Chemical Engineering and Processing - Process Intensification最新文献

{"title":"Desalination systems for minimal and zero liquid discharge purposes: A review","authors":"N. Anjomani ,&nbsp;S. Shamshiri ,&nbsp;A. Babapoor ,&nbsp;Z. Rahimi-Ahar ,&nbsp;M. Mastani Joybari ,&nbsp;M. Khiadani","doi":"10.1016/j.cep.2025.110442","DOIUrl":"10.1016/j.cep.2025.110442","url":null,"abstract":"<div><div>Freshwater reserves are being depleted as a result of natural and production processes, including industrialization, agriculture, and rapid population growth. Water scarcity can be effectively compensated for with various desalination techniques. However, the release of high concentrate brine from the desalination systems is the major environmental concern. As such, minimal or zero liquid discharge (MLD or ZLD) desalination techniques are vital for high water recovery and zero waste production. This study aims to review recent literature on the use and management of brine from various sectors of brine production and seawater desalination industries using MLD and ZLD technologies. Thermal, membrane, and hybrid desalination systems are also reviewed with a focus on highlighting the operating principles, advantages, and challenges. It can be concluded that hybrid systems have the lowest specific energy consumption (SEC) and cost compared to membrane and thermal systems. Multi-effect desalination/multi-stage flash (MED-MSF) has the lowest SEC of 1.107 kWh.m⁻³ and a water recovery of 98 %. Furthermore, ZLD desalination systems consume less energy when pretreatment techniques are applied before the thermal process. The hybrid MD-MSF-Cr process has the lowest cost with a cost of 0.62 $.m⁻³ (with a water recovery of 89 %).</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110442"},"PeriodicalIF":3.8,"publicationDate":"2025-07-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144634150","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":"Numerical and experimental analysis of droplet dynamics in constricted milli and microchannels","authors":"A.T.S. Cerdeira ,&nbsp;J.B.L.M. Campos ,&nbsp;J.M. Miranda ,&nbsp;J.D.P. Araújo","doi":"10.1016/j.cep.2025.110448","DOIUrl":"10.1016/j.cep.2025.110448","url":null,"abstract":"<div><div>This study investigates the dynamics of droplets flowing through constricted channels at milli and microscales using a combination of experimental and numerical approaches. Experiments were conducted in a 3D-printed millichannel with three immiscible fluid pairs, spanning a wide range of viscosity ratios between dispersed and continuous phases (10^–2&lt;X&lt;10²) and Capillary numbers of the continuous phase (10^-⁴&lt;Ca_c&lt;10^-¹). Numerical simulations, employing the Volume of Fluid (VOF) methodology and performed with Ansys FLUENT® 2021 R2, complemented the experiments by exploring two geometrical scales: milli (aspect ratio: 5:3 at the inlet channel; 1:3 in the constricted region) and micro (aspect ratio: 5:1.5 before the contraction; 1:1.5 after contraction). For milliscale simulations, X ranged from 10^–1 to 10² and Ca_c from 10^–3 to 10^–1, while in microscale simulations, 10^–2&lt;X&lt;10² and 10^–4&lt;Ca_c&lt;10⁰. A comprehensive analysis of velocity profiles, film thickness, and droplet deformation was conducted numerically. Strong agreement between experimental and numerical results for average droplet velocity and length within the constricted region validated the computational model’s robustness. This work elucidates the influence of Ca_c and X on droplet deformation, velocity, and film thickness, providing valuable insights into the optimization of multiphase microfluidic systems.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110448"},"PeriodicalIF":3.8,"publicationDate":"2025-07-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144666054","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":"Scale-up of a thermally coupled milli-scale wall coated reactor through a fractals-based reactor design approach","authors":"Md. Malik Nawaz Khan,&nbsp;Sreenivas Jayanti","doi":"10.1016/j.cep.2025.110445","DOIUrl":"10.1016/j.cep.2025.110445","url":null,"abstract":"<div><div>As an alternative to thermally inefficient packed bed reactors, micro-scale reactors have been researched extensively due to their excellent heat and mass transfer characteristics. Nevertheless, their scope is restricted within specialty chemicals and other low volume production processes because of high pressure drop and difficulty in scale-up. Wall-coated milli-scale reactor combine merits of both packed bed and micro-scale reactors as they have low thermal resistances with high flow capacities at negligible pressure drop. Literature on milli-scale reactors is scarce. In this work we study scale up of a dual-channel milli-scale thermally integrated reactor. It is shown that the fractals-based Hilbert curve, when used as a generating function for the scaled-up reactor structure (HR), provides a systematic and compact way of scale-up of the dual-channel milli-scale reactor. The case of process intensification by a factor of up to 300 in terms of the integrated reaction rate is illustrated through CFD modelling. Effects of varying inlet and wall boundary conditions in the dual-channel reactor and the HR reactor are explored. The intensified reactor can be manufactured with accuracy and repeatability by additive manufacturing techniques.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110445"},"PeriodicalIF":3.8,"publicationDate":"2025-07-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144666053","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":"Enzymatic hydrolysis of used cooking oil and palm olein using a Starbon-immobilized Candida Antarctica lipase B","authors":"Alexander Baena ,&nbsp;Alvaro Orjuela ,&nbsp;Laura R. Conde","doi":"10.1016/j.cep.2025.110443","DOIUrl":"10.1016/j.cep.2025.110443","url":null,"abstract":"<div><div>This study investigated the enzymatic hydrolysis of UCOs and refined palm olein using <em>Candida Antarctica lipase B</em> (CALB) immobilized on a mesoporous carbon (Starbon A800), and commercial immobilized lipases (Lipozyme TLIM and Novozyme 435). Various immobilization techniques were assessed, with physisorption onto an amino-functionalized surface followed by crosslinking (CALBAC3) providing the best results, achieving the highest enzyme loading (11.3 wt. %), anchoring efficiency (56.36 %), and hydrolytic activity (136.5 LU/g). Activity remained stable at pH 6–7.3, with optimal performance at 45–50 °C. The best hydrolytic activity was achieved at 45 °C, pH 7, 7.0 wt. % enzyme loading, ultrasonic mixing during initial 120 min at 100 W and 37 kHz, a 1:30 oil-to-water ratio, and mechanical stirring at 300 rpm. Under these conditions, conversion reached 91.04 ± 3.92 %. The obtained data were used to correlate kinetic expressions using the Michaelis-Menten-type and water-inhibition models, and they agreed reasonably well with experiments showing relative errors below 2 %. Despite high initial activity comparable to Novozyme 435, CALBAC3 exhibited a significant drop in performance after reuse, likely due to mechanical instability of the support and enzyme immobilization strength. Future work should focus on enhancing the support strength, optimizing mesoporous pore distribution, and exploring alternative crosslinking strategies.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110443"},"PeriodicalIF":3.8,"publicationDate":"2025-07-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144656366","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":"Towards hydrogen production by methane pyrolysis in a microwave-assisted fluidized bed reactor: Hydrodynamics of a catalytic fluidized bed and 1D convection-dispersion modelling","authors":"Robert Cherbański,&nbsp;Stanisław Murgrabia,&nbsp;Leszek Rudniak,&nbsp;Eugeniusz Molga,&nbsp;Andrzej Stankiewicz,&nbsp;Tomasz Kotkowski","doi":"10.1016/j.cep.2025.110440","DOIUrl":"10.1016/j.cep.2025.110440","url":null,"abstract":"<div><div>This study investigates the minimum fluidization velocity (<span><math><msub><mi>U</mi><mrow><mi>m</mi><mi>f</mi></mrow></msub></math></span>) of Fe/C catalyst and presents preliminary modelling results for a microwave-assisted fluidized bed reactor (MAFBR). The hydrodynamics was examined experimentally and through a Discrete Element Method-Computational Fluid Dynamics (DEM-CFD) modelling approach. A satisfactory agreement was observed between the experimentally determined <span><math><msub><mi>U</mi><mrow><mi>m</mi><mi>f</mi></mrow></msub></math></span> and the value predicted by the model, which assumed a spherical shape for Fe/C catalyst particles as a simplification. Further testing of the model using reference glass beads highlighted the importance of incorporating particle shape factors and particle size distribution for improved accuracy. The model also demonstrated good performance when applied to a mixture of two different glass bead fractions. Additionally, MAFBR modelling was conducted using an axially dispersed plug flow model, incorporating a CH₄ pyrolysis rate equation for the Fe/C catalyst formulated in our previous work [1]. The model provided insight into FBR behaviour under varying conditions including temperature, catalyst mass and methane flow rate. Such approach provides basis for the MAFBR design.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110440"},"PeriodicalIF":3.8,"publicationDate":"2025-07-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144605501","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":"Effect of ultrasonic pretreatment on methane production from peat","authors":"Lili Xia ,&nbsp;Litong Ma ,&nbsp;Jun Li","doi":"10.1016/j.cep.2025.110441","DOIUrl":"10.1016/j.cep.2025.110441","url":null,"abstract":"<div><div>This study investigated the effects of ultrasonic pretreatment on the chemical composition and biomethane production of herbaceous, woody, and mossy peats. The optimal conditions for ultrasonic pretreatment were established through single-factor and orthogonal experiments, utilizing reducing sugar yield as a key metric. Daily gas production, volatile fatty acids concentrations, pH levels, and reducing sugar yields during methane fermentation were measured to assess the effects of ultrasonic pretreatment on peat biomethanation. The optimal pretreatment conditions for mossy, herbaceous plants, and woody peat are 25 min, 35 min, and 2 min of ultrasonic treatment at 50 °C, 70 °C, and 60 °C, respectively. The solid-liquid ratios are 1:5, 1:3, and 1:3, respectively, and the particle sizes are 250 mesh, 250 mesh, and 40 mesh, respectively. After ultrasonic treatment, the contents of hemicellulose, and lignin decreased by 2.32 %, 1.77 %, respectively, in mossy peat; 1.00 %, and 2.70 %, respectively, in herbaceous peat; and 0.76 %, and 2.28 %, respectively, in woody peat. After ultrasonic treatment, the total biomethane production from mossy, herbaceous, and woody peats increased by 119.05 %, 84.69 %, and 13.55 %, respectively. Ultrasonic pretreatment enhances peat's biodegradability and biomethane production, thus being an effective strategy for increasing peat's biomethane yield.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110441"},"PeriodicalIF":3.8,"publicationDate":"2025-07-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144631713","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":"Continuous precipitation of nanosized calcium phosphates, including HAp: the role of operating conditions and highly hydrolyzed PVA additive on particles’ characteristics, phase composition, and precipitation kinetics","authors":"Magdalena Stec ,&nbsp;Piotr Maria Synowiec ,&nbsp;Agnieszka Stolarczyk","doi":"10.1016/j.cep.2025.110436","DOIUrl":"10.1016/j.cep.2025.110436","url":null,"abstract":"<div><div>The research describes the continuous precipitation of hydroxyapatite nanoparticles from aqueous solutions of (NH₄)₂HPO₄ and Ca(NO₃)₂, carried out in the Koflo static mixer. The role of a specific turbulence distribution and its intensity, solutions’ concentrations, and the addition of polyvinyl alcohol (PVA) on both the chemical and phase compositions, and final product features have been investigated. The driving force of the process, nucleation sources, and mechanisms controlling particles’ growth have also been determined. It was shown that the shape of HAp particles is primarily influenced by the unit power input <em>ε_mix</em> and may be changed within petals, whiskers/needles, or spheres. The mean size of single particles varied from 390 to 94 nm, however, agglomeration was observed. Its share was reduced to some extent by i) an increase of <em>ε_mix</em> and/or ii) the use of a small amount of PVA (up to 2 % w/v). The conditions limiting the formation of other than hydroxyapatite CaP phases (i.e. monetite, brushite), allowing to obtain high purity HAp (≥ 99 %) were defined. As the sources of nuclei, primary heterogeneous nucleation and secondary one were indicated. It was also recognized that the particle growth in the system was controlled by bulk diffusion.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110436"},"PeriodicalIF":3.8,"publicationDate":"2025-07-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144694697","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":"Numerical study on the performance improvement of bubble columns incorporating innovative helical tube internals","authors":"Peng Pan ,&nbsp;Shi-Jiao Li ,&nbsp;Hui-Long Wei ,&nbsp;Xi-Bao Zhang ,&nbsp;Zheng-Hong Luo","doi":"10.1016/j.cep.2025.110435","DOIUrl":"10.1016/j.cep.2025.110435","url":null,"abstract":"<div><div>The bubble columns widely applied in chemical engineering were confronted with poor contact efficiency between different phases. In this study, novel helical tube internals were designed and their performance was evaluated in a 0.38 m diameter bubble column using air and Tellus oil. Eulerian multi-fluid simulations revealed that double helical internals increased the overall gas holdup by 33.5 % at 0.25 m/s, while promoting a more uniform gas holdup distribution and presenting a significant reduction in the turbulent kinetic energy and turbulent dissipation rate. Moreover, the turbulence characteristic length was reduced by internals, indicating the generation of small-scale vortices that enhanced gas holdup. This discovery provided a novel design strategy for bubble columns: the bottleneck of uneven gas distribution and low interphase contact efficiency was improved through helical internals to optimize the turbulence, thereby improving the design and scale-up of bubble columns.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110435"},"PeriodicalIF":3.8,"publicationDate":"2025-07-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144595581","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":"Recipe-based 1-D dynamic modeling of an integrated NH3-synthesis-sorption reactor","authors":"C. Sengoba,&nbsp;M. Illner,&nbsp;J.-U. Repke","doi":"10.1016/j.cep.2025.110387","DOIUrl":"10.1016/j.cep.2025.110387","url":null,"abstract":"<div><div>Long-term green hydrogen storage can be realized via flexible and efficient ammonia (NH₃) synthesis. Process intensification via a sorbent-integrated, ideally recycle-less NH₃-synthesis unit enables milder pressure and temperature levels during NH<span><math><msub><mrow></mrow><mrow><mn>3</mn></mrow></msub></math></span> synthesis, while shifting the single-pass conversion beyond the thermodynamic equilibrium. Understanding the process behavior of this novel, integrated synthesis-sorption reactor (SSR) requires an analysis and choice of suitable materials for catalysis and sorption based on the chemical equilibrium and kinetics of both the sorption and reaction phenomena. This study first proposes an equilibrium thermodynamic analysis to provide an initial performance assessment of a desired SSR, evaluating several sorbent material candidates. On this basis, a novel, pressure-driven dynamic model is developed to rigorously assess the inherently transient dynamics of a fixed-bed SSR in cyclic batch-wise operation under a predefined operation recipe. By consistent formulation of the conservation equations to describe the interplay of flow, reaction, and sorption phenomena, a physically accurate model is derived. Given the operation recipe, the simulation results highlight an NH<span><math><msub><mrow></mrow><mrow><mn>3</mn></mrow></msub></math></span> yield of 60.9%, substantially exceeding the single-pass conversion of 10<span><math><mspace></mspace></math></span>-<span><math><mrow><mspace></mspace><mn>15</mn><mspace></mspace></mrow></math></span>%, typically achieved in state-of-the-art Haber–Bosch reactors. Additionally, a sensitivity analysis reveals that sorbent kinetics, rather than catalyst kinetics, should be the primary focus of material development to mitigate the effects of back-reaction in the presence of catalyst material during desorption. While the need for further material development is highlighted, this study provides the first rigorous dynamic evaluation of an integrated SSR for ammonia synthesis.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110387"},"PeriodicalIF":3.8,"publicationDate":"2025-07-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144656369","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":"Numerical simulation of structured surface roughness effects on flow boiling characteristics in microchannel","authors":"Yumei Gong,&nbsp;Guobing Zhou","doi":"10.1016/j.cep.2025.110439","DOIUrl":"10.1016/j.cep.2025.110439","url":null,"abstract":"<div><div>Effects of structured roughness shape and size on flow boiling heat transfer in microchannels are numerically investigated with the Volume of Fluid (VOF) method and the Lee model. <em>Rh</em> is proposed to characterize the area-averaged height of 3D roughness. First, roughness shapes of triangular pyramid, cube, and hemisphere are compared by assessing the Nusselt (<em>Nu</em>) and Poiseuille (<em>fRe</em>) numbers. Then, the base edge length <em>a</em> and height <em>h</em> of the triangular pyramid roughness elements are varied to examine their effects on flow boiling. The results indicate that microchannels with triangular pyramid roughness exhibit the best heat transfer performance among the three shapes. Furthermore, increasing either <em>a</em> or <em>h</em> of the triangular pyramid roughness elements can enhance the thermal-performance of the rough microchannels. Additionally, <em>Nu</em> increases by 1.64 % when <em>a</em> is raised by 25 %, while increasing <em>h</em> by 25 % results in a 4.45 % increase in <em>Nu</em>. Similar scenario occurs for <em>fRe</em>. This indicates that <em>h</em> rather than <em>a</em> has greater effects on the microchannel flow boiling. However, the effect of <em>Rh</em> on <em>Nu</em> and <em>fRe</em> exhibits complexity due to the shape dependence.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110439"},"PeriodicalIF":3.8,"publicationDate":"2025-07-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144595576","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}