Chemical Engineering and Processing - Process Intensification最新文献_第7页

Less pressure loss with extra packing — The counterintuitive behavior of rotating packed beds 额外填料减少压力损失-旋转填料床的反直觉行为

IF 3.8 3区工程技术

Chemical Engineering and Processing - Process Intensification Pub Date : 2025-06-03 DOI: 10.1016/j.cep.2025.110366

Felix Febrian , Georg Brösigke , Paul H. Kamm , Jens-Uwe Repke

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Process intensification control: Advancing efficiency and sustainability, a review 过程强化控制：提高效率和可持续性，综述

IF 3.8 3区工程技术

Chemical Engineering and Processing - Process Intensification Pub Date : 2025-06-01 DOI: 10.1016/j.cep.2025.110388

César Ramírez-Márquez , José María Ponce-Ortega , Juan Gabriel Segovia-Hernández , Salvador Hernández

{"title":"Process intensification control: Advancing efficiency and sustainability, a review","authors":"César Ramírez-Márquez , José María Ponce-Ortega , Juan Gabriel Segovia-Hernández , Salvador Hernández","doi":"10.1016/j.cep.2025.110388","DOIUrl":"10.1016/j.cep.2025.110388","url":null,"abstract":"<div><div>Process intensification has revolutionized chemical process design by integrating reaction and separation, enhancing efficiency, reducing energy consumption, and promoting sustainability. However, these advancements introduce significant control challenges due to increased process complexity, nonlinear interactions, and dynamic constraints. Over the past 25 years, conventional control strategies have been progressively replaced by predictive, adaptive, and data-driven methods, which are better suited for managing multivariable interactions and real-time optimization. The widespread adoption of predictive control frameworks has improved stability, reduced response times, and enhanced energy efficiency in reactive and extractive distillation, dividing-wall columns, and hybrid separation processes. Furthermore, integrating intelligent decision-making tools has enabled real-time adaptability, ensuring robust performance under fluctuating operating conditions. The emergence of hybrid control strategies, which combine predictive models with data-driven learning techniques, has further enhanced the ability to address nonlinearities and process uncertainties. This shift underscores a transition toward more intelligent and sustainable process operations, where control systems not only optimize efficiency but also minimize emissions and improve resource utilization. As process intensification continues to advance, future research should focus on scalable, autonomous, and computationally efficient control solutions to ensure operational reliability and economic feasibility in sustainable chemical manufacturing.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110388"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144212886","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}

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Double vapor recompression strategy as a retrofit solution for the conventional benzene-toluene-xylene distillation 双蒸汽再压缩策略作为传统苯-甲苯-二甲苯精馏的改进方案

IF 3.8 3区工程技术

Chemical Engineering and Processing - Process Intensification Pub Date : 2025-05-30 DOI: 10.1016/j.cep.2025.110382

Fernanda Ribeiro Figueiredo, Diego Martinez Prata

{"title":"Double vapor recompression strategy as a retrofit solution for the conventional benzene-toluene-xylene distillation","authors":"Fernanda Ribeiro Figueiredo, Diego Martinez Prata","doi":"10.1016/j.cep.2025.110382","DOIUrl":"10.1016/j.cep.2025.110382","url":null,"abstract":"<div><div>The benzene-toluene-xylene (BTX) mixture stands out as one of the most important in the petrochemical industry. In an effort to improve operational conditions and enhance the sustainability of separation systems, new technologies are continuously developed. Thus, this study aims to evaluate the potential economic and environmental benefits of two optimal double vapor recompression schemes applied to the conventional BTX separation plant (DVR and DVRC), while contrasting the outcomes with two previous configurations proposed for the same system, which incorporate the divided-wall strategy, with (DWC-VR) and without (DWC) vapor recompression. The economic analysis shows that the DVRC configuration achieves the lowest total annual cost (TAC) at $12.98 million/year, followed by DVR ($13.09 million/year) and DWC-VR ($13.36 million/year). In terms of environmental performance, DVRC presents the lowest CO₂ emissions, offering an 8.6 % reduction over DWC-VR. However, DWC-VR leads to a greater reduction in water consumption, surpassing DVRC by approximately 34 %. These results suggest that DVRC may be a more suitable configuration for retrofitting existing, older plants worldwide, offering both cost and environmental benefits. On the other hand, DWC-VR can be considered as a more complex improvement and revamping alternative, particularly for new projects or advanced process upgrades.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110382"},"PeriodicalIF":3.8,"publicationDate":"2025-05-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144212885","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}

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State-of-the-art in forward osmosis membrane process: materials, fabrication, and applications 正向渗透膜工艺的最新进展：材料、制造和应用

IF 3.8 3区工程技术

Chemical Engineering and Processing - Process Intensification Pub Date : 2025-05-29 DOI: 10.1016/j.cep.2025.110385

Jamaledin Jamadi-Torab , Assadollah Malekzadeh , Masoud Rahbari-Sisakht , Ahmad Fauzi Ismail

{"title":"State-of-the-art in forward osmosis membrane process: materials, fabrication, and applications","authors":"Jamaledin Jamadi-Torab , Assadollah Malekzadeh , Masoud Rahbari-Sisakht , Ahmad Fauzi Ismail","doi":"10.1016/j.cep.2025.110385","DOIUrl":"10.1016/j.cep.2025.110385","url":null,"abstract":"<div><div>Forward osmosis (FO) is a promising, low-energy membrane process as compared to pressure-driven technologies like reverse osmosis. This review critically discusses the progress in FO membrane technology, taking the advances in materials, preparation methods, and real-world applications into consideration. Recent progress in nanoparticle-doped micro- or nanoporous membranes, bioinspired nanostructured membranes and stimuli-responsive polymers may boost the water permeation, selectivity and anti-fouling capacity. Electrospinning and layer-by-layer assembly, as novel fabrication strategies provide better control of membrane architecture and performance. One more approach can also be found in introducing materials including, but not limited to, graphene oxide, carbon nanotubes and metal-organic frameworks into FO membranes to enhance water flux, salt rejection and membrane mechanical stability. In particular, optimized membranes have achieved water flux up to 83.55 % higher and reverse salt flux up to 75.58 % lower than their simulated counterparts, highlighting their enhanced performance. Moreover, inherent challenges including internal concentration polarization, scalability and membrane long-term stability are outlined, as well as potential strategies for circumventing these drawbacks. They are also discussed for potential applications in industrial desalination, wastewater treatment, food processing, and resource recovery, and their importance in achieving sustainability in the utilization of water.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110385"},"PeriodicalIF":3.8,"publicationDate":"2025-05-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144204456","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}

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Modeling and optimization of an integrated system for the green dimethyl ether production: Process simulation, modeling with artificial intelligence, and optimization methods 绿色二甲醚生产集成系统建模与优化：过程仿真、人工智能建模与优化方法

IF 3.8 3区工程技术

Chemical Engineering and Processing - Process Intensification Pub Date : 2025-05-29 DOI: 10.1016/j.cep.2025.110383

Bannih Teresita Zamora-Aguirre, Francisco Javier López-Flores, César Ramírez-Márquez, Fabricio Nápoles-Rivera, José María Ponce-Ortega

{"title":"Modeling and optimization of an integrated system for the green dimethyl ether production: Process simulation, modeling with artificial intelligence, and optimization methods","authors":"Bannih Teresita Zamora-Aguirre, Francisco Javier López-Flores, César Ramírez-Márquez, Fabricio Nápoles-Rivera, José María Ponce-Ortega","doi":"10.1016/j.cep.2025.110383","DOIUrl":"10.1016/j.cep.2025.110383","url":null,"abstract":"<div><div>Green dimethyl ether is emerging as a promising alternative fuel due to its environmental benefits and potential integration into carbon-neutral energy systems. This study presents a comprehensive workflow for modeling, simulation, and optimization of green dimethyl ether production using an integrated approach that combines artificial neural networks and multi-objective optimization. Process simulation in Aspen Plus was employed to model key units, including methanol synthesis, CO<sub>2</sub> capture, desalination, electrolysis, and cogeneration. Artificial neural networks were trained to predict system performance, achieving high accuracy across multiple process units. A comparative analysis of deterministic, Bayesian, and metaheuristic optimization approaches showed that deterministic optimization offered the best balance between economic feasibility and energy efficiency. The optimized configuration achieved a green dimethyl ether production rate of 3035.7 kg/h, reducing total annual costs and energy consumption. These findings highlight the effectiveness of AI-driven optimization in enhancing sustainable fuel production. The proposed methodology contributes to the transition toward a low-carbon economy by improving green dimethyl ether process efficiency and economic viability.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110383"},"PeriodicalIF":3.8,"publicationDate":"2025-05-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144223276","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}

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Ultrasound-assisted solvent-free synthesis of Citronellyl acetate using Fermase: Kinetics and intensification 超声波辅助发酵酶无溶剂合成醋酸香茅酯：动力学和强化

IF 3.8 3区工程技术

Chemical Engineering and Processing - Process Intensification Pub Date : 2025-05-29 DOI: 10.1016/j.cep.2025.110386

Rishit D. Desai, Virendra K. Rathod

{"title":"Ultrasound-assisted solvent-free synthesis of Citronellyl acetate using Fermase: Kinetics and intensification","authors":"Rishit D. Desai, Virendra K. Rathod","doi":"10.1016/j.cep.2025.110386","DOIUrl":"10.1016/j.cep.2025.110386","url":null,"abstract":"<div><div>Citronellyl acetate is a flavour ester with a fresh-rosy, fruity smell. It can be synthesized by transesterification reaction of citronellol and vinyl acetate with Fermase as a biocatalyst where vinyl acetate acts as a reactant and a solvent. With advanced process intensification techniques like ultrasound, the maximum conversion can be achieved in reduced reaction time, as concluded by the current study. Under optimized process conditions with a 1:2 mole ratio of citronellol to vinyl acetate, 2 % enzyme loading at 60 °C and 300 RPM agitation speed, using ultrasound power 60 W with 30 % duty cycle at 25 kHz frequency, a maximum citronellol conversion of 99.8 % was achieved within 60 min of reaction time. The enzyme retained 90 % of its activity after six cycles of reuse. Several kinetic models governing the enzymatic reaction were explored, and a modified Ping pong bi-bi model that considered both reactant inhibitions was found to explain the reaction mechanism best. Advanced optimization techniques like the Response Surface Methodology (RSM) were used to compare the results obtained from the one factor at a time method. The ultrasound-assisted method is also compared in detail with the conventional batch stirring method to showcase the process intensification achieved using ultrasound.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110386"},"PeriodicalIF":3.8,"publicationDate":"2025-05-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144279577","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}

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Flow and mass transfer performance in the ejector and reaction kettle of a loop reactor: A CFD-PBM Analysis 循环反应器喷射器和反应釜内的流动和传质性能：CFD-PBM分析

IF 3.8 3区工程技术

Chemical Engineering and Processing - Process Intensification Pub Date : 2025-05-29 DOI: 10.1016/j.cep.2025.110378

Minhua Zhang , Xiaohan Ye , Fengrui Bao , Zhongfeng Geng , He Dong

{"title":"Flow and mass transfer performance in the ejector and reaction kettle of a loop reactor: A CFD-PBM Analysis","authors":"Minhua Zhang , Xiaohan Ye , Fengrui Bao , Zhongfeng Geng , He Dong","doi":"10.1016/j.cep.2025.110378","DOIUrl":"10.1016/j.cep.2025.110378","url":null,"abstract":"<div><div>Loop reactors, recognized for their exceptional gas-liquid mixing and mass transfer capabilities, have been less explored in the context of methanol carbonylation, particularly regarding mass transfer performance within the ejector mixing tube and reaction kettle. This study, aimed at an annual acetic acid production of 250,000 tons, evaluates key performance metrics of the loop reactor—such as gas holdup and Sauter mean bubble diameter—using the CFD-PBM method and calculates the mass transfer coefficient. By keeping other structural parameters of the ejector optimized and constant, the findings reveal that the mass transfer coefficient at the end of the mixing tube initially increases with tube length, peaks at <em>H<sub>T</sub>/D<sub>T</sub></em> = 1, and then declines. Meanwhile, gas holdup decreases as the mixing tube length increases. For the reaction kettle, modeled using the ejector outlet conditions as the inlet, an increase in the height-to-diameter ratio and the number of ejectors results in a larger Sauter mean bubble diameter, thereby reducing mass transfer efficiency. Notably, positioning the ejector at <em>r/R</em> = 0.6 produces the smallest bubble size, maximizing mass transfer effectiveness.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"216 ","pages":"Article 110378"},"PeriodicalIF":3.8,"publicationDate":"2025-05-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144204455","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}

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Design and numerical investigations of mixing enhancement for single-layer SAR micromixer with localized offsets and slots 具有局部偏置和槽的单层SAR微混频器的混合增强设计与数值研究

IF 3.8 3区工程技术

Chemical Engineering and Processing - Process Intensification Pub Date : 2025-05-28 DOI: 10.1016/j.cep.2025.110360

Priya Ranjan , Basanta Kumar Rana , Jitendra Kumar Patel

{"title":"Design and numerical investigations of mixing enhancement for single-layer SAR micromixer with localized offsets and slots","authors":"Priya Ranjan , Basanta Kumar Rana , Jitendra Kumar Patel","doi":"10.1016/j.cep.2025.110360","DOIUrl":"10.1016/j.cep.2025.110360","url":null,"abstract":"<div><div>The present work focuses on developing a single-layer separation and recombination <strong>(SAR)</strong> based micromixer to enhance the mixing process of two miscible fluids. As in recent findings, separation and recombination type micromixers demonstrate their outstanding mixing efficiency in diverse flow scenarios. An accurate and stable platform, OpenFOAM V21 is used to perform the numerical investigations. We propose the four noteworthy SAR-based micromixers, which are designed by integrating the offsets and slots in selected micromixers. The first micromixer is without offset and slots, while the offsets are provided in the second, and slots are integrated into the third variant. The final design comprises both offset and slots by superimposing the above mentioned micromixers. We critically analyze the flow physics in these micromixers by detailing the concentration contours, streamlines, and velocity vectors. The results indicate that the inclusion of the offset promotes the twisting flow, while slots are responsible for stretching and folding phenomena. We found micromixer with offsets and slots provides the highest mixing index than the other proposed designs. Furthermore, it achieves 99.99% mixing efficiency across a wide range of Reynolds numbers, including low values (<span><math><mrow><mi>R</mi><mi>e</mi><mo>≥</mo><mn>20</mn></mrow></math></span>), and we also provide data on pressure drop and mixing cost to facilitate optimal design selection. At last, the present obtained results are compared with the existing two-layer micromixers which are found to be on par or even superior for a wide range of Reynolds numbers.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"215 ","pages":"Article 110360"},"PeriodicalIF":3.8,"publicationDate":"2025-05-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144166445","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}

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Runway-shaped microchannel with flow rate insensitivity for high-throughput blood plasma extraction 高通量血浆提取中流速不敏感的跑道型微通道

IF 3.8 3区工程技术

Chemical Engineering and Processing - Process Intensification Pub Date : 2025-05-28 DOI: 10.1016/j.cep.2025.110384

Shuai Jin , Yu Liu , Sheng Hu

{"title":"Runway-shaped microchannel with flow rate insensitivity for high-throughput blood plasma extraction","authors":"Shuai Jin , Yu Liu , Sheng Hu","doi":"10.1016/j.cep.2025.110384","DOIUrl":"10.1016/j.cep.2025.110384","url":null,"abstract":"<div><div>Conventional inertial microfluidic devices are plagued by a low throughput, sheath fluid dependency, and constrained operational flow rate range during plasma extraction processes. Thus, a runway-shaped inertial microfluidic device for continuous blood plasma extraction has been proposed. By integrating curved channels with semicircular obstacles into the CEA channels, the device can generate stable and enhanced Dean vortices in each loop of the channel without the need for sheath fluid assistance. This configuration effectively promoted the rapid formation of steady focusing states for particles of different diameters (5, 10, and 15 μm). The device demonstrated remarkable flow rate insensitivity (0.2 to 1.7 mL/min) for blood cell focusing, enabling plasma extraction across a wide flow rate range. For 1 % hematocrit blood sample operated at a flow rate of 1.4 mL/min, the plasma collected from outlet 3 showed a 1528-fold reduction in blood cell concentration, and the blood cell rejection efficiency reached 99.93 %. These results confirmed that the device is capable of extracting highly purified blood plasma with the advantages of simple operation, insensitivity to flow rates, and high throughput. The device is also expected to provide a favorable opportunity for the preparation and analysis of blood samples for disease diagnosis.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"215 ","pages":"Article 110384"},"PeriodicalIF":3.8,"publicationDate":"2025-05-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144190465","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}

引用次数: 0

Fast liquid–liquid dispersion for low volumina in an active micromixer — AI-based investigation 主动微混合器中小体积快速液液分散——基于人工智能的研究

IF 3.8 3区工程技术

Chemical Engineering and Processing - Process Intensification Pub Date : 2025-05-27 DOI: 10.1016/j.cep.2025.110362

Inga Burke, Lucas Brockerhoff, Norbert Kockmann

{"title":"Fast liquid–liquid dispersion for low volumina in an active micromixer — AI-based investigation","authors":"Inga Burke, Lucas Brockerhoff, Norbert Kockmann","doi":"10.1016/j.cep.2025.110362","DOIUrl":"10.1016/j.cep.2025.110362","url":null,"abstract":"<div><div>Miniaturized equipment offers many benefits for mixing and liquid–liquid dispersion processes, such as fast and controllable mixing, high surface-to-volume ratio, and lower specific energy consumption. Rapidly changing product mixtures, as can be found in cosmetics industry, require special knowledge of the performance of the mixing and emulsification processes. Here, the droplet size distribution (DSD) is important to define the quality, consistency, and stability of the product and is often regarded as a critical quality attribute. In this work, a modified microstructured annular gear pump is examined as an active mixer for emulsification processes. The active micromixer has the benefit that the mixing power can be freely adjusted, independently of the volumetric flow rate, which enables performance investigation of the DSD based on the specific energy dissipation rate. Important process parameters, such as volumetric flow rate (0.5 to 1.5 mL<span><math><mi>⋅</mi></math></span>min<sup>-1</sup>), rotor speed (6000 to 12000 min<sup>-1</sup>) , and mass fraction of the dispersed phase (10 to 18.4 w% of the oil phase) are examined to investigate their effects on the DSD. For this, an AI-based image recognition is used for emulsion characterization. This methodology provides real-time monitoring and the opportunity to define operation ranges for rapid optimization of rotor, housing, geometry of mixing devices, and further process conditions such as volumetric flow rate for liquid–liquid mixing.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"215 ","pages":"Article 110362"},"PeriodicalIF":3.8,"publicationDate":"2025-05-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144185675","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}

引用次数: 0