Chemical Engineering and Processing - Process Intensification最新文献

{"title":"Oily wastewater treatment via a visible-light-responsive slurry membrane photocatalytic reactor incorporating Bi2WO6-based photocatalysts","authors":"Mohammad Reza Akrami ,&nbsp;Zahra Sadeghian ,&nbsp;Seyed Nezameddin Ashrafizadeh","doi":"10.1016/j.cep.2025.110365","DOIUrl":"10.1016/j.cep.2025.110365","url":null,"abstract":"<div><div>This study focuses on the development and integration of Bi₂WO₆-based visible-light-responsive photocatalysts with a zirconia/alumina ultrafiltration membrane in a slurry photocatalytic ceramic membrane reactor (SPCMR) for oily wastewater treatment, highlighting the synergistic effect of combining photocatalysis with membrane separation. To this end, several visible-light-active photocatalysts, including NH₂-MIL-125(Ti)/Bi₂WO₆, WO₃/Bi₂WO₆, and Bi₂O₃/Bi₂WO₆, were synthesized via hydrothermal methods and characterized using X-ray diffraction (XRD), Fourier-transform infrared spectroscopy (FTIR), scanning electron microscopy (SEM), and nitrogen adsorption–desorption analyses. The filtration performance of the system was evaluated under varying oil concentrations ranging from 1000 to 3000 ppm, at natural pH, with a photocatalyst dosage of 1 g/L over a 4-hour operational period. Removal efficiency was assessed based on total organic carbon (TOC) content. Results showed that membrane performance declined at higher concentrations (3000 ppm) due to surface fouling; however, this limitation was mitigated by incorporating the SPCMR system. TOC removal varied depending on parameters such as transmembrane pressure (TMP), flow rate, and light intensity. Among the tested photocatalysts, NH₂-MIL-125(Ti)/Bi₂WO₆ exhibited the highest efficiency, achieving up to 92% TOC removal. These findings highlight the potential of Bi₂WO₆-based composite photocatalysts in SPCMR systems as a promising approach for sustainable oily wastewater remediation.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"215 ","pages":"Article 110365"},"PeriodicalIF":3.8,"publicationDate":"2025-05-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144098456","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":"Dilution and flocculation prediction of a pilot-scale thickener feedwell by hybrid modelling approach","authors":"Xiaoyu Wang ,&nbsp;Baoyu Cui ,&nbsp;Xuetao Wang ,&nbsp;Qiang Zhao ,&nbsp;Yiye Zhang ,&nbsp;Yunhai Zhang","doi":"10.1016/j.cep.2025.110364","DOIUrl":"10.1016/j.cep.2025.110364","url":null,"abstract":"<div><div>Dilution plays a significant role in the flocculation process, which relies on the structure and dimensions of the dilution port. The dilution port was optimized by the hybrid modelling approach between Response Surface Methodology (RSM) and Computational Fluid Dynamics (CFD), considering the interactive impact of sidewall immersion length (L), reference angle (α) to bending pipe, and width of the cuboid (W). Batch simulation tests were performed to explore the effect of structure and dimension on dilution quantity. A quadratic regression model forecasted the optimal feedwell would be capable of a self-diluting water volume of 1.53 L/s compared to the basic case of negative1.32 L/s, and the α was most sensitive factor that influence the dilution quantity. Subsequently, the flow characteristics and flocculation performance were compared between the two cases using the coupled CFD-Population Balance Model (PBM) approach. Results showed that the outer well was subdivided into four zones following the predicted variation of floc size along the vertical direction. The optimal case exhibited better flocculation performance than the basic case evaluated by the mean floc size distribution in and around the feedwell, thereby guiding the design of feedwell dilution ports for enhancing the flocculation performance.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"215 ","pages":"Article 110364"},"PeriodicalIF":3.8,"publicationDate":"2025-05-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144115130","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":"Electrochemical CO2 reduction from NH4HCO3 in ammonia-based carbon capture: Comparison of external and in-situ carbon sources","authors":"Huiyi Li ,&nbsp;Jianmin Gao ,&nbsp;Qian Du ,&nbsp;Yu Zhang ,&nbsp;Xin Guo ,&nbsp;Zhijiang Wang","doi":"10.1016/j.cep.2025.110361","DOIUrl":"10.1016/j.cep.2025.110361","url":null,"abstract":"<div><div>Combining ammonia-based carbon capture technology with electrocatalytic reduction powered by excess energy from power plants enables efficient use of captured carbon products while avoiding energy-intensive CO₂ release and compression process. Revealing the impact of <em>in-situ</em> carbon sources on reaction activity and product selectivity is crucial in the direct electrocatalytic reduction of ammonium bicarbonate (NH₄HCO₃). This study compares the reduction performance of <em>in-situ</em> and external carbon source systems via potentiostatic reduction on Ag-based electrodes in Ar- or CO₂-saturated bicarbonate electrolytes. We found that high NH₄HCO₃ concentrations in the <em>in-situ</em> system enhance CO₂ and intermediate adsorption on Ag-based catalysts, achieving CO production efficiencies comparable to external carbon sources, with a peak CO Faradaic efficiency of 62.2 % at −0.6 V and a current density of 9.84 mA·cm⁻² at −0.8 V. NH₄⁺ has a larger ionic radius, which increases local CO₂ concentration and proton availability, enhancing CO yield and catalytic efficiency over <em>K</em>⁺ in <em>in-situ</em> carbon source systems. It also promotes hydrogen evolution reactions (HER), enabling efficient syngas production via dual-reaction synergy. We hope these findings provide theoretical support and guidance for system control strategies in the ammonia-based carbon capture coupled with electrocatalytic conversion technology.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"215 ","pages":"Article 110361"},"PeriodicalIF":3.8,"publicationDate":"2025-05-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144090410","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":"Preparation of yttrium carbonate using ultrasound-assisted sodium carbonate system","authors":"Runding Guo ,&nbsp;Yuanhong Liu ,&nbsp;Weichao Huang ,&nbsp;Shaohua Yin ,&nbsp;Bugang Xu","doi":"10.1016/j.cep.2025.110363","DOIUrl":"10.1016/j.cep.2025.110363","url":null,"abstract":"<div><div>Sodium carbonate has been widely employed in industry as a precipitant for the preparation of yttrium carbonate. However, challenges in crystallization have been encountered, including poor dispersibility, broad particle size distribution, and severe agglomeration. Ultrasound has been introduced to address these issues of agglomeration and uneven particle size distribution. The optimal conditions have been identified as the ultrasound power density of 30,000 W/m³, the co-precipitation method, the liquid flow rate of 10 mL/min, the molar ratio of yttrium ion concentration to sodium carbonate concentration of 1:1.575, the yttrium chloride solution with a pH of 4, the precipitation temperature of 40 °C, the stirring speed of 300 rpm, no aging time and seed crystal cycle. The prepared yttrium carbonate crystals have been characterized by scanning electron microscopy, laser particle size analysis, and X-ray diffraction. The yttrium carbonate crystals have been observed to exhibit quasi-spherical structures formed by the aggregation of needle-like and plate-like morphologies, with a D₅₀ value of 3.777 μm and a (D₉₀-D₁₀)/2D₅₀ value of 0.913.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"215 ","pages":"Article 110363"},"PeriodicalIF":3.8,"publicationDate":"2025-05-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144090409","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":"Treatment of membrane concentrates using anodic oxidation process: A review","authors":"Fares Zouaoui ,&nbsp;Victor Rezende Moreira ,&nbsp;Míriam Cristina Santos Amaral ,&nbsp;Pierre-François Biard ,&nbsp;Florence Fourcade","doi":"10.1016/j.cep.2025.110357","DOIUrl":"10.1016/j.cep.2025.110357","url":null,"abstract":"<div><div>Membrane processes, including nanofiltration and reverse osmosis, are essential in water reuse due to their ability to deliver consistently high-quality treated water. However, these processes generate membrane concentrates (MC), highly pollutant-laden waste streams that present significant treatment and disposal challenges. Conventional treatment methods, while effective, often face limitations such as high operational costs, environmental risks, and inefficiencies in handling complex effluents. Anodic oxidation (AO), an advanced oxidation process, offers a promising solution for MC management. By generating reactive species, AO can efficiently degrade refractory organic pollutants, thereby improving the overall treatment effectiveness. This approach aligns with process intensification principles by enhancing energy efficiency and reducing waste discharge, as it enables the treatment and potential reuse of a stream previously considered a residual by-product from the membrane process. Therefore, this review highlights the potential of AO in enhancing water recovery and addressing sustainability challenges in MC management. Key considerations for optimizing AO performance, including operating conditions and effluent-specific parameters, are discussed to support its broader application in MC treatment and resource recovery.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"214 ","pages":"Article 110357"},"PeriodicalIF":3.8,"publicationDate":"2025-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143948666","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":"Design, construction and evaluation of an innovative horizontal trickle bed reactor for intensification of pectinase production process","authors":"Kavita Singh,&nbsp;Ganti S. Murthy","doi":"10.1016/j.cep.2025.110343","DOIUrl":"10.1016/j.cep.2025.110343","url":null,"abstract":"<div><div>An innovative horizontal trickle bed reactor (HTBR) was designed and constructed for pectinase production in solid-state fermentation with provisions of mixing and trickling. The HTBR of horizontal configuration consisted of a newly designed impeller with angled blades that provided efficient mixing in linear and circular motions. The moisture and temperature were controlled with a liquid recirculation system which improved heat and mass transfer and also prevented bed drying and compaction. The HTBR performance was evaluated and compared with packed bed and tray bioreactors. The pectinase yield of 242.9 IU/gds was obtained in HTBR, was 2.7-fold higher than the tray reactor and 1.76-fold higher than the packed bed configuration. The pectinase productivity of HTBR was 2.5 IU/gds/h which was 3.5-fold higher than packed bed and 6.09-fold higher than tray configurations. A mathematical model was developed to describe the kinetics of pectinase production as a function of biomass, substrate, agitation, and trickling rates.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"214 ","pages":"Article 110343"},"PeriodicalIF":3.8,"publicationDate":"2025-05-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143931985","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":"Application of ZnAlFeO4 spinel and residual ash generated from pyrometallurgical magnetic separation processes: Catalysis and heavy metals immobilization","authors":"Weilu Yang ,&nbsp;Jiabao Qin ,&nbsp;Suiyi Zhu ,&nbsp;Leilei Zhang ,&nbsp;Jiancong Liu ,&nbsp;Zhan Qu","doi":"10.1016/j.cep.2025.110359","DOIUrl":"10.1016/j.cep.2025.110359","url":null,"abstract":"<div><div>The recycling of electroplating sludge (ES), a byproduct rich in heavy metals (HMs), is receiving increasing attention in recent years, especially in the context of HMs recovery and recycling. This study investigated the application of ZnAlFeO₄ spinel and residual ash generated from pyrometallurgical magnetic separation processes, focusing on the catalytic performance and solidification of HMs. The photocatalytic degradation of methylene blue and tetracycline using ZnAlFeO₄ spinel was conducted, with degradation rates of 74.9 % and 83.6 %, respectively. The residue ash, rich in Zn and Si/Al impurities, was stabilized through co-sintering with fly ash, forming calcium silicate glass, which immobilized HMs effectively. The optimal solidification of HMs was achieved at 1400 °C with 50 % fly ash, reducing Zn leaching to 3.35 mg/L and Cr below detectable levels. The mechanism of HMs solidification involves the formation of vitreous liquid slag, providing fixed sites for the immobilization of HMs within the silicate structure and effectively restraining their release. However, an excess of fly ash resulted in the formation of CaAl₂Si₂O₈ crystals, disrupting the silicate glass framework and releasing HMs. The study provides insights into the transformation of ES into functional materials, contributing to waste management and environmental protection through the development of sustainable technologies.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"214 ","pages":"Article 110359"},"PeriodicalIF":3.8,"publicationDate":"2025-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144070909","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 valuable metals from cathode material from spent lithium-ion batteries","authors":"Yanying Jiang ,&nbsp;Aimin Liu ,&nbsp;Fengguo Liu ,&nbsp;Yulong Cao ,&nbsp;Xianwei Hu ,&nbsp;Zhongning Shi ,&nbsp;Zhaowen Wang","doi":"10.1016/j.cep.2025.110358","DOIUrl":"10.1016/j.cep.2025.110358","url":null,"abstract":"<div><div>Thermodynamic analysis shows that reducing agent coke can reduce Co₃O₄, CoO and NiO to Co and Ni at 1300–1500 °C. MnO₂ is gradually carbothermal reduced to Mn₂O₃, Mn₃O₄ and MnO, while MnO is reduced to metallic Mn when the temperature is higher than 1402 °C. The effects of smelting temperature, Na₂CO₃ addition and smelting time on the retention rate of Li in slag have been studied. Using 10–20 % Na₂CO₃ as an additive can inhibit the volatilization loss of Li during the smelting of ternary cathode materials of lithium-ion batteries, and realize the enrichment of Li in slag. When the smelting temperature is 1300 °C, Na₂CO₃ addition is 20 %, and the smelting time is 60 min, the retention rate of Li in slag is as high as 96.37 %. FAAS, XRD and SEM-EDS analysis of products obtained by smelting at 1300 °C for 120 min show that the main phases of metal product were Co and Ni, among which the mass fractions of Ni, Co, Mn, and Fe are 52.9 %, 19.4 %, 8.3 % and 3.1 %, respectively. The residue after smelting at 1300 °C for 60 min is leached by sulfuric acid with the liquid-solid ratio of 2:1 at 90 °C for 60 min, and the leaching rate of Li is 82.11 %.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"215 ","pages":"Article 110358"},"PeriodicalIF":3.8,"publicationDate":"2025-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144083608","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":"Comprehensive numerical and experimental analysis of dynamic gas-liquid separator with various oil-gas ratios","authors":"Zhi Qiu ,&nbsp;Ling Bai ,&nbsp;Jun Fu ,&nbsp;Bing Qu ,&nbsp;Ling Zhou","doi":"10.1016/j.cep.2025.110332","DOIUrl":"10.1016/j.cep.2025.110332","url":null,"abstract":"<div><div>Dynamic gas-liquid separator is a critical equipment extensively utilized in oil extraction, the nuclear industry, and chemical engineering. The operating parameters, such as flow rate and oil-gas ratio, can vary significantly in real-world applications. To enhance the separator’s performance, this study employs the computational fluid dynamics (CFD)–population balance model (PBM) method to investigate how different oil-gas ratios affect the internal flow field and the overall performance of the dynamic gas-liquid separator. An experimental platform was constructed to test various oil-gas ratios, and the numerical results were compared with experimental data to validate the numerical model's accuracy and reliability. The findings indicate a positive correlation between the oil-gas ratio and both separation performance and energy consumption. As the oil-gas ratio increases, the internal flow field becomes more stable, which is conducive to gas-liquid separation, thereby enhancing the separator's efficiency. However, this also leads to increased energy consumption due to the higher liquid phase volume fraction, necessitating greater power to maintain stable operation. For instance, when the <em>Q</em>_o=60 m³‧d^-1 and <em>ε</em> increases from 0.5 to 2.5, the degassing rate, power and pressure difference of the separator increase by 20.24 %, 210.03 % and 176.67 %, respectively. Interestingly, while the separator’s degassing rate decreases with a higher flow rate, the deoiling rate improves. The optimal separation efficiency was achieved at a flow rate of 140 m³·d⁻¹, where the degassing and deoiling rates reached 95.21 % and 93.97 %, respectively. As the flow rate continues to rise, the fluid volume per unit time, energy consumption, power requirements, and differential pressure also increase. Based on these findings, prediction equations for separator performance across various oil-gas ratios were developed. These equations offer a valuable theoretical foundation for designing, operating, and optimizing high-performance dynamic separators, contributing to the efficiency and sustainability of industrial applications.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"214 ","pages":"Article 110332"},"PeriodicalIF":3.8,"publicationDate":"2025-05-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143948665","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":"Purification of 1-butanol from rich and lean aqueous heteroazeotropic mixture by sponge-like ionic liquid process","authors":"René Cabezas ,&nbsp;Karin Jaramillo ,&nbsp;Laura Azocar ,&nbsp;Nicolas Monsalve ,&nbsp;Roberto Castro-Muñoz","doi":"10.1016/j.cep.2025.110356","DOIUrl":"10.1016/j.cep.2025.110356","url":null,"abstract":"<div><div>The Acetone-Butanol-Ethanol (ABE) fermentation process is a promising approach for sustainable biobutanol production. However, separation and purification of butanol following membrane-based or distillation separation processes remain challenging due to the formation of a water-butanol heteroazeotropic mixture (55.5 wt% 1-butanol), requiring multiple distillation columns and generating both lean and rich aqueous phases. In this study, a novel sponge-like ionic liquid extraction process was employed to recover 1-butanol from these aqueous mixtures using 1-Methyl-3-octadecylimidazolium bis(trifluoromethyl sulfonyl)imide (C₁₈MIM[Tf₂N]). The liquid C₁₈MIM[Tf₂N] was contacted with a rich and lean butanol aqueous phases at temperatures above IL´s melting point (60 °C to 90 °C) and an IL/aqueous ratio of 1:1. After phase separation, the IL solidified at room temperature, allowing the extraction of the dissolved component via centrifugation.</div><div>The results indicated that optimal recovery from the lean phase occurred at 80 °C, achieving enhanced solubility of 1-butanol in the IL while minimizing losses. Under these conditions, the remaining aqueous phase contained only 1 wt% 1-butanol, and over 95 % of the butanol was recovered from the IL. For the rich phase, high butanol concentrations altered the hydrophobicity of C₁₈MIM[Tf₂N], causing water retention and resulting in an aqueous phase with a higher butanol content. These findings highlight the potential of sponge-like IL extraction for efficient butanol purification, reducing energy-intensive distillation steps.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"214 ","pages":"Article 110356"},"PeriodicalIF":3.8,"publicationDate":"2025-05-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143934920","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}