Chemical Engineering and Processing - Process Intensification最新文献

{"title":"Study on gas-solid flow characteristics of loop seal surge in circulating fluidized bed boiler","authors":"Xin Shen ,&nbsp;Xiaoqian Li ,&nbsp;Hairui Yang ,&nbsp;Yan Jin","doi":"10.1016/j.cep.2025.110322","DOIUrl":"10.1016/j.cep.2025.110322","url":null,"abstract":"<div><div>During the operation of a 350 MWe supercritical circulating fluidized bed (CFB) boiler, a low-frequency surge in the loop seal can lead to cracks in the castable material of the internal insulation layer, thereby impacting normal and safe boiler operation. Using the computational particle fluid dynamics (CPFD) method, the effect of a low-frequency loop seal surge on the gas-solid flow of a 350 MWe supercritical CFB boiler was studied in this paper. The causes, parameters and elimination conditions of the loop seal surge were analysed. The results show that when the loop seal is under a surge condition, the pressure drop gradient is greater than the critical material sealing value of 3526 Pa/m, and the material flow in the downcomer is not smooth. The volume fraction of material particles in the loop seal is low, which cannot effectively seal the material. When the primary fluidized air, supply air, and recycle air are controlled within a reasonable range, the loop seal surge can be effectively prevented. The acceptable range for primary fluidized air is 14.5 m/s to 16.0 m/s; for supply air, it is 0.05 m/s to 0.10 m/s; and for recycle air, it is 1.0 m/s to 1.5 m/s.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110322"},"PeriodicalIF":3.8,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143860575","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":"Creating resilient networks of microreactors: A graph theory approach","authors":"Jaxyn Kirian ,&nbsp;Michael Abeiku Daniels ,&nbsp;Krista Harris ,&nbsp;Agnieszka Truszkowska","doi":"10.1016/j.cep.2025.110306","DOIUrl":"10.1016/j.cep.2025.110306","url":null,"abstract":"<div><div>The practical integration of numerous microreactors into networks is still a challenge that hinders the use of microtechnology on a commercial scale. One major difficulty is achieving uniform flow rates inside all interconnected microreactors. In this work, we construct microreactor networks using topologies inspired by the classical graph theory and study them with the flow network model. We propose methodology for creating, modeling, and quantifying the performance of the networks with up to 58 devices. We study the flow uniformity inside the microreactor networks, their response to malfunctioning, and their recovery from various levels of damage. We found that all investigated network topologies had acceptable performance, even after sustaining considerable damage, and identified designs that outperformed the others in various aspects. We also showed that repairing a heavily malfunctioning network is not trivial for any topology, including simple ones. Finally, we confirmed select findings with three-dimensional direct numerical simulations.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110306"},"PeriodicalIF":3.8,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143843625","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":"Deep purification of trace fine particles in hydrogenated oil by microchannel separator","authors":"Pengcheng Tao ,&nbsp;Aosong Wei ,&nbsp;Li Dai ,&nbsp;Zhuofan Deng ,&nbsp;Dingliang Xu ,&nbsp;Cao Heng ,&nbsp;Xiafei Wu ,&nbsp;Wenjie Lv ,&nbsp;Hualin Wang","doi":"10.1016/j.cep.2025.110321","DOIUrl":"10.1016/j.cep.2025.110321","url":null,"abstract":"<div><div>The purification of hydrogenated oil using diatomaceous earth filtration separators has the high economic costs and material consumption. Previously, our team had achieved some industrial advantages by treating hydrogenated oils with microchannel separators; however there is still room for deep purification of micron-sized particulate pollutants.</div><div>In this study, a pilot-scale microchannel separator with a capacity of 1 m³/h was used for the deep purification of hydrogenated oil following the industrial-scale microchannel separator to enhance the its separation precision. Two separation media with equivalent diameters were used. The pilot microchannel separator was filled with a finer separating medium with an equivalent diameter of 0.3 ∼ 0.6 mm, which achieved an average turbidity reduction of 13.3 %. Moreover, the total particle number exhibited an average decrease of 43.4 %. The deep purification treatment extended the operation cycle of the downstream diatomite filter to 1.7 times its original duration. Using the microchannel separator, a projected reduction of 15 tons/year in solid waste discharge is anticipated for a petroleum resin process with a treatment capacity of 40 m³/h. This translates to an annual cost saving of 27 %.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110321"},"PeriodicalIF":3.8,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143833811","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":"Efficiency and multi-objective optimization of gas-liquid-phase mass transfer in high-viscosity fluids within heart-shaped microchannels","authors":"Feiyu Gao ,&nbsp;Jinli Guo ,&nbsp;Wei Zhang ,&nbsp;Yaqi Hou ,&nbsp;Jiahua Hu","doi":"10.1016/j.cep.2025.110319","DOIUrl":"10.1016/j.cep.2025.110319","url":null,"abstract":"<div><div>Microchannels are widely utilized in the microchemical industry due to their highly efficient and enhanced mass transfer properties. However, when processing high-viscosity fluids, the flow pressure drop in microchannels significantly increases, posing challenges for system performance. To address this, it is crucial to control both mass transfer and pressure drop in gas-liquid two-phase systems in microchannels under high-viscosity conditions. This study investigates the mass transfer and flow behavior of high-viscosity fluids in heart-shaped microchannels (Advanced Flow Reactor, AFR). Experimental visualization techniques are employed to explore the effects of bubble size distribution, gas content, and pressure drop on the gas-liquid two-phase flow and its mass transfer characteristics in high-viscosity systems. A predictive model for the pressure drop in these heart-shaped microchannels is also developed. Air and high-viscosity glycerol-water solution (viscosity range of 50–320 mPa·s) are selected as the gas-liquid two-phase system. The experimental operating conditions are optimized using the enhanced multi-objective NSGA-II algorithm to identify a set of critical process parameters that balance low pressure drop with high mass transfer coefficient. The results demonstrate that compared to the liquid-phase volumetric mass transfer coefficients (<em>K_la</em>) at the lowest gas-phase flow rate for each viscosity, the increase in <em>K_la</em> is 53 %–122.7 % for viscosities ranging from 50 to 150 mPa·s. This improvement is accompanied by a 70 %–100 % increase in gas-phase flow rate and a corresponding 30 %–58 % rise in pressure drop. Optimization results indicate under ideal experimental conditions, mass transfer efficiency is enhanced, and pressure drop loss is reduced by an average of 53 %, despite a small reduction in the mass transfer coefficient. This suggests that an optimal design can effectively balance mass transfer efficiency with pressure drop reduction, offering practical solutions for high-viscosity gas-liquid two-phase systems. The findings provide a theoretical foundation for optimizing microchannel operating parameters in high-viscosity systems and achieving multi-objective optimization with low pressure drop and high mass transfer efficiency.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110319"},"PeriodicalIF":3.8,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143850771","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":"Prediction of bend-pipeline erosion field based on CFD and reduced order method","authors":"Lijing Mu ,&nbsp;Shengxuan He ,&nbsp;Sheng Chen ,&nbsp;Xizhong Chen ,&nbsp;Jinhai Shi ,&nbsp;Yongmin Zhang ,&nbsp;Cenfan Liu","doi":"10.1016/j.cep.2025.110320","DOIUrl":"10.1016/j.cep.2025.110320","url":null,"abstract":"<div><div>In this paper the accuracy and efficiency of the Reduced Order Model (ROM), a machine learning algorithm, for predicting hydrodynamic behavior and erosion wear phenomena in a gas-solid two-phase flow pipeline system were investigated by performing a comprehensive comparison between ROM predictions and Computational Fluid Dynamics (CFD) results. Firstly, the accuracy of CFD simulation results among three erosion models, Oka, Vieira and DNV erosion models, was validated by comparison with experimental data. The Oka model was found to be more precise in predicting the erosion phenomena of the multiphase flow in pipeline. Secondly, the rational and efficiency of ROM predictions were examined, which the tendencies of hydrodynamic multiphase flow behaviors and erosion wear phenomena were discerned in agreement with CFD results. Furthermore, it is found that ROM predictions could save computational time by more than three orders of magnitude compared to the CFD method. Thirdly, the influence of design points and mode number on static pressure and erosion rate distribution was studied to enhance the accuracy of ROM predictions. Then, for a comprehensive validation of ROM predictions, four operating conditions with different gas inlet velocities and particle mass fluxes were analyzed. The result indicates that ROM predictions, under the recommended selection of design points and mode number, demonstrate a relatively good correspondence with CFD results both quantitatively and qualitatively. Finally, ROM predictions were utilized on a 135-degree industry pipe, enabling prompt and precise prediction of both the erosion position and erosion rate for the gas-particle industrial elbow pipe by conducting a comparison with the industrial measurement data.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110320"},"PeriodicalIF":3.8,"publicationDate":"2025-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143829817","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":"Determining residence time distributions in oscillatory baffled reactors: A comparison between experiments and CFD-simulations","authors":"Matthias Adams ,&nbsp;Georgios D. Stefanidis ,&nbsp;Tom Van Gerven","doi":"10.1016/j.cep.2025.110297","DOIUrl":"10.1016/j.cep.2025.110297","url":null,"abstract":"<div><div>Oscillatory flow reactors are a process intensification technology that aims at enabling plug flow-like operation for inherently slow processes. However, the plug flow regime is usually challenging to obtain in practice. To that end, this work focuses on simulating residence time distributions in oscillatory baffled reactors with for the first time an experimental validation of the simulated results. Four different physical models are implemented to simulate residence time distributions: 2D-axisymmetric laminar, 2D-axisymmetric turbulent <span><math><mi>κ</mi></math></span>-<span><math><mi>ϵ</mi></math></span>, 3D laminar and 3D turbulent <span><math><mi>κ</mi></math></span>-<span><math><mi>ϵ</mi></math></span>. Different flow conditions are tested ranging between 50 and 250 for the net Reynolds number and 50 and 300 for the oscillatory Reynolds number. The comparison between experiments and simulations is done qualitatively and quantitatively. The quantitative parameters include: the mean residence time, the root mean square error and the number of ideal tanks in series. The results show that in almost all tested flow conditions 3D laminar physics are necessary to predict the experimental residence time distribution. However, for the tested flow parameters, literature advises in general to use 2D-axisymmetric laminar physics to model local flow patterns. This demonstrates the need for new guidelines to model global parameters in oscillatory baffled reactors and the importance of experimental validation.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110297"},"PeriodicalIF":3.8,"publicationDate":"2025-04-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143833896","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":"Examining the efficiency of the stirred structure packed extraction column with hands-on investigation using simulation incorporating artificial neural networks","authors":"Khayyam Mehrabi ,&nbsp;Hossein Bahmanyar ,&nbsp;Mehdi Asadollahzadeh ,&nbsp;Rezvan Torkaman ,&nbsp;Meisam Torab-Mostaedi","doi":"10.1016/j.cep.2025.110318","DOIUrl":"10.1016/j.cep.2025.110318","url":null,"abstract":"<div><div>Liquid-liquid extraction (LLX) is a fundamental application of separation processes utilized in various industries. Extraction columns are essential equipment in LLX operations. Designing and scaling up extraction columns necessitates a comprehensive understanding of hydrodynamic parameters and mass transfer performance. Therefore, this study investigates the mass transfer characteristics of Scheibel column. A total of 42 experimental data points were collected to explore the impact of operating conditions on the overall mass transfer coefficient. The results indicated that rotor speed (N) significantly affects K_od, while the flowrates of the continuous and dispersed phases have a minimal impact. Subsequently, K_od was determined using previous models, but none of them accurately predicted K_od. As a result, a new correlation was proposed to estimate K_od as function of the Reynolds (<em>Re</em>) and Weber (We) numbers, and the holdup of dispersed phase (x_d). This new correlation demonstrated excellent agreement with experimental data, making it a valuable tool for designing Scheibel extraction columns. Lastly, four different ANN models were applied to forecast K_od using rotor speed (N), continuous phase velocity (V_c), dispersed phase velocity (V_d), and diffusion coefficient (D_d) as input parameters. MLPNN, RBFNN, and CFFNN models proved to be accurate and reliable in predicting K_od.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110318"},"PeriodicalIF":3.8,"publicationDate":"2025-04-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143860578","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":"Exploring the potential of cashew nut shell biochar for chlorpyrifos pesticide removal","authors":"Pooja Pandey,&nbsp;Pooja Kenchannavar,&nbsp;Anupama Surenjan","doi":"10.1016/j.cep.2025.110307","DOIUrl":"10.1016/j.cep.2025.110307","url":null,"abstract":"<div><div>India generates over 620 million metric tons of agricultural waste yearly. Agricultural wastes have limited economic worth and are underutilized. Agro-waste recycling into circular economy products is essential for environmental health. In small-scale cashew industries, shell waste generation is 67.5 % of the seed weight. Cashew nut shells (CNS), a residual product of the industry, are burned following the extraction of pulp and oils, resulting in negative environmental impacts. This study focuses on the application of CNS biochar for the removal of chlorpyrifos, a highly toxic organophosphate pesticide. Prepared biochar was analyzed using SEM, BET, and FTIR. After adsorption, the specific surface area of biochar decreased from 111.62 m²/g to 14.00 m²/g. For an initial chlorpyrifos concentration of 15 mg/L, the highest removal efficiency of 94.2 % was obtained with a 120-minute contact time, a biochar dose of 0.5 g/L and a pH of 6. Adsorption studies demonstrated a maximum adsorption capacity of 31.34 mg/g, with results following the Langmuir isotherm and pseudo-second-order kinetics, indicating monolayer chemisorption. The findings highlight CNS biochar as a promising alternative to conventional adsorbents, offering an environmentally friendly solution for water purification.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110307"},"PeriodicalIF":3.8,"publicationDate":"2025-04-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143843626","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":"Heat resistance network model of corrugated honeycomb monolith catalysts based on heat flux field","authors":"Xingwei Wang,&nbsp;Li Zhang","doi":"10.1016/j.cep.2025.110315","DOIUrl":"10.1016/j.cep.2025.110315","url":null,"abstract":"<div><div>The energy conversion between hydrogen, ammonia, methanol and liquid fuel is often accompanied by strong exothermic or endothermic heterogeneous catalytic reactions. Different metal substrate structured catalysts were used for heat transfer enhancement in our previous literature. In this paper, the enhancement mechanism was further studied by numerical simulation. The results showed that increasing the heat conductivity of the material and improving the structural integrity are effective methods to enhance the effective radial heat conductivity. Then, the heat resistance networks of corrugated honeycomb substrate structured catalysts composed of several local heat resistances were derived through theoretical analysis. The heat flux field was applied to modify the heat resistance networks, and the error was lower than 10 %. The total heat resistance of rolling FeCrAl substrate and selective laser melting AlSiMg substrate were calculated according to the heat resistance network, and verified by simulation results. The results showed that the AlSiMg substrate reduced total heat resistance by 93 % compared to FeCrAl substrate. Finally, the difference between AlSiMg and FeCrAl substrate was analyzed by analyzing local heat resistance, and the structural optimization method was proposed.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110315"},"PeriodicalIF":3.8,"publicationDate":"2025-04-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143848214","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":"Mitigating gas maldistribution in a cross-flow rotating packed bed via optimizing guide baffle structures","authors":"Yi-Hang Xu ,&nbsp;Han-Zhuo Xu ,&nbsp;Yan-Bin Li ,&nbsp;Guang-Wen Chu ,&nbsp;Jian-Feng Chen","doi":"10.1016/j.cep.2025.110317","DOIUrl":"10.1016/j.cep.2025.110317","url":null,"abstract":"<div><div>A cross-flow rotating packed bed (CF-RPB) is a promising solution for offshore gas purification applications. In this work, gas flow fields and maldistribution phenomena were investigated via three-dimensional Computational fluid dynamics (CFD) simulations inside the CF-RPB. Relative error of simulation results within ±10 % compared to experimental pressure drop. The results of contours and streamlines showed that disturbed flow paths resulted from asymmetry of internal structures gave rise to gas maldistribution. Three baffles were proposed to guide gas upward flow, including the baffle with straight blades (BSTB), the baffle with spiral blades (BSPB), and the single-turn louvre baffle (SLB). After systematically compared the gas distribution characteristics for different baffle types and parameters, the preferred baffle was SLB with <em>δ</em>_B/<em>R</em>_C = 0.0146, <em>γ</em> = 45°, <em>n</em> = 5, and <em>H</em>_B/<em>H</em>_P = 0.040. The SLB could drastically reduce total maldistribution by 29.49 % while incurring a modest pressure drop increase of 12.69 % compared to the original structure, indicating effectiveness of baffle in resolving gas maldistribution inside the CF-RPB for offshore application.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110317"},"PeriodicalIF":3.8,"publicationDate":"2025-04-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143829799","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}