical, and biological extraction methods for plant cellulose, comparing efficiency and cost-effectiveness. For BC, key factors such as microbial strains, culture media, and process conditions are examined, with a performance comparison across methods. Challenges in scaling up production are also discussed. The study introduces a circular system: extracting plant cellulose as the primary product and converting residues into BC as a by-product. This dual approach improves sustainability, reduces fruit waste, and aligns with eco-economic goals—a gap unexplored in prior research. By optimizing waste utilization and lowering costs, this integrated model could advance bacterial and plant cellulose production while addressing environmental concerns.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"222 ","pages":"Article 110730"},"PeriodicalIF":3.9,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146102464","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":"Integrated DES-based biphasic extraction of bromelain and bioethanol: A DFT-guided approach for waste-to-resource process intensification","authors":"Srimathi Umasekar,&nbsp;Nagajyothi Virivinti","doi":"10.1016/j.cep.2026.110731","DOIUrl":"10.1016/j.cep.2026.110731","url":null,"abstract":"<div><div>Efficient valorization of agro-industrial waste is essential for advancing circular bioeconomy strategies, however, the simultaneous recovery of biochemicals with contrasting physicochemical properties remains a major challenge in biorefinery design. Although deep eutectic solvent (DES)–based aqueous biphasic extraction (ABE) and Density Functional Theory (DFT)–guided solvent screening have been independently reported, their integrated application for concurrent enzyme and biofuel recovery has not been demonstrated. This study presents a DFT-guided, DES-based biphasic extraction framework for the simultaneous recovery of bromelain (BN) and bioethanol (BEtOH) from pineapple waste, addressing both solvent selection inefficiency and downstream separation complexity. Unlike prior studies that rely on empirical screening or target single products, this work links molecular-level solvent design with experimental biphasic extraction to enable dual-product recovery within a single process configuration. Nine binary Type III DES (T3-DES) and their oxalic acid–modified ternary analogues (T3-DES*) were screened using B3LYP-D3/6-311++G(d,p), supported by QTAIM, NBO, and COSMO-RS analyses to evaluate DES–solute interactions and extraction selectivity. The screening identified T3-DES7–Na₂SO₄ and T3-DES8*–Na₂CO₃ as optimal systems, which were experimentally validated by high partition coefficients (K = 6.42 for BN and 5.7 for BEtOH) and extraction yields of 89 wt% and 82 wt%, respectively. Integration with enzymatic hydrolysis and fermentation of the residual biomass yielded 18.7 g/L BEtOH at 97 wt% purity, confirming effective coupling of conversion and separation. Overall, this work establishes a novel, DFT-assisted DES–ABE strategy for dual enzyme–biofuel recovery, reducing experimental trial-and-error and enabling scalable green waste-to-resource process intensification.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"222 ","pages":"Article 110731"},"PeriodicalIF":3.9,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146186757","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":"Comparison of ibuprofen photodegradation by persulfate-assisted and magnetic field-assisted photocatalysis processes","authors":"Elvana Çako ,&nbsp;Cristina Gómez Polo ,&nbsp;Marta Kowalkińska ,&nbsp;Marcin Pisarek ,&nbsp;Anna Zielińska-Jurek","doi":"10.1016/j.cep.2026.110740","DOIUrl":"10.1016/j.cep.2026.110740","url":null,"abstract":"<div><div>In the present study, two approaches combining photocatalysis in the presence of TiO₂ nanosheets with ZnFe₂O₄/(P,S)-doped g-C₃N₄ heterocomposite with magnetic field and persulfate activation were investigated. Combining TiO₂ with layered structures, elemental-doped carbon nitride (g-C₃N₄), and zinc ferrite (ZnFe₂O₄) improved light absorption, charge separation, and magnetic recovery properties. Furthermore, coupling photocatalysis with persulfate activation enhanced pollutant degradation efficiency through the formation of long-lived reactive species. An additional innovative approach involved applying an external magnetic field to mainly inhibit charge carriers recombination. Both processes were efficient in the removal of ibuprofen, a drug frequently detected in aqueous systems. Sulfate radicals (SO₄^•−), hydroxyl radicals (HO^•) and superoxide radicals (O₂^•−) were responsible for ibuprofen transformation and degradation. The improved photocatalytic activity shows potential for effective degradation of persistent pharmaceutical compounds in water, while the use of persulfates and magnetic field opens new possibilities for more advanced water treatment processes.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"222 ","pages":"Article 110740"},"PeriodicalIF":3.9,"publicationDate":"2026-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146186755","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":"Machine learning assisted optimization of an industrial visbreaker plant","authors":"Melike Duvanoglu ,&nbsp;Sena Kurban ,&nbsp;Gizem Kuşoğlu Kaya ,&nbsp;Erdal Aydin","doi":"10.1016/j.cep.2026.110706","DOIUrl":"10.1016/j.cep.2026.110706","url":null,"abstract":"<div><div>This study proposes a data-driven prediction–optimization framework to improve operational efficiency and extend furnace run length in an industrial visbreaker unit subject to coke formation. Using ten years of real refinery operating data, Decision Tree and Artificial Neural Network (ANN) models were developed to predict furnace coil skin temperatures and the remaining operational days before shutdown. The ANN achieved acceptable test-set Mean Absolute Errors for four critical coils and approximately 15 days for remaining-cycle prediction, corresponding to less than 13 % of a typical furnace run length.</div><div>The trained ANN was embedded into a Genetic Algorithm to optimize seven controllable operating variables under industrial constraints. This framework contributes to predicted run-length extensions of 7.5–12.5 % during early-cycle operation and up to 50 % near end-of-cycle conditions. These improvements translate into delayed decoking requirements, improved thermal stability, and enhanced maintenance planning.</div><div>The main contribution of this work lies in the integration of long-horizon industrial data, lag-based dynamic feature representation, and ANN–GA optimization for an industrial visbreaker unit. Unlike prior studies based on simulated or short-term datasets, the proposed framework demonstrates industrial feasibility and provides actionable decision support for proactive coking mitigation and operational optimization.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110706"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145974069","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":"Recent advances in macroalgae–plastic co-pyrolysis for high-quality fuel production","authors":"Apip Amrullah ,&nbsp;Jingang Yao ,&nbsp;Motasem Y.D. Alazaiza ,&nbsp;Obie Farobie","doi":"10.1016/j.cep.2026.110713","DOIUrl":"10.1016/j.cep.2026.110713","url":null,"abstract":"<div><div>The global accumulation of plastic waste and the underutilization of macroalgae pose significant environmental challenges. Co-pyrolysis, a thermochemical process, has shown promise in converting these waste streams into high-quality biofuels. This review specifically focuses on macroalgae-plastic co-pyrolysis, a distinct area which differs from broader biomass-plastic studies because of the unique chemical composition and thermal behavior of macroalgae. We explored the synergistic effects during co-pyrolysis, such as enhanced bio-oil yield (typically 10–25% compared to biomass alone), improved heating value, and reduced oxygen content, driven by mechanisms such as hydrogen donation from plastics and mineral-catalyzed cracking from macroalgae ash. Recent studies have demonstrated that co-pyrolysis of macroalgae and plastics can lead to significant improvements in bio-oil yield compared to biomass-only pyrolysis. Co-pyrolysis typically results in a 10–25% increase in bio-oil yield, enhanced heating values, and reduced oxygen content in the bio-oil. This synergistic effect arises from the interaction between the oxygen-rich volatiles from macroalgae and the hydrogen-rich radicals from plastics, which facilitates polymer degradation and improves the thermal characteristics of the pyrolysis process. Several studies have observed improvements in bio-oil quality, with some noting substantial increases in the carbon content of the oil, thus enhancing its calorific value. Unlike previous reviews that generally cover biomass-plastic co-pyrolysis, this study emphasizes the specific interactions between macroalgae and plastics, with a focus on feedstock characteristics, reaction mechanisms, and strategies for optimizing product yield and quality. Key strategies, including optimal feedstock ratios, temperature ranges, and catalyst types, are discussed in detail. The novelty of this review lies in its comprehensive synthesis of the specific mechanisms that enhance the co-pyrolysis process, offering new insights into this promising yet underexplored field. Despite the potential, challenges such as feedstock variability, catalyst deactivation, and scale-up issues remain, and future research directions to address these barriers are outlined.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110713"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146023423","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 sonochemical co-precipitation of α-Fe2O3 nanoparticles from pickling waste: Impact of ultrasound and air flow on particle formation","authors":"Shubham Bonde,&nbsp;Aditya Potode,&nbsp;Bharat Bhanvase","doi":"10.1016/j.cep.2026.110710","DOIUrl":"10.1016/j.cep.2026.110710","url":null,"abstract":"<div><div>The potential of ultrasound-assisted processes to intensify Fe oxidation, accelerate Fe(OH)₃ formation, and produce value-added products such as Fe₂O₃ nanomaterials directly from industrial waste have not been explored in the present investigation. In the present study, ultrasound-assisted coprecipitation method was employed for the synthesis of α-Fe₂O₃ nanoparticles using acid pickling waste as the precursor. With a specific focus on the role of air flow rate as a key intensification parameter. The methodology integrates calcium hydroxide neutralization under ultrasound with controlled aeration. The results show that ultrasound with air significantly enhanced the oxidation, achieving 94.27% Fe²⁺ and 89.27% Fe³⁺ conversion at 10 LPM air flow. Reaction kinetics were modeled using a second-order rate equation, confirming the role of ultrasound in enhancing mass transfer and accelerating nucleation. Reaction kinetics, particle formation behavior, and structural evolution were systematically evaluated using atomic absorption spectrophotometer (AAS), UV–Vis, Fourier-transform infrared (FTIR), and X-ray diffraction (XRD) analysis. XRD analysis indicated a rhombohedral hematite structure with a 21 nm crystalline size. The results demonstrate that ultrasound not only facilitates effective waste valorization but also enables the controlled synthesis of iron oxide nanoparticles. This approach provides a dual benefit of environmental remediation and the production of value-added nanomaterials from hazardous waste.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110710"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146023428","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":"Recent Advances in the continuous synthesis of zeolite using tubular reactor","authors":"Jialong Liu,&nbsp;Subing Fan,&nbsp;Yurong He,&nbsp;Junmin Lv","doi":"10.1016/j.cep.2026.110719","DOIUrl":"10.1016/j.cep.2026.110719","url":null,"abstract":"<div><div>Zeolite has broad applications in the fields of catalysis and adsorption separation. The conventional batch synthesis process suffers from drawbacks such as low efficiency, complex operation and inconsistent product quality. Therefore, developing reliable and efficient zeolite synthesis routes has become a research hotspot in recent years. Compared to traditional batch reactors, tubular reactor offers superior heat and mass transfer performance, playing a crucial role in process intensification for zeolite synthesis. Continuous synthesis in tubular reactors is a potential effective route, as it not only significantly reduces crystallization time and improves space-time yield but also ensures consistent product quality across batches. Based on recent advances in this field, this review mainly introduces the reactor configurations for continuous zeolite synthesis in tubular systems, discusses the advantages of the synthesis process and product characteristics, clarifies the crystallization mechanisms of zeolites under continuous flow conditions, and especially emphasizes the reasons and solutions to the key problem of pipeline clogging in this process. Furthermore, perspectives on future research and industrial applications are suggested.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110719"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146074187","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":"Hydrodynamic cavitation-assisted biodiesel production from waste oils: A scalable strategy with fuel quality enhancement","authors":"Nirav Prajapati ,&nbsp;Surendra Singh Kachhwaha ,&nbsp;Pravin Kodgire ,&nbsp;Rakesh Kumar Vij ,&nbsp;Jeffrey S. Cross","doi":"10.1016/j.cep.2026.110721","DOIUrl":"10.1016/j.cep.2026.110721","url":null,"abstract":"<div><div>Despite extensive research in biodiesel synthesis, there is a notable scarcity of pilot-scale studies that integrate hydrodynamic cavitation (HC), individually with mixed-alcohol transesterification, as well as high-free fatty acid (FFA) feedstock blends, along with experimentally validated property improvements and rigorous techno-economic analysis (TEA). This study reports, for the first time, the use of a 100-L pilot scale HC system incorporating a 32-hole orifice for biodiesel production from low-FFA waste cooking oil (WCO) evaluated through two distinct data sets: (i) high-FFA rice bran acid oil (RAO) blending using a two-step esterification followed by transesterification, and (ii) equimolar methanol-ethanol transesterification. The first run produced an FFA conversion of 96.87 ± 0.6 %, along with a biodiesel yield of 92.86 ± 0.5 % and an overall yield efficiency of 0.40 × 10^-3 kg/kJ, whereas the second run achieved a biodiesel yield of 93.52 ± 0.5 % and a yield efficiency of 0.76 × 10^-3 kg/kJ. Both runs demonstrated enhancements in the physicochemical properties of produced biodiesel with all measured values complying with ASTM <span><span>D6751</span><svg><path></path></svg></span> and EN 14214 standards. TEA results indicated high profitability, evidenced by robust return on investment (ROI), internal rate of return (IRR), energy return on investment (EROI), and payback values, along with strong scalability for both data sets.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"221 ","pages":"Article 110721"},"PeriodicalIF":3.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146074285","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}