Wenkai Yang , Xiuhui Huang , Yi Jin , Zeqiu Li , Ying Tian
{"title":"Energy-efficient optimization design of bio-butanol fermentation broth purification process","authors":"Wenkai Yang , Xiuhui Huang , Yi Jin , Zeqiu Li , Ying Tian","doi":"10.1016/j.cep.2024.110023","DOIUrl":"10.1016/j.cep.2024.110023","url":null,"abstract":"<div><div>To address the downstream processing challenges of the IBE (isopropanol-butanol-ethanol) system and obtain biobutanol products with a mass fraction of 0.9999, as well as obtain a mass fraction of 0.99975 for the IE (isopropanol-Ethanol) mixture product as a gasoline additive, this study proposes a four-column distillation process termed \"Dehydration-Butanol-Extractive Four Column Distillation\" (DBE-4CD). With the heat load as the optimization target, the DBE-4CD process was optimized to determine the optimal operating parameters. Based on the optimized process and considering the energy-saving potential of the dividing wall column, an “Azeotropic Dividing Wall-Extractive Three Column Distillation” (ADE-3CD) process was subsequently proposed to further enhance energy efficiency and reduce consumption. Compared to both conventional literature process and the DBE-4CD process, the total load of the ADE-3CD process decreased to 7433.5 kW, representing reductions of 20.35% and 10.11%, respectively. Additionally, the mass recovery rates of butanol and the IE mixture reached 99.90% and 99.64%, respectively, exceeding those of the conventional literature process, which were 99.11% and 99.18%.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"205 ","pages":"Article 110023"},"PeriodicalIF":3.8,"publicationDate":"2024-10-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142446805","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}
Antônio Demouthie de Sales Rolim Esmeraldo, Amélia de Santana Cartaxo, Mariana Rodrigues Del Grande, Sérgio Alvaro de Souza Camargo Jr, Tiago Albertini Balbino
{"title":"Salt scaling dynamics in microfluidic channels: Impact of channel geometry and process parameters","authors":"Antônio Demouthie de Sales Rolim Esmeraldo, Amélia de Santana Cartaxo, Mariana Rodrigues Del Grande, Sérgio Alvaro de Souza Camargo Jr, Tiago Albertini Balbino","doi":"10.1016/j.cep.2024.110025","DOIUrl":"10.1016/j.cep.2024.110025","url":null,"abstract":"<div><div>Salt scaling, a prevalent challenge in industrial processes, often leads to reduced efficiency, equipment failure, and environmental impact. Understanding and mitigating scaling in miniaturized systems for process intensification applications is crucial. In this study, we indigenously developed and utilized microfluidic reactors to investigate calcium carbonate (CaCO<sub>3</sub>) scaling dynamics in microfluidic channels, offering real-time visualization under continuous flow; a significant advancement over static methods. We explore the impact of channel geometry (curvature of 0°, 45°, 90°, and 135°) and process parameters (temperature, supersaturation index (SI), and flow velocity) on CaCO<sub>3</sub> deposition behavior. Our findings reveal significant influences: higher temperature and SI promote deposition, while microchannel curvature and increased flow velocity enhance removal. X-ray diffraction (XRD) and scanning electron microscopy (SEM) analyses confirmed the morphology and phase changes of the deposited CaCO<sub>3</sub>. Calcite and aragonite were the dominant polymorphs, with their occurrence influenced by temperature and SI. These insights can be translated to the design and operation of miniaturized equipment for process intensification, such as micro heat exchangers. By understanding and controlling scaling phenomena, this research might pave the way for improved performance, sustainability, and resource efficiency in various industrial settings.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"205 ","pages":"Article 110025"},"PeriodicalIF":3.8,"publicationDate":"2024-10-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142446806","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}
Cui Wu , Fuyi Sun , Yaojie Zhang , Cheng Xie, Xunke Zhao, Yuanyuan Che
{"title":"Numerical simulation of fluid flow characteristics and ultrasonic cavitation performance in novel-designed stirred tank sonoreactor","authors":"Cui Wu , Fuyi Sun , Yaojie Zhang , Cheng Xie, Xunke Zhao, Yuanyuan Che","doi":"10.1016/j.cep.2024.110026","DOIUrl":"10.1016/j.cep.2024.110026","url":null,"abstract":"<div><div>A novel-designed stirred tank sonoreactor was developed to well solve large-scale dispersion of nanoparticles in liquid phase system. The fluid flow characteristics and ultrasonic cavitation performance in the sonoreactor were numerically simulated by CFD method. By comparing the pressure, cavitation bubble and velocity distribution under different situations, it is found that larger ultrasonic amplitude, relatively smaller ultrasonic frequency, higher saturated vapor pressure and lower viscosity of liquid medium are beneficial to ultrasonic cavitation. Besides, the acoustic flow action is strengthened with the increase of ultrasonic frequency and decrease of gas-liquid mixture's average density. For the designed sonoreactor, it is critical that high-frequency transducers should be determined near the bottom and upper region of the kettle, and large-amplitude transducers can be confirmed in the middle position. The research findings will provide theoretical and technical supports for developing state-of-the-art sonoreactors and optimizing ultrasonic process parameters in the industrialized preparation of nanocomposites.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"205 ","pages":"Article 110026"},"PeriodicalIF":3.8,"publicationDate":"2024-10-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142527966","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":"Process intensification in the direct contact membrane distillation (DCMD) desalination by patterning membrane surface: A CFD study","authors":"Sahar Zare , Ali Kargari","doi":"10.1016/j.cep.2024.110027","DOIUrl":"10.1016/j.cep.2024.110027","url":null,"abstract":"<div><div>In this research, the impact of pattern geometry on the intensification of the performance of surface patterned membranes for saline water desalination by direct contact membrane distillation (DCMD) is investigated by computational fluid dynamics (CFD) simulation. The Comsol Multiphysics software was applied to solve the governing transport equations for heat, momentum, and mass transfer. The result of the model was validated by the published experimental data, and the maximum deviation was <10 %. The target was to maximize the permeate flux by altering surface pattern geometry and dimensions. Based on the previous studies, a prism pattern was chosen in this work, and the influences of pattern type (3 types), pattern dimension (25–150 µm valley depth), and the distance between the valleys (0–400 µm) were studied on the temperature polarization coefficient (TPC) and DCMD permeate flux. The results showed that the pattern with a valley depth of 25 µm and a distance between the valleys of 300 µm had the best performance in DCMD operation. In this situation and feed temperature of 80 °C, a TPC of 0.78 and a water flux of 49.3 kg m<sup>-12</sup>.h were attained. The characteristics of flow close to the patterned membrane surface were also investigated, and it was observed that there are weak shear stresses in the lower zone of the valleys, while stronger shear stresses are created in the upper regions that are responsible for improving the TPC and water flux in the patterned membranes.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"205 ","pages":"Article 110027"},"PeriodicalIF":3.8,"publicationDate":"2024-10-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142527972","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}
Linus Biffar , Anh Thi Pham , Walther Benzinger , Peter Pfeifer
{"title":"Performance of a RuCs/MgO catalyst coated on additive manufactured support structures via electrophoretic deposition for ammonia synthesis","authors":"Linus Biffar , Anh Thi Pham , Walther Benzinger , Peter Pfeifer","doi":"10.1016/j.cep.2024.110019","DOIUrl":"10.1016/j.cep.2024.110019","url":null,"abstract":"<div><div>This work investigates the electrophoretic deposition of a catalytic coating on so-called fluid guiding elements (FGE) with a ruthenium-based catalyst for use in ammonia synthesis reactors. FGE are additive manufactured metallic pipe inserts that have shown to enhance the heat transfer compared to empty pipes by dividing the fluid flow and alternately guiding the partial flows to the wall. Consequently, they could improve the performance of temperature sensitive structured catalytic systems. To be able to demonstrate the degree of process intensification, the required steps to enable the deposition of a reference catalyst for ammonia synthesis are developed. Further, the distribution of catalytically active compounds is characterized. The catalytic activity is assessed in a plug flow reactor under pressures up to 5<!--> <!-->MPa and compared against a fixed bed from the same batch. The expected activity from the reference catalyst is calculated by a kinetic rate expression. The coating process does not affect catalytic activity, but a steady deactivation and high sensitivity to feed gas impurities are observed. Possible mechanisms for the deactivation are examined and discussed.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"205 ","pages":"Article 110019"},"PeriodicalIF":3.8,"publicationDate":"2024-10-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142446807","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":"Elucidating flow-directed 98% CO2 absorption using millimeter-sized coiled flow inverters: Nanocellulose-aided sustainable scope","authors":"Anikesh Tripathi , Karan Sarkar , Swapna Patel , Utsav Mishra , Krishna Prasad Deo Nigam , Debashis Panda , Koushik Guha Biswas","doi":"10.1016/j.cep.2024.110022","DOIUrl":"10.1016/j.cep.2024.110022","url":null,"abstract":"<div><div>The Sustainable Development Goals (SDGs) adopted by the United Nations drive the global efforts to discover a sustainable carbon capture method for the reduction of anthropogenic CO<sub>2</sub> emissions. Concentrated alkanolamine solutions are being used as CO<sub>2</sub> capture mediums for batch processes amid several disadvantages, such as energy intensiveness and poor efficiency. In this work, millimeter-sized coiled flow inverters (CFI) have been explored as a point-source CO<sub>2</sub> capture tool for highly efficient, continuous operations. Solvent and CO<sub>2</sub> gas flow rates are found to dictate the slug flow regime and, more specfically, slug lengths. High interfacial area and residence time remain the driving factors for enhanced CO<sub>2</sub> capture using CFI. About 98% CO<sub>2</sub> absorption efficiency has been achieved for 3% aqueous diethanolamine solution in CFI . The efficacy of nanocellulose, a sustainable nanomaterial has been unearthed for CO<sub>2</sub> capture at low flow rate.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"205 ","pages":"Article 110022"},"PeriodicalIF":3.8,"publicationDate":"2024-10-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142442206","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}
Xin Zhang , Yu-Qi Sun , Xiang-Yang Cui , Yu-Wei Xiang , Zhi-Yong Tang , Hai-Kui Zou , Bao-Ju Wang , Yong Luo
{"title":"Hydrogenation process intensification of 2-nitro-4-acetylamino anisole by HiGee technology","authors":"Xin Zhang , Yu-Qi Sun , Xiang-Yang Cui , Yu-Wei Xiang , Zhi-Yong Tang , Hai-Kui Zou , Bao-Ju Wang , Yong Luo","doi":"10.1016/j.cep.2024.110020","DOIUrl":"10.1016/j.cep.2024.110020","url":null,"abstract":"<div><div>The catalytic hydrogenation of 2-nitro-4-acetylamino anisole (NMA) is the main path to synthesize 2-amino-4-acetylamino anisole (AMA), belonging to a typical gas-liquid-solid system. However, the small mass transfer rate of traditional hydrogenation reactor can't match its intrinsic fast reaction rate, resulting in the low hydrogenation efficiency. In this work, a rotating packed bed (RPB) reactor with excellent mass transfer performance was applied for the hydrogenation process intensification of NMA. The characterization analysis of the commercial Raney-Ni catalyst shows that the liquid-solid mass transfer resistance during the reaction process can be ignored, and improving the gas-liquid mass transfer rate is the key to improve the macroscopic reaction rate. The effects of operating conditions (solvent, rotational speed, hydrogen pressure, temperature, and catalyst dosage) on NMA conversion and AMA selectivity were investigated. A macro-kinetic equation of NMA catalytic hydrogenation in the RPB reactor was proposed. Under optimized conditions, the NMA was completely converted in the RPB reactor within 30 min, while it took 4 h in the stirred tank reactor. The overall reaction efficiency of RPB reactor was increased by 87.5 % in comparison with STR. This study provides practical guidance for the industrial application of RPB reactor for gas-liquid-solid hydrogenation.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"205 ","pages":"Article 110020"},"PeriodicalIF":3.8,"publicationDate":"2024-10-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142425490","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":"Jet cavitation-enhanced hydration method for the preparation of magnesium hydroxide","authors":"Maosheng Zuo , Honglei Yu , Dexi Wang , Lihua Fan","doi":"10.1016/j.cep.2024.110003","DOIUrl":"10.1016/j.cep.2024.110003","url":null,"abstract":"<div><div>During the preparation of magnesium hydroxide via the hydration method, in-situ growth and agglomeration often inhibit the reaction. This study used active magnesium oxide as the raw material and employed jet cavitation technology to enhance the hydration process. Based on the growth process of magnesium hydroxide, the mechanism of jet-enhanced hydration was analyzed. The effects of reaction temperature (<em>T</em>), reaction time (<em>t</em>), solid-liquid ratio (<em>s</em>), and cavitation number (<em>σ</em>) on the hydration rate were investigated. An L<sub>25</sub>(5<sup>4</sup>) orthogonal experiment explored the significance of each factor's impact on the hydration rate. The hydration products were characterized using scanning electron microscopy (SEM), X-ray diffraction (XRD), and a specific surface area analyzer. Results indicate that the factors affecting the hydration rate, in order of significance, are cavitation number > reaction temperature > solid-liquid ratio > reaction time. The optimal process parameters were determined to be a reaction temperature of 70 °C, reaction time of 80 min, solid-liquid ratio of 1:12, and cavitation number of 0.42. Under these conditions, the hydration rate reached 94.87 %, producing well-dispersed lamellar magnesium hydroxide with a narrow particle size distribution (median particle size D50 = 4.511 μm) and a BET specific surface area of 11.345 m²/g.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"205 ","pages":"Article 110003"},"PeriodicalIF":3.8,"publicationDate":"2024-10-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142425445","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":"Bubble characteristics in a novel microbubble gas-liquid-solid fluidized bed","authors":"Shuai Gao , Yongli Ma , Mingyan Liu","doi":"10.1016/j.cep.2024.110018","DOIUrl":"10.1016/j.cep.2024.110018","url":null,"abstract":"<div><div>The bubble characteristics are critical in gas-liquid-solid fluidized beds and microbubbles significantly enhance mass transfer in multiphase systems. In this work, a novel concept of microbubble gas-liquid-solid fluidized bed is proposed. Telecentric camera is employed to measure and analyze the microbubble characteristics including bubble size and gas holdup in this three-phase fluidized bed. Additionally, solid holdups in the fluidized bed are also examined. The results demonstrate that the bubble size adheres a lognormal distribution and is significantly influenced by superficial gas velocity. Bubble diameter exhibit a relatively uniform distribution in the radial direction. Bubbles exceeding than 1 mm substantially affect local gas holdup, and the microbubble flow promotes a more uniform distribution of local gas holdup in radial position. The average gas holdup deviation is less than 15 % compared to overall gas holdup obtained from pressure drop. Although microbubbles are more abundant, larger bubbles (> 1 mm) contribute more to solid particle fluidization. This paper introduces a methodology for assessing smaller-sized microbubbles in three-phase flow. The hydrodynamic analysis of the microbubble gas-liquid-solid fluidized bed establishes a foundational framework for enhancing gas-liquid mass transfer in fluidized bed.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"205 ","pages":"Article 110018"},"PeriodicalIF":3.8,"publicationDate":"2024-10-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142425492","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}
S K Murugesan, Akanksha Rajput, Malladi V Pavan Kumar
{"title":"Decentralized control of ideal ternary reactive distillation column with inert","authors":"S K Murugesan, Akanksha Rajput, Malladi V Pavan Kumar","doi":"10.1016/j.cep.2024.110017","DOIUrl":"10.1016/j.cep.2024.110017","url":null,"abstract":"<div><div>Decentralized control of an ideal hypothetical ternary reactive distillation column with an inert component is explored. Both composition measurement based and temperature inferential control structures are designed using simple heuristic approaches (two and three-point). The three-point composition control structure is proposed for the example RD column for the first time in this work. Although stable closed loop responses are seen for the throughput changes for all, the two-point structures have failed to achieve tight control of the product purity in the bottoms or purity of inert in the distillate for the inert composition changes due to fixed reflux ratio. The performances of the three-point control structures for the inert composition changes are quite satisfactory due to the indirect manipulation of the reflux ratio. The independent manipulation of the reflux rate and distillate (instead of fixed reflux ratio policy) is an important control decision for the successful regulation of the example RD column.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"205 ","pages":"Article 110017"},"PeriodicalIF":3.8,"publicationDate":"2024-10-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142433342","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}