Peng Liu , Kexin Gong , Dongmei Lin , Shuguo Guo , Zijian Ma , Zhongqiu Liu , Hong Zhang
{"title":"Numerical study of particle deposition and removal behavior in the water-cooled flue of a submerged arc furnace","authors":"Peng Liu , Kexin Gong , Dongmei Lin , Shuguo Guo , Zijian Ma , Zhongqiu Liu , Hong Zhang","doi":"10.1016/j.cep.2025.110404","DOIUrl":"10.1016/j.cep.2025.110404","url":null,"abstract":"<div><div>To solve the issue of fouling in traditional insulated flues, this study proposed a coil type water-cooled flue. Firstly, a comprehensive fouling model was developed based on the Johnson-Kendall-Roberts (JKR) theory and the Grant and Tabakoff particle-wall rebound model to simulate particle deposition, rebound, and removal behaviors within the water-cooled flue. Then, the effects of the cooling water inlet velocity, wall roughness, and inflection angle of tee section on the particle fouling characteristics were investigated. The results show that the particles are primarily deposited in the furnace mouth section, the external corners of the flue between sections I to III, the tee section, and the end of the blind pipe section within water-cooled flues owing to inertial collisions, low-velocity vortices, and thermophoretic force. Additionally, as the inlet velocity of cooling water increases from 0 to 1.6 m/s, the particle fouling mass decreases from 8.63 to 0.48 kg at <em>t</em> = 200 h. Conversely, as wall roughness increases from 0.1 to 1 mm, the particle fouling mass increases from 0.49 to 0.72 kg at <em>t</em> = 18 h. Furthermore, when the inflection angle <em>α</em> of the tee section increases from 60° to 110°, the fouling mass decreases from 0.54 to 0.48 kg at <em>t</em> = 18 h. Based on the comparative study of water-cooled and insulated flues, the water-cooled flue has a significant advantage in reducing particle deposition. To optimize particle deposition, the optimum inlet velocity of cooling water and the angle <em>α</em> are 1.2 m/s and 90°, respectively.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110404"},"PeriodicalIF":3.8,"publicationDate":"2025-06-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144313943","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}
Arman Mirchi, Mohammad Kazemeini, Vahid Hosseinpour
{"title":"Continuous-flow synthesis of Clopidogrel through different chip-microreactors and comparing of performances with that of a batch approach: A CFD simulation and an optimization study","authors":"Arman Mirchi, Mohammad Kazemeini, Vahid Hosseinpour","doi":"10.1016/j.cep.2025.110389","DOIUrl":"10.1016/j.cep.2025.110389","url":null,"abstract":"<div><div>Clopidogrel, is a widely used antiplatelet medication for heart patients globally. In recent years, the pharmaceutical industry has increasingly recognized the advantages of using a flow-based approach to drug production over traditional batch processing, which offers improved performance and safety, enhanced automation, and precise process control. The current research investigated the production of Clopidogrel using a continuous-flow approach in chip-microreactors. The study encompassed the design and simulation of novel micromixers and microreactors, followed by fabricating microfluidic chips with various geometries using laser engraving techniques. Clopidogrel was initially synthesized via the batch method and subsequently using a flow approach in the microreactors, with residence times of 25, 45, and 65 min, via a one-step synthesis route. The production and yield of the drug were validated through FTIR, HNMR, TLC, and HPLC analyses. The results indicated that microreactor C outperformed the others at all residence times, achieving a product yield of 38.9 % with a residence time of 65 min, compared to only 11.2 % from the batch approach under quite similar conditions. The continuous-flow approach demonstrated a promising yield of Clopidogrel in a significantly shorter duration of time and in a safer manner compared to the conventional batch procedure.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110389"},"PeriodicalIF":3.8,"publicationDate":"2025-06-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144261371","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}
Vinícius de C. Doimo da Silva , João P.M. de Souza , Antônio C.L. Horta , Thais S. Milessi , Gustavo D. Maia
{"title":"Intermittent bed homogenization as a strategy for improving the biodrying process of orange solid waste biomass","authors":"Vinícius de C. Doimo da Silva , João P.M. de Souza , Antônio C.L. Horta , Thais S. Milessi , Gustavo D. Maia","doi":"10.1016/j.cep.2025.110399","DOIUrl":"10.1016/j.cep.2025.110399","url":null,"abstract":"<div><div>This study investigates the effects of intermittent air flow rate (<em>Q</em>) and bed homogenization period (<em>BHP</em>) on the biodrying process of orange processing waste. A central composite design (CCD) was used to analyze the effect of these parameters on temperature and water removal. The minimum bed temperature (<em>T<sub>min</sub></em>) during the experiments ranged from 6.8 °C to 17.8 °C, while the mean and maximum temperatures ranged from 11.8 °C to 27.2 °C and 19.9 °C to 44.9 °C, respectively. The final moisture content ranged from 2.59 db to 1.58 db. Besides process achievement of 44.9 °C without external heat, CCD analysis showed that neither <em>Q</em> nor <em>BHP</em> had a significant effect on temperature during the biodrying process. While higher air flow rates improved moisture removal by convective mechanisms, they also increased evaporative cooling, which limited the temperature increase. Bed homogenization increased porosity and prevented preferential pathways but had a negligible effect on water loss and temperature increase. Biomass energy analysis showed that the biomass higher heating value (<em>HHV</em>) was maintained even in experiments where organic matter was consumed to generate heat. This indicates the integrity of the lignocellulosic compounds and preserves the potential of the waste for energy recovery. It was possible to identify challenges in optimizing biodrying processes, especially in systems with native microorganisms, highlighting the importance of detailed characterization of the microbiota. Future research should focus on refining operational parameters to improve water removal and thermal efficiency, thus contributing to sustainable waste management and process intensification.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110399"},"PeriodicalIF":3.8,"publicationDate":"2025-06-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144261373","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}
Mohammad Hossein Karimi Darvanjooghi , Sara Magdouli , Satinder Kaur Brar
{"title":"Process development for biooxidation of refractory gold ore using Ferroplasma acidophilum: A bench-scale case study of gold recovery","authors":"Mohammad Hossein Karimi Darvanjooghi , Sara Magdouli , Satinder Kaur Brar","doi":"10.1016/j.cep.2025.110377","DOIUrl":"10.1016/j.cep.2025.110377","url":null,"abstract":"<div><div>This study investigates the effects of biooxidation using <em>Ferroplasma acidiphilum</em> on gold recovery from high-grade (HGOS) and low-grade ore samples (LGOS). Pretreatment methods are caaried out in stirred tank reactors and column tests. Results showed that the stirred tank reactor yielded higher recovery rates for key elements, with gold recovery reaching 55 % for HGOS compared to 40 % for LGOS using the column test. Optimal conditions for biooxidation were identified, including aeration flow rates of 1.0–1.5 L/min and agitation speeds of 300–450 rpm, which facilitated effective microbial activity and pyrite dissolution. During cyanidation, gold recovery was highest at a pH of 10.5, with up to 60 % recovery at 8 (g/L) NaCN. However, at pH levels above 11, gold recovery decreased to around 40 % due to competing chemical species and metal hydroxide precipitation. The study also found that extending cyanidation time enhanced gold recovery, with significant increases observed within the first 10 h.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110377"},"PeriodicalIF":3.8,"publicationDate":"2025-06-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144223265","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}
Yihang Shi , Bangfu Huang , Keying Zhu , Fu Yuan , Xinchao Fan , Wei Li , Kui Zheng
{"title":"Mechanism of NO removal by NH3 + CO coupling over Fe-Ce/AC catalyst at low temperature","authors":"Yihang Shi , Bangfu Huang , Keying Zhu , Fu Yuan , Xinchao Fan , Wei Li , Kui Zheng","doi":"10.1016/j.cep.2025.110392","DOIUrl":"10.1016/j.cep.2025.110392","url":null,"abstract":"<div><div>In order to explore the activity and mechanism of low-temperature NH<sub>3</sub> + CO coupling removal of NO by catalysts prepared by loading transition metal element Fe and rare earth element Ce into activated carbon, Fe/AC, Ce/AC and Fe-Ce/AC catalysts were prepared in this paper. Based on the test of NO conversion rate and characterization of physicochemical properties of catalysts, the mechanism of low-temperature NH<sub>3</sub> + CO coupling removal of NO by catalysts was proposed. The results show that the Fe-Ce/AC catalyst has higher NO conversion than the single metal supported catalyst. Although the surface of Fe-Ce/AC catalyst is rough, the pores are fully developed, and the metal oxides are better loaded and uniformly dispersed. The N<sub>2</sub> isothermal adsorption-desorption curve showed typical I-type and IV-type isotherms, with H<sub>4</sub>-type hysteresis loop. Ce doping makes Fe uniformly loaded, the diffraction peaks of metal oxides weakened. Fe-Ce/AC has more oxygen-containing functional groups and oxygen vacancies than single metal supported catalysts. The Fe-Ce/AC catalyst is dominated by physical adsorption and <span>L</span>-H mechanism before 150 °C. Some Ce active components are dominated by E-R mechanism at 150∼200 °C. After 200 °C, the E-R mechanism is dominant.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110392"},"PeriodicalIF":3.8,"publicationDate":"2025-06-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144239972","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}
Binchuan Li , Xinwei Luan , Xiaoge Wang , Daxue Fu , Yongfeng Chang , Shuang Cui , Kuiren Liu , Xiaocai He , Jianshe Chen , Qing Han
{"title":"Immobilization of hazardous components in zinc leaching residue by autothermal roasting with pyrite","authors":"Binchuan Li , Xinwei Luan , Xiaoge Wang , Daxue Fu , Yongfeng Chang , Shuang Cui , Kuiren Liu , Xiaocai He , Jianshe Chen , Qing Han","doi":"10.1016/j.cep.2025.110391","DOIUrl":"10.1016/j.cep.2025.110391","url":null,"abstract":"<div><div>In this paper, pyrite is innovatively used as sulfur source, and its combustion heat is used to achieve effective detoxification of zinc leaching residue. Realize the treatment of waste with waste. The effects of several factors on the immobilization of hazardous components like Zn, Pb, As, and Cd were systematically investigated. The results show that under the condition of a roasting temperature of 975 °C, roasting time of 2.5 h, sulfur content of 20 %, and air flow of 0.8 m<sup>3</sup>·h<sup>-1</sup>, the leaching concentrations of Zn, Pb, As, and Cd in the roasted residue were 15.9 mg·L<sup>-1</sup>, 0.1 mg·L<sup>-1</sup>, 1.72 mg·L<sup>-1</sup>, and 0.84 mg·L<sup>-1</sup>, respectively, all of which are below the limits of hazardous waste identification standard. Thermodynamic analysis of the pyrite roasting process revealed that the heat generated by its combustion facilitates the roasting process of zinc leaching residue. The combustion product SO<sub>2</sub> can transform PbCO<sub>3</sub> in the leaching residue into PbSO<sub>4</sub>, and Fe<sub>2</sub>O<sub>3</sub> can convert ZnO, ZnS and ZnSO<sub>4</sub> into ZnFe<sub>2</sub>O<sub>4</sub>. PbFe<sub>6</sub>(SO<sub>4</sub>)<sub>4</sub>(OH)<sub>12</sub> transforms to PbSO<sub>4</sub>, Fe<sub>2</sub>O<sub>3</sub> and SO<sub>3</sub>. CdO generates CdFe<sub>8</sub>O<sub>16</sub>Zn<sub>3</sub> after roasting. As is immobilizated in the roasted residue in the form of FeAsO<sub>4</sub>. Magnetic separation was performed on the roasted residue to recover Fe, and the obtained concentrate had an Fe content of 54.20 %. The residue mass decreased by 25.73 % post-roasting, realizing “waste-treats-waste” through sulfur self-consumption and SO<sub>2</sub> fixation.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110391"},"PeriodicalIF":3.8,"publicationDate":"2025-06-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144253371","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}
Felix Febrian , Georg Brösigke , Paul H. Kamm , Jens-Uwe Repke
{"title":"Less pressure loss with extra packing — The counterintuitive behavior of rotating packed beds","authors":"Felix Febrian , Georg Brösigke , Paul H. Kamm , Jens-Uwe Repke","doi":"10.1016/j.cep.2025.110366","DOIUrl":"10.1016/j.cep.2025.110366","url":null,"abstract":"<div><div>The Rotating Packed Bed (RPB), as a process intensification unit in heat and mass transfer of multiphase processes, has been gaining growing attention in recent years as reflected in the numerous investigations of the device. However, many questions remain unanswered regarding the fluid dynamics in RPBs, including the counterintuitive behavior of higher dry pressure drop in operations with empty rotor compared to operations with packed rotor. To address this issue, we employ numerical methods to acquire a detailed description of the fluid flow inside the device. The metal foam as the packing material is resolved through reconstruction techniques found in the literature. The simulation results reveal that the absence of packing, due to conservation of angular momentum, induces higher local velocities and therefore higher pressure loss. Further, we derive fundamental mechanism of the pressure loss inside the RPB from the local data that can potentially enhance existing correlations.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110366"},"PeriodicalIF":3.8,"publicationDate":"2025-06-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144261537","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}
César Ramírez-Márquez , José María Ponce-Ortega , Juan Gabriel Segovia-Hernández , Salvador Hernández
{"title":"Process intensification control: Advancing efficiency and sustainability, a review","authors":"César Ramírez-Márquez , José María Ponce-Ortega , Juan Gabriel Segovia-Hernández , Salvador Hernández","doi":"10.1016/j.cep.2025.110388","DOIUrl":"10.1016/j.cep.2025.110388","url":null,"abstract":"<div><div>Process intensification has revolutionized chemical process design by integrating reaction and separation, enhancing efficiency, reducing energy consumption, and promoting sustainability. However, these advancements introduce significant control challenges due to increased process complexity, nonlinear interactions, and dynamic constraints. Over the past 25 years, conventional control strategies have been progressively replaced by predictive, adaptive, and data-driven methods, which are better suited for managing multivariable interactions and real-time optimization. The widespread adoption of predictive control frameworks has improved stability, reduced response times, and enhanced energy efficiency in reactive and extractive distillation, dividing-wall columns, and hybrid separation processes. Furthermore, integrating intelligent decision-making tools has enabled real-time adaptability, ensuring robust performance under fluctuating operating conditions. The emergence of hybrid control strategies, which combine predictive models with data-driven learning techniques, has further enhanced the ability to address nonlinearities and process uncertainties. This shift underscores a transition toward more intelligent and sustainable process operations, where control systems not only optimize efficiency but also minimize emissions and improve resource utilization. As process intensification continues to advance, future research should focus on scalable, autonomous, and computationally efficient control solutions to ensure operational reliability and economic feasibility in sustainable chemical manufacturing.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110388"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144212886","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":"Double vapor recompression strategy as a retrofit solution for the conventional benzene-toluene-xylene distillation","authors":"Fernanda Ribeiro Figueiredo, Diego Martinez Prata","doi":"10.1016/j.cep.2025.110382","DOIUrl":"10.1016/j.cep.2025.110382","url":null,"abstract":"<div><div>The benzene-toluene-xylene (BTX) mixture stands out as one of the most important in the petrochemical industry. In an effort to improve operational conditions and enhance the sustainability of separation systems, new technologies are continuously developed. Thus, this study aims to evaluate the potential economic and environmental benefits of two optimal double vapor recompression schemes applied to the conventional BTX separation plant (DVR and DVRC), while contrasting the outcomes with two previous configurations proposed for the same system, which incorporate the divided-wall strategy, with (DWC-VR) and without (DWC) vapor recompression. The economic analysis shows that the DVRC configuration achieves the lowest total annual cost (TAC) at $12.98 million/year, followed by DVR ($13.09 million/year) and DWC-VR ($13.36 million/year). In terms of environmental performance, DVRC presents the lowest CO₂ emissions, offering an 8.6 % reduction over DWC-VR. However, DWC-VR leads to a greater reduction in water consumption, surpassing DVRC by approximately 34 %. These results suggest that DVRC may be a more suitable configuration for retrofitting existing, older plants worldwide, offering both cost and environmental benefits. On the other hand, DWC-VR can be considered as a more complex improvement and revamping alternative, particularly for new projects or advanced process upgrades.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110382"},"PeriodicalIF":3.8,"publicationDate":"2025-05-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144212885","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":"State-of-the-art in forward osmosis membrane process: materials, fabrication, and applications","authors":"Jamaledin Jamadi-Torab , Assadollah Malekzadeh , Masoud Rahbari-Sisakht , Ahmad Fauzi Ismail","doi":"10.1016/j.cep.2025.110385","DOIUrl":"10.1016/j.cep.2025.110385","url":null,"abstract":"<div><div>Forward osmosis (FO) is a promising, low-energy membrane process as compared to pressure-driven technologies like reverse osmosis. This review critically discusses the progress in FO membrane technology, taking the advances in materials, preparation methods, and real-world applications into consideration. Recent progress in nanoparticle-doped micro- or nanoporous membranes, bioinspired nanostructured membranes and stimuli-responsive polymers may boost the water permeation, selectivity and anti-fouling capacity. Electrospinning and layer-by-layer assembly, as novel fabrication strategies provide better control of membrane architecture and performance. One more approach can also be found in introducing materials including, but not limited to, graphene oxide, carbon nanotubes and metal-organic frameworks into FO membranes to enhance water flux, salt rejection and membrane mechanical stability. In particular, optimized membranes have achieved water flux up to 83.55 % higher and reverse salt flux up to 75.58 % lower than their simulated counterparts, highlighting their enhanced performance. Moreover, inherent challenges including internal concentration polarization, scalability and membrane long-term stability are outlined, as well as potential strategies for circumventing these drawbacks. They are also discussed for potential applications in industrial desalination, wastewater treatment, food processing, and resource recovery, and their importance in achieving sustainability in the utilization of water.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110385"},"PeriodicalIF":3.8,"publicationDate":"2025-05-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144204456","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}