Xinjun Yang , Xiaohan Lin , Dongxiang Wang , Fangyang Yuan , Wei Yu , Jiyun Du
{"title":"Micromixing performance of a static mixer with an internal triply periodic minimal surface structure","authors":"Xinjun Yang , Xiaohan Lin , Dongxiang Wang , Fangyang Yuan , Wei Yu , Jiyun Du","doi":"10.1016/j.cep.2025.110264","DOIUrl":"10.1016/j.cep.2025.110264","url":null,"abstract":"<div><div>This study explores TPMS-Diamond structures in static mixers to enhance mixing and reaction processes. Pressure drops were measured in the fine chemicals flow range (0.6–3 L/min), and correlations between Reynolds number, porosity, unit size, and friction factor were established. Energy dissipation rates were calculated, and micromixing performance was evaluated using the Villermaux–Dushman reaction system.The results indicated that micromixing predominantly occurred in the initial contact region, with smaller unit sizes enhancing micromixing performance. When the porosity, ε, is greater than or equal to 0.75, the local energy dissipation rate of the TPMS-Diamond structure was found to be similar to that of the Kenics mixer, yet it achieved significantly better micromixing performance. Additionally, the effects of H+ concentration, flow rate, and volume flow ratio on the micromixing performance of the TPMS-Diamond structure were analyzed. By applying experimental data and agglomeration model techniques, micromixing times for TPMS-Diamond structures with different unit sizes and porosity were determined to range from 0.15 to 1.02 ms, all shorter than those of Kenics mixers. The relationship between micromixing time and energy dissipation rate demonstrates the excellent energy efficiency of TPMS structures. These results demonstrate the substantial potential of TPMS structures in optimizing chemical reaction processes.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"212 ","pages":"Article 110264"},"PeriodicalIF":3.8,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143620084","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}
Baoxin Liu , Qingfeng Dong , Jing Li , Zhanqing Lu , Guang Fu , Junchang Liu , Te Zhang
{"title":"Research on the enhancement effect of ultrasonic field combined with monoclinic FeS on arsenic removal behavior","authors":"Baoxin Liu , Qingfeng Dong , Jing Li , Zhanqing Lu , Guang Fu , Junchang Liu , Te Zhang","doi":"10.1016/j.cep.2025.110266","DOIUrl":"10.1016/j.cep.2025.110266","url":null,"abstract":"<div><div>Arsenic is a toxic element in industrial wastewater. The removal of arsenic by sulfide method has been a prominent research topic in the academic community. In this paper, arsenic was removed from arsenic-containing wastewater by ultrasound intensification combined with monoclinic FeS. This method avoids the common problems of H<sub>2</sub>S gas spillage and inefficiency in the sulfide method, and has the advantages of being clean and efficient. The effects of S/As molar ratio, initial temperature, reaction time and ultrasonic power on arsenic removal were studied. Under the optimum condition, the arsenic concentration was reduced from 1889 mg/L to 0.32 mg/L, and the arsenic removal rate reached 99.98 %. The precipitation after arsenic removal was characterized by X-ray diffraction (XRD), Scanning electron microscope-energy dispersive spectrometry (SEM-EDS), X-ray fluorescence spectrum analysis method (XRF) and X-ray photoelectron spectroscopy (XPS) to analyze the precipitation phase, surface morphology, element content and chemical composition. A high-speed camera was used to observe the effect of ultrasound on the kinematic behavior of monoclinic FeS.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"212 ","pages":"Article 110266"},"PeriodicalIF":3.8,"publicationDate":"2025-03-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143601801","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":"Spinning disc technology for intensified continuous flow processing: An overview of recent progress and future prospects","authors":"Kamelia Boodhoo","doi":"10.1016/j.cep.2025.110265","DOIUrl":"10.1016/j.cep.2025.110265","url":null,"abstract":"<div><div>Continuous thin film flow on a spinning disc has attracted much attention for its enhanced mass and heat transfer, very short, controllable residence times and its ability to intensify fast, exothermic reactions. This perspective paper presents recent advancements in the spinning disc technology, focusing on more detailed film flow and mixing characterisation and quantifying key parameters such as micromixing and residence time distribution. Reactive-precipitation, polymerisations and organometallic reactions are some of the applications that have been extensively studied on the spinning disc. Application to areas of significant interest to net-zero carbon emissions such as biotechnology and biomass/biorefinery industries have most recently also demonstrated performance enhancements compared to traditional, non-intensified processes. Although several challenges remain to be overcome, future prospects of spinning disc technology are promising. The development of advanced designs of multiple stages incorporating ‘green’ electrified energy input and novel disc architectures, such as 3D printed structured and porous surfaces, to further enhance mixing, transport properties and reaction kinetics are some of the exciting prospects. The spinning disc technology also holds much promise for the less well-studied photo-activated reactions, where its dynamic thin film characteristics offer significant potentials for efficient light penetration in photocatalytic synthesis processes.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"212 ","pages":"Article 110265"},"PeriodicalIF":3.8,"publicationDate":"2025-03-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143679803","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Effects of the characteristics of silica microcapsules with nanoholes on the reaction rate of calcium chloride for chemical heat pump","authors":"Linbin Zeng , Ruri Hidema , Yuxin Tang , Aito Shimamoto , Keiko Fujioka , Hiroshi Suzuki","doi":"10.1016/j.cep.2025.110267","DOIUrl":"10.1016/j.cep.2025.110267","url":null,"abstract":"<div><div>An optimized-double emulsion method for preparing hollow silica microcapsules with nanoholes was developed for encapsulating calcium chloride to enable its long-term use in chemical heat pumps. The hydration/dehydration of calcium chloride was achieved by permeating water vapour through the surface holes, allowing the thermal upgrading and storage of low-temperature waste heat. The effects of the solution mass and surfactant concentration during the fabrication process on the texture of the microcapsules and thermal properties of the composites were investigated. The results demonstrated the successful encapsulation of calcium chloride in the microcapsules to occupy the entire void and complete hydration/dehydration reaction. Changing the fabrication conditions affected the diameter, shell thickness and opening fraction of microcapsules, thereby further controlling the void fraction and hole specific surface area, which were proven to be key parameters for improving heat storage density and hydration output power density. Composite microcapsules with a heat storage density of 809.1 J·g<sup>−1</sup> at a void fraction of 54.7 vol% and a power density of 0.95 W·g<sup>−1</sup> at a hole specific surface area of 0.089 μm<sup>-1</sup> and satisfactory thermal stability after 50 cycles were obtained.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"212 ","pages":"Article 110267"},"PeriodicalIF":3.8,"publicationDate":"2025-03-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143601709","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Shichao Su , Yaqiao Tian , Huifeng Li , Weiyao Yang , Hongda Zhang , Feng Liu , Le Sang
{"title":"Hydrogenation of vanillin to vanillyl alcohol over Pd/PDA/Ni foam in micropacked bed reactors","authors":"Shichao Su , Yaqiao Tian , Huifeng Li , Weiyao Yang , Hongda Zhang , Feng Liu , Le Sang","doi":"10.1016/j.cep.2025.110262","DOIUrl":"10.1016/j.cep.2025.110262","url":null,"abstract":"<div><div>The micropacked bed reactor (μPBR) with monolithic catalyst hydrogenation technology has received widespread attention due to its high efficiency, continuous operation, and safety. In this study, the Pd/PDA/foam catalyst was prepared via impregnation method and vanillin (VL) hydrogenation was investigated in green water solution based on the μPBRs. The effect of operating temperature, pressure, the number of foam catalyst block, VL concentration, liquid and H<sub>2</sub> flow rate on VL conversion and VA yield was discussed. The highest conversion of VL was 99.4 % and product yield of vanillyl alcohol (VA) reached 84.9 % with 2.8 MPa, 120 °C, 22 blocks of Pd/PDA/Ni foam catalyst, H<sub>2</sub> flow rate of 10 mL min<sup>−1</sup> and liquid flow rate of 0.1 mL min<sup>−1</sup>, and short reaction time (0.106 h) in μPBRs. The kinetic of hydrogenation VL to VA was established. The reaction rate constant and activation energy in μPBRs were from 0.63 to 1.39 min<sup>−1</sup> and 16.94 kJ·mol<sup>−1</sup>. The <em>STY</em> of VA in μPBRs was 0.0824 kg·L<sup>−1</sup>·h<sup>−1</sup>·g<sup>−1</sup>, which was bigger than that of batch hydrogenation devices.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"212 ","pages":"Article 110262"},"PeriodicalIF":3.8,"publicationDate":"2025-03-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143679804","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":"Accelerated metal separation from chalcopyrite assisted with ozone","authors":"Mingzhu Ren , Jiang Zhang , Zhaomeng Xu , Jing Wang , Jiakai Qiu , Yongbing Xie","doi":"10.1016/j.cep.2025.110263","DOIUrl":"10.1016/j.cep.2025.110263","url":null,"abstract":"<div><div>Chalcopyrite is a very important mineral resource, but metal separation from chalcopyrite requires a long time and high energy. This work proposed an ozonation enhanced acid leaching strategy, and typical operating parameters were optimized. The results showed that the leaching rates of Cu and Fe reached 35.9 % and 36.9 % after 5 h, respectively, with 0.1 mol/L of H<sub>2</sub>SO<sub>4</sub>, 100 mg/L of O<sub>3</sub> and a L/S ratio of 50:1 at 45 °C, which were about 29.7 and 10.2 times higher than that without O<sub>3</sub>. Two novel approaches are further employed to enhance the leaching rates. It was found that the coupling of UV radiation did not play a synergistic role for metal leaching, while it increased rapidly when H<sub>2</sub>O<sub>2</sub> was added into the leaching system, though the enhancement effect was not continuous. In addition, ball milling pretreatment and ozone micro-nano bubbles both greatly improved the metal leaching rates from chalcopyrite. The leaching rate of Cu can reach to 86.5 % after ball milling, and the concentrations of Fe and Cu in the leaching solution with O<sub>3</sub> micro-nano bubbles increased by 7.7 and 10.0 times than those with common O<sub>3</sub> bubbles. This work provides a new idea for the development of novel leaching technology of chalcopyrite.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"212 ","pages":"Article 110263"},"PeriodicalIF":3.8,"publicationDate":"2025-03-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143591900","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":"Wastewater treatment through a hybrid electrocoagulation and electro-Fenton process with a porous graphite air-diffusion cathode","authors":"Ziad T. Alismaeel, Osama F. Saeed, Ali H. Abbar","doi":"10.1016/j.cep.2025.110258","DOIUrl":"10.1016/j.cep.2025.110258","url":null,"abstract":"<div><div>Wastewater from hospitals is a major source of pollution, and its treatment to protect the environment is a challenge. Different traditional methods have been applied to treat hospital wastewater (HW). Recently, hybrid processes, such as electrocoagulation (EC) with the electro-Fenton (EF) process, have been found to outperform traditional methods in terms of their high removal rate, low sludge generation and energy consumption and environmental sustainability. Herein, a combined EF process integrated with EC was successfully applied to reduce the chemical O demand (COD) of HW. A batch tubular electrochemical reactor composed of a microporous graphite air diffusion cathode and a hollow cylinder Al anode was used as a new design to remove pollutants from HW. Response surface methodology was adopted to explore the effects of operating factors, which were represented by current density, Fe<sup>2+</sup> concentration and time, on COD removal and identify their interactions. The best operating conditions were a current density of 20 mA/cm<sup>2</sup>, an Fe<sup>2+</sup> concentration of 6 mM and a reaction time of 63 min. These conditions yielded a COD removal efficiency (RE %) of 93.5 % with an energy consumption of 18.325 kWh/kg COD. Time had the main effect on the RE % due to the synergistic effect of EC and EF. The hybrid system had higher efficiency and lower energy consumption and sludge production than individual EC or EF. Therefore, combining EC with EF could be a promising approach for the treatment of HW.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"212 ","pages":"Article 110258"},"PeriodicalIF":3.8,"publicationDate":"2025-03-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143601710","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}
Victorino Diez , José María Cámara , Miguel Cantera , Adrián Bonilla , Cipriano Ramos
{"title":"Comparing a new semi-empirical mathematical model and a neural network for the description and forecasting of reversible fouling in membrane bioreactors","authors":"Victorino Diez , José María Cámara , Miguel Cantera , Adrián Bonilla , Cipriano Ramos","doi":"10.1016/j.cep.2025.110256","DOIUrl":"10.1016/j.cep.2025.110256","url":null,"abstract":"<div><div>This study compares the predictive capability of membrane fouling between a new semi-empirical mathematical model and a neural network. Calibration and validation involved 21 replicated flux-step experiments with 8 filtration fluxes ranging from 9.8 to 18.9 L/m²·h and 40-hour random-flux experiments conducted in an anaerobic membrane bioreactor. The inherent variability of reversible fouling linked to cake build-up was quantified.</div><div>In addition to cake build-up and compression, the mathematical model incorporates the restoration of residual fouling not removed by backwashing, including the rearrangement of non-detached particles and colloids, initial pore-blocking, and concentration polarization. The model predicts reversible fouling across a wide range of filtration fluxes, even beyond those used for calibration. Random-flux experiments revealed fouling trends undetectable via direct transmembrane pressure inspection. However, the mathematical model fails when the effective membrane area decreases during filtration.</div><div>The neural network predicts fouling patterns independently of underlying mechanisms, offering adaptability across a broader range of operating conditions. Nonetheless, it struggles to predict reversible fouling for flux ranges outside its training dataset, particularly at fluxes significantly higher or lower than those used in training.</div><div>The present study offers insight into reversible fouling description in order to enhance the performance of membrane bioreactors.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"212 ","pages":"Article 110256"},"PeriodicalIF":3.8,"publicationDate":"2025-03-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143549956","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}
Dominik Nieweś, Kinga Marecka, Jakub Zieliński, Marta Huculak-Mączka
{"title":"Modelling and optimization of spent mushroom substrate valorization into humic-like substances through alkaline extraction intensified by ultrasound","authors":"Dominik Nieweś, Kinga Marecka, Jakub Zieliński, Marta Huculak-Mączka","doi":"10.1016/j.cep.2025.110261","DOIUrl":"10.1016/j.cep.2025.110261","url":null,"abstract":"<div><div>The present study aimed to assess the possibility of humic-like substances (HSLs) isolation from spent mushroom substrate (SMS) through alkaline extraction intensified by ultrasound. The Box-Behnken design (BBD) coupled with the response surface methodology (RSM) was applied for the process evaluation. Based on the polynomial model, the values of NaOH concentration, process time, and temperature values were selected to maximize the extraction efficiency. The coefficient of determination for the created model was 97.61 %, and the experimental verification of the response showed that the extraction efficiency under optimal process conditions was equal to 32.66 % ± 1.26 %. Obtained humic-like substances were fractionated into humic-like acids (HLAs) and fulvic-like acids (FLAs) and qualitatively assessed. The ATR-FTIR and CP/MAS <sup>13</sup>C NMR spectra of the isolated samples revealed the presence of aliphatic, aromatic, carboxyl and carbonyl structures, which were also evident for the humic and fulvic acids extracted from peat and lignite. Furthermore, HLAs and FLAs were characterized by lower concentrations of heavy metals compared to samples isolated from peat and lignite, which combined with a significant content of micro and macronutrients may indicate the potential to use humic-like and fulvic-like acids extracted from the spent mushroom substrate for agricultural purposes.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"212 ","pages":"Article 110261"},"PeriodicalIF":3.8,"publicationDate":"2025-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143579610","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}
Linfa Bao , Han Chen , Mian Hu , Ange Chen , Guodong Wang , Liwei Huang
{"title":"Removal of nitric oxide from gas streams by droplet triggered gas discharge","authors":"Linfa Bao , Han Chen , Mian Hu , Ange Chen , Guodong Wang , Liwei Huang","doi":"10.1016/j.cep.2025.110260","DOIUrl":"10.1016/j.cep.2025.110260","url":null,"abstract":"<div><div>The study investigated nitrogen oxide (NO) removal using gas discharge plasma technology, by an enhanced plate-plate corona discharge reactor. This reactor was an improvement over the traditional wire-plate reactor, featuring an added water dripping device above the reactor. The downward dripping water facilitated the discharge between the electrode plates, while simultaneously absorbing the nitrogen dioxide (NO<sub>2</sub>) produced during the reaction and converting it into nitric acid (HNO<sub>3</sub>). The effects of water droplets and different process parameters (voltage, residence time, NO inlet concentration, and oxygen concentration) on NO removal were investigated. The reaction mechanism and the optimal energy efficiency were further discussed. The results showed that the removal efficiency of NO reached 61.5 %, with an energy efficiency of 0.204 mg kJ<sup>−1</sup>, under the optimal conditions of a 14 kV direct current voltage, a flue gas flow rate of 1.5 L·min<sup>−1</sup>, an initial NO concentration of 350 mg·m<sup>−3</sup>, an oxygen flow rate of 40 mL min<sup>−1</sup>, and a droplet dropping rate of 10 mL min<sup>−1</sup>. Moderate water droplets can promote discharge reactions and NO conversion to HNO<sub>3</sub>, but excessive droplets can reduce discharge effectiveness and NO removal efficiency, and lead to voltage breakdown and electric leakage. Moreover, the generated HNO<sub>3</sub> in water solution can be recycled and reused, suggesting significant industrial application potential.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"212 ","pages":"Article 110260"},"PeriodicalIF":3.8,"publicationDate":"2025-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143579708","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}