Chemical Engineering and Processing - Process Intensification最新文献

{"title":"CO2 capture and utilization for production of precipitated calcium carbonate in a rotating packed bed: simultaneous design and control using distributed computing","authors":"Thomas Prousalis ,&nbsp;George Gkizas ,&nbsp;Panagiotis Kazepidis ,&nbsp;Panos Seferlis ,&nbsp;Athanasios I. Papadopoulos","doi":"10.1016/j.cep.2025.110509","DOIUrl":"10.1016/j.cep.2025.110509","url":null,"abstract":"<div><div>A novel design optimization approach is presented for the integrated CO₂ capture (CC) and utilization (CU) process design with simultaneous economic and controllability assessment. The CC process accounts for multiple solvents and process flowsheet options. The CU process targets the production of nano-sized precipitated calcium carbonate (PCC) using a rotating packed bed (RPB). The algorithm enables parallel computing and uses the approximate computing techniques of memoization and task dropping. It is implemented considering 20 alternative options for the CC process, as combinations of 4 solvents with 5 process flowsheet configurations. The tailored CU process is designed simultaneously with the aim to identify combinations that exhibit high economic performance both in steady state operation and under variability. The algorithm is tested in two case studies with different flue gas characteristics and different yearly operating scenarios, exhibiting excellent scalability in 100 parallel threads. The results showed that 2-(2-hydroxyethylamino) ethanol (DEA) is the optimal choice in both case studies. An absorber with intercooling (ICA) increased the driving forces in the CC process and led to better performance in both cases. The optimal design in the case of higher CO₂ content in the flue gas involved a double-side stripper (DSS) for solvent regeneration.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110509"},"PeriodicalIF":3.9,"publicationDate":"2025-08-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144831338","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":"Comparing catalyst powders and pellets for microwave assisted biogas reforming","authors":"Andrea Merlo,&nbsp;Léon Thomann,&nbsp;Yuna Han,&nbsp;Emmanuel Landrivon,&nbsp;Nolven Guilhaume,&nbsp;Yves Schuurman","doi":"10.1016/j.cep.2025.110507","DOIUrl":"10.1016/j.cep.2025.110507","url":null,"abstract":"<div><div>Reactor electrification is a promising technology to reduce carbon dioxide emissions in the chemical industry. Moreover, it allows for more compact reactor design and leads to process intensification. Microwave technology can be used to effectively heat solid catalysts for endothermic reactions with numerous benefits. However, microwave heating is restricted to certain materials only and in most cases new catalyst development is necessary. Whereas many studies focus on microwave assisted catalysis over powder samples, studies on industrial pellets or extrudates are far less common. This study compares microwave-assisted biogas reforming over 5 wt.% Ni/SiC in powder and pellet form (2 mm × 2 mm), tested at different temperatures (750, 800, and 850 °C) and gas flow rates (100, 200, 300, and 400 mL/min). Both forms of the catalyst show good activity, but limited long-term stability. Radial temperature gradients caused by radiation losses through the quartz reactor wall, were measured directly by using a fiber optic temperature sensor located inside the bed center and an IR camera at the reactor wall.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110507"},"PeriodicalIF":3.9,"publicationDate":"2025-08-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144841327","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":"Systematic design and analysis of an industrial symbiosis: Integrating power-to-X technologies with bioprocessing systems","authors":"Guilherme Esteves Oliveira Frizado ,&nbsp;César Ramírez-Márquez ,&nbsp;Rofice Dickson ,&nbsp;Juan Gabriel Segovia-Hernández ,&nbsp;Andreas Ibrom ,&nbsp;Seyed Soheil Mansouri","doi":"10.1016/j.cep.2025.110505","DOIUrl":"10.1016/j.cep.2025.110505","url":null,"abstract":"<div><div>This research presents a vital framework for designing and evaluating the feasibility of industrial symbiosis projects. By employing the theory of Metabolic Analysis, the framework systematically assesses the synergistic potential of integrating novel bioprocesses, such as single-cell protein production, with Power-to-X (Pt-X) and carbon capture technologies. A case study application demonstrates the framework's capacity to uncover critical trade-offs in energy and waste streams, thereby providing a clear, data-driven foundation for creating circular manufacturing networks. Finally, the study underscores the necessity for continued development of the tool itself, specifically to create pathways for integrating its complex output data into subsequent techno-economic and life cycle assessments.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110505"},"PeriodicalIF":3.9,"publicationDate":"2025-08-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144841326","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":"Characteristics and removal efficiency of microplastics in sewage treatment plants in typical northern cities","authors":"Zhennan Shi ,&nbsp;Jiayao Li ,&nbsp;Xin Meng ,&nbsp;Simin Li ,&nbsp;Jie Qi","doi":"10.1016/j.cep.2025.110506","DOIUrl":"10.1016/j.cep.2025.110506","url":null,"abstract":"<div><div>This study focused on six wastewater treatment plants in Handan City, a typical industrial city in northern China with a population equivalent of ≥100,000, addressing the issue of “high industrial wastewater content leading to prominent microplastic (MPs) loads.” The study employed FTIR-microscopy combined identification (double-blind testing with κ=0.87) and ANCOVA covariance correction to systematically evaluate the occurrence characteristics and removal efficiency of MPs in tertiary treatment processes (A²O, oxidation ditch, V-type filter). The main results are as follows: the log-normal distribution of inlet MPs abundance ln(MP) = N(3.81, 0.32²), with a 15.2% linear increase in abundance for every 10% increase in industrial wastewater proportion (β = 1.52, R² = 0.93, p&lt;0.001); the main components were PE and PP, accounting for 60–70% of the total; particle sizes were concentrated in the 0–500 μm range, accounting for &gt;50%. The average removal rate for primary treatment is 38.5 ± 18.2% (mean ± standard deviation), and the removal rate for secondary treatment significantly increases to 62.8 ± 9.7%. This study provides important data support for understanding and optimizing the efficiency of wastewater treatment plants in reducing microplastic pollution, and has significant implications for developing effective environmental management strategies and reducing environmental emissions of microplastics.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110506"},"PeriodicalIF":3.9,"publicationDate":"2025-08-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144831336","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":"Biogenic synthesis of the mixed-valence FexOy/g-CN electrocatalyst using coiled flow inverter for green hydrogen evolution","authors":"Shivam Singh Tomar ,&nbsp;Nishith Verma ,&nbsp;Krishna D.P. Nigam","doi":"10.1016/j.cep.2025.110503","DOIUrl":"10.1016/j.cep.2025.110503","url":null,"abstract":"<div><div>The development of earth-abundant and cost-effective electrocatalysts for hydrogen evolution reaction (HER) is ciritcal for advancing green hydrogen production. In this study, we report the green synthesis of the mixed-valence Fe_xO_y nanoparticle (NP)-doped g-CN (Fe_xO_y/g-CN) electrocatalyst using a coiled flow inverter (CFI) reactor. The Fe_xO_y NPs, including Fe₂O₃, and Fe₃O₄, are synthesized using an aqueous green tea extract, which serves as a biogenic reducing and stabilizing agent. The CFI-assisted synthesis enables uniform dispersion, good control over Fe-loading in the catalyst, and high-throughput production, overcoming the limitations of conventional batch processes. A comprehensive morphological, physicochemical, and electrochemical characterization of the synthesized electrocatalyst confirms the enhanced conductivity, active site density, and stability of the material. The electrocatalyst exhibits an HER overpotential of 256 mV at 10 mA cm^-2, Tafel slope of 154 mV dec^‑1, and excellent long-term stability over 24 h in 1 M KOH electrolyte. These improvements are attributed to the synergistic effects of the mixed-valence Fe_xO_y species and the conductive g-CN matrix, which enhance charge transfer and electron mobility. This study pitches the biogenic Fe_xO_y/g-CN electrocatalyst as a sustainable alternative to noble metal-based catalysts, contributing to the present global transition towards the scalable green hydrogen production.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110503"},"PeriodicalIF":3.9,"publicationDate":"2025-08-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144851902","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":"Investigation of methane plasmalysis in a nanosecond pulsed plasma reactor","authors":"E. Delikonstantis ,&nbsp;F. Cameli ,&nbsp;N. Rivolta ,&nbsp;P. Roquiny ,&nbsp;H. Wiame ,&nbsp;G.D. Stefanidis","doi":"10.1016/j.cep.2025.110483","DOIUrl":"10.1016/j.cep.2025.110483","url":null,"abstract":"<div><div>Methane (CH₄) pyrolysis driven by electric energy in the form of plasma represents a powerful valorization strategy that could lead to reducing the emissions of a potent greenhouse gas. Nanosecond pulsed discharge (NPD) plasma is particularly effective in delivering high-energy and short pulses to the gas feedstock. Thereby, by controlling the specific energy input (SEI) to the pure CH₄ feed stream, conversion levels above 80% can be attained. Acetylene (C₂H₂) and hydrogen (H₂) are the main reaction products and are produced with individual selectivity above 70%. Hence, H₂ energy cost can be as low as 35 kWh/kg, which matches the thermodynamic limit of water electrolysis, and is close to high-temperature plasma set-ups. Besides, an energy conversion efficiency (ECE) of 57% is obtained by accounting for all the gas products, indicating effective transformation of discharge energy into chemical energy.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110483"},"PeriodicalIF":3.9,"publicationDate":"2025-08-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144865309","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":"Debottlenecking a 2-phase multi-enzymatic cascade by an enzyme membrane reactor – Modelling and experimental validation","authors":"Francesca von Ziegner ,&nbsp;Grit Brauckmann ,&nbsp;Volkan Filiz ,&nbsp;Torsten Brinkmann ,&nbsp;Paul Bubenheim ,&nbsp;Thomas Waluga","doi":"10.1016/j.cep.2025.110499","DOIUrl":"10.1016/j.cep.2025.110499","url":null,"abstract":"<div><div>Biotechnological processes have a high potential to make industrial processes more sustainable. However, biotechnological processes often have low product concentrations and production rates. This is where process intensification can help to make these processes competitive. Using the example of the multi-enzymatic synthesis of natural cinnamyl cinnamate, it is shown how an existing multi-enzymatic process can be intensified by using an enzyme membrane reactor. The individual enzymatic reactions are first characterised in laboratory scale and then combined in a mini plant. In addition, a process model of the mini plant is developed. It is shown that the use of an enzyme membrane reactor can increase the production rate of the multi-enzymatic process by a factor of 10 compared to a previously investigated set-up.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110499"},"PeriodicalIF":3.9,"publicationDate":"2025-08-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144831334","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":"Photothermal synergistic chlorination of ethylene carbonate in a solvent-free microchannel reactor","authors":"Qi Wang,&nbsp;Yaxin Dong ,&nbsp;Yuyu Wei,&nbsp;Chuanwei Zhang,&nbsp;Qi Zhang,&nbsp;Huijun Song,&nbsp;Jianlu Liu","doi":"10.1016/j.cep.2025.110497","DOIUrl":"10.1016/j.cep.2025.110497","url":null,"abstract":"<div><div>The photothermal chlorination of ethylene carbonate (EC) using liquid chlorine and benzoyl peroxide (BPO) initiator offers a green approach to C-H chlorination. However, batch reactors present challenges including prolonged reaction times and low chlorine utilization efficiency. These limitations may be effectively overcome through microchannel reactor technology. This study developed a green, safe process for selectively chlorinating EC to chloroethylene carbonate (CEC). In the microchannel reactor, liquid chlorine served as chlorinating agent and BPO as initiator under UV irradiation. After parameter optimization, the optimal conditions achieved 99.5% EC conversion and 84.1% CEC yield.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110497"},"PeriodicalIF":3.9,"publicationDate":"2025-08-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144851903","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":"Enhancing ammonia reactor efficiency: Numerical modeling and optimization with internal cooling exchanger","authors":"M.R. Ghorbanie,&nbsp;Z. Arab aboosadi,&nbsp;E. Dehghanfard","doi":"10.1016/j.cep.2025.110498","DOIUrl":"10.1016/j.cep.2025.110498","url":null,"abstract":"<div><div>This study presents a comprehensive modeling and optimization framework for enhancing the performance of an industrial-scale ammonia synthesis reactor through the integration of internal intermediate cooling exchangers (IICE), which has not been previously modeled or optimized in a real industrial context. Focusing on the Shiraz Petrochemical Complex, both one-dimensional (radial) and two-dimensional (radial–axial) reactor models were developed using MATLAB and COMSOL, respectively, to solve the mass, energy, and momentum conservation equations under realistic operating conditions. Model validation against plant data demonstrated excellent agreement, confirming the accuracy of the proposed models. To improve reactor performance, a Differential Evolution (DE) algorithm was applied to optimize key operating parameters namely reactor inlet temperature, pressure, and feed flow rate. The optimized conditions (463.9 K, 169.99 bar, and 292,476 kg/h kg/h) led to a 16.2 % increase in ammonia molar fraction compared to current operation, achieving a maximum value of 0.21. The novelty of this work lies in the systematic integration and assessment of IICEs in a multi-bed configuration, previously unvalidated in literature. It also evaluates potential economic impacts, demonstrating that coupling internal heat recovery with numerical optimization can enhance ammonia synthesis and lower energy consumption in industrial reactors.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"218 ","pages":"Article 110498"},"PeriodicalIF":3.9,"publicationDate":"2025-08-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145045526","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Integrated ultrasound, enzymatic, and chemical pretreatments for process intensification in the sustainable valorization of passion fruit peel","authors":"Newton Carlos Santos ,&nbsp;Raphael L.J. Almeida ,&nbsp;Shênia S. Monteiro ,&nbsp;Luanna A. da Silva ,&nbsp;Yaroslávia F. Paiva ,&nbsp;Mateus de Oliveira Leite ,&nbsp;Carolina S. Santos ,&nbsp;Ana Nery A. Martins ,&nbsp;Ariadne Soares Meira ,&nbsp;Poliana H.D. Felix ,&nbsp;Ronildo P.de Sousa Júnior ,&nbsp;Severina de Sousa ,&nbsp;Alexandre J.de M. Queiroz ,&nbsp;Josivanda P. Gomes ,&nbsp;Ana Paula T. Rocha","doi":"10.1016/j.cep.2025.110484","DOIUrl":"10.1016/j.cep.2025.110484","url":null,"abstract":"<div><div>The processing of passion fruit generates residues, with the peels being the main by-product. In this study, to promote the valorization of these residues, passion fruit peels were subjected to different pretreatments. These included ultrasonic (US), chemical (CP, using potassium carbonate), and enzymatic (EP, using Viscozyme® L) methods. The pretreatments were applied individually and in combination (CP+US and EP+US), prior to convective drying at 70 °C. During the drying process, US alone reduced drying time by 47.06% (270 min vs. 510 min for the control), increasing effective moisture diffusivity (7.28 × 10^–9 m²/min) and convective coefficient (5.66 × 10^–4 m/min) (<em>p</em> &lt; 0.05). The combinations CP+US and EP+US reduced drying time by 35.29% (330 min) compared to the control. The adsorption isotherm revealed lower hygroscopicity for EP+US (<em>Xm</em> = 7.989 g H₂O/g), suggesting improved physical stability and reduced moisture absorption during storage. On the other hand, thermal properties indicated greater thermal stability for CP (Tp = 70.02 °C) and EP+US (ΔH = 2.39 J/g), suggesting higher resistance to thermal degradation. The bioactive compound profile by HPLC identified 19 phenolic compounds, with emphasis on myricetin (17.25 mg/100 g in CP+US), catechin (7.36 mg/100 g), and caftaric acid (10.12 mg/100 g). EP+US retained 70.2% of phenolics after 180 days (258.86 vs. 368.71 mg GAE/100 g initially), with lower antioxidant loss (26.7% in ABTS). Principal component analysis (PCA) and hierarchical cluster analysis (HCA) confirmed the effectiveness of the combined pretreatments in bioactive extraction. Finally, it is concluded that US, EP, and their combinations optimize the drying process and help preserve bioactive compounds. Among the tested strategies, EP+US proved to be the most promising for industrial applications. In addition, this approach supports sustainable practices for the valorization of by-products from passion fruit processing.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110484"},"PeriodicalIF":3.9,"publicationDate":"2025-08-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144831335","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}