Chemical Engineering and Processing - Process Intensification最新文献

{"title":"Film flow and micromixing behaviours of a turbulent jet impinging on a radially grooved spinning disk reactor","authors":"Dongxiang Wang ,&nbsp;Yuqing Qiu ,&nbsp;Fangyang Yuan ,&nbsp;Zhong Chen ,&nbsp;Xinjun Yang ,&nbsp;Jiyun Du ,&nbsp;Wei Yu ,&nbsp;Xiang Ling ,&nbsp;Hao Peng","doi":"10.1016/j.cep.2025.110314","DOIUrl":"10.1016/j.cep.2025.110314","url":null,"abstract":"<div><div>The film flow and micromixing behaviour of a turbulent jet impinging on a radially grooved spinning disk reactor were investigated. The results indicate that the number and depth of the grooves significantly influenced the formation of wavelet flow. Wavelet flow was achieved at lower rotational speeds, with an increased number and depth of grooves further reducing the required rotational speed. The formation radii of the waves were smaller than those observed on a smooth disk. Disks with grooves consistently demonstrated superior mixing performance, and the segregation index (<em>X_S</em>) decreased with the increasing number of grooves. At high flow rates, greater depths and larger angles resulted in lower <em>X_S</em>. Mixing times were on the order of 10^–4–10^–3 s for specific energy dissipation rate ranging from 6 to 1.43 × 10³ W/kg, and these times gradually decreased with the increasing of number and angle of grooves. According to the power law, the mixing time was scaled with dissipation with exponents ranging from −0.221 to −0.291, approximately half of those for the Kolmogorov time scale. Notably, rectangular grooves with a depth of 0.5 mm exhibited the best mixing behaviour, with the mixing time being primarily determined by <span><math><msubsup><mi>τ</mi><mi>k</mi><mrow><mn>0.56</mn></mrow></msubsup></math></span>.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110314"},"PeriodicalIF":3.8,"publicationDate":"2025-04-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143820732","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":"Review of insertion scenarios in enhancement performance of double-pipe heat exchanger: Case of cut twist tape","authors":"Saif Ali Kadhim ,&nbsp;Ali M. Ashour ,&nbsp;Jenan S. Sherza ,&nbsp;Abdallah Bouabidi ,&nbsp;Ahmed Kadhim Hussein ,&nbsp;Hussein Togun ,&nbsp;Farhan Lafta Rashid ,&nbsp;Shabbir Ahmad","doi":"10.1016/j.cep.2025.110308","DOIUrl":"10.1016/j.cep.2025.110308","url":null,"abstract":"<div><div>Double-Pipe Heat Exchanger (DPHX) is used in a wide range of applications including heating and cooling, chemical and food industries as well as a wide range of fields where heat transfer is necessary. This diversity of uses has made it a subject of wide interest to scholars and developers to enhance its performance. Due to ease of application and efficient, the insertion method is considered one of the important passive methods in enhancing the thermal performance of DPHX. This review is the first of its kind to survey and analyze studies that have enhanced DPHX thermal performance using cut Twist Tape (TT) inserts into the inner pipe. Several impact parameters were considered, most notably Twist Ratio (TR), Depth Ratio (DR), and Width Ratio (WR), as well as several performance parameters, most notably the Nusselt number (Nu), friction factor (<em>f</em>), and Thermal Performance Factor (TPF). The review results indicate that the thermal performance of DPHX is enhanced at the inserted of cut TT regardless of the difference of the cut geometries, especially with decrease TR and DR and increase WR, but with negative impact on hydraulic performance, which requires consideration of TPF and a wide range of Reynolds number (<em>Re</em>). Finally, most studies have shown that cut TT is superior in thermal performance enhancement over plain TT, and this enhancement can be increased when adding other techniques such as the use of nanofluid as heat transfer fluid. This review also provides recommendations that will document the gaps of the cut TT in order to future address.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110308"},"PeriodicalIF":3.8,"publicationDate":"2025-04-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143820735","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":"Design and operation of a cost-effective reactor for large protic ionic liquid synthesis","authors":"Amir H.M. Dezashibi,&nbsp;Jason P. Hallett,&nbsp;Paul S. Fennell","doi":"10.1016/j.cep.2025.110312","DOIUrl":"10.1016/j.cep.2025.110312","url":null,"abstract":"<div><div>Over the past three decades, researchers have been establishing the possibility of ionic liquids as green alternatives to conventional solvents for industrial applications, such as the delignification of biomass. Protic ionic liquids (PILs), in particular, have gained significant attention due to their cost-effectiveness and straightforward synthesis. The next step towards industrialization is to address the challenges associated with the large-scale production of these novel solvents. PILs are synthesized through the neutralization of an acid and a base, which inherently involves highly exothermic reactions that are corrosive and reactive towards metals. Therefore, a comprehensive design study should be conducted around the careful selection of materials while maximizing reactor throughput. The current study focuses on the design and operation of a semi-batch reactor that exhibits flexibility, allowing it to be easily switched to a continuous-flow reactor. The reactor has been successfully commissioned to produce 0.8 kg h^-1 of 80 w/w % triethylamine hydrogen sulfate ([TEA][HSO₄]_{80 %}). The scale-up analysis showed that a reactor, which was scaled up by a factor of 15 in dimensions based on a constant power per unit volume, resulted in a design production capacity of 105 kg h^-1 [TEA][HSO₄]_{80 %}. To date, we have produced ca. 800 kg 80 w/w % of <em>N,N</em>-dimtheylbutyl ammonium hydrogen sulfate ([DMBA][HSO₄]_{80 %}), and [TEA][HSO₄]_{80 %} combined.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110312"},"PeriodicalIF":3.8,"publicationDate":"2025-04-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143833812","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":"Topology optimization design of electrode integrated with flow field for intensifying reactive transfer process of non-aqueous iron-vanadium redox flow battery","authors":"Qiang Ma ,&nbsp;Hui Shi ,&nbsp;Huanhuan Li ,&nbsp;Huaneng Su ,&nbsp;Zhuo Li ,&nbsp;Qian Xu","doi":"10.1016/j.cep.2025.110309","DOIUrl":"10.1016/j.cep.2025.110309","url":null,"abstract":"<div><div>To probe the optimal flow field for boosting the reactive transfer performance of non-aqueous redox flow battery (RFB) electrode, this work uses a topology optimization method to design the electrode integrated with flow field for positive side of deep eutectic solvent (DES) electrolyte-based iron-vanadium RFB. Based on variable-density method and finite element simulation, this topology optimization algorithm is conducted to solve the integrated flow field/electrode structure achieving the maximum output current under the potentiostatic discharging with the given electrode porosity and pumping power condition. The results show that all topology-optimized structures present bifurcated tree-like morphology and have the highest discharging performance compared to other usual flow field structures. Moreover, to facilitate the porous electrode integrated with flow field employing in further production process, a fractal binary tree-like flow field is proposed to simplify the complex topology-optimized results. Using the full-cell numerical simulations of DES based iron-vanadium RFB, the positive-side electrode integrated with simplified tree-like structure, which has the fractal similarity with the according topology-optimized morphology, can play a positive role of enhancing reactive transfer process during RFB discharging. Consequently, this work provides a significative design thought for the advanced porous electrode integrated with flow field of non-aqueous RFB.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110309"},"PeriodicalIF":3.8,"publicationDate":"2025-04-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143826291","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":"Modulating temporal temperature pattern of dicyclopentadiene conversion reaction network for efficient production of tricyclopentadiene","authors":"Xinyue Pan ,&nbsp;Ruichen Liu ,&nbsp;Yi Zhao ,&nbsp;Li Wang ,&nbsp;Xiangwen Zhang ,&nbsp;Guozhu Li","doi":"10.1016/j.cep.2025.110311","DOIUrl":"10.1016/j.cep.2025.110311","url":null,"abstract":"<div><div>Tricyclopentadiene (TCPD) has received widespread attention as a competitive precursor of high-performance liquid fuel with a density greater than 1 g/cm³. However, the efficiency of TCPD synthesis using the traditional heating method is still low due to the difficulty in regulating the reaction network for suppressing side reactions. Because the temporal temperature profile can not be finely tuned in the traditional reactor. Herein, the programmed temperature-controlled electrical heating (PCH) technique is employed to realize transient temperature control of the reaction system. The optimal reaction conditions are determined by Bayesian optimization method for improving the yield of TCPD. In continuous flow reaction, a TCPD yield of 66.39 % is achieved using PCH, which is only 32.84 % by the traditional continuous heating method. The space-time yield of TCPD is increased from 5.71 g/h to 11.47 g/h. This work provides a new perspective on the network regulation of traditional thermochemical reactions.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110311"},"PeriodicalIF":3.8,"publicationDate":"2025-04-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143823696","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 electrocatalytic performance for SnO2-Sb, Ni coatings induced by high-resistance layer and surface active layer in combination with alternating thick/thin layer method","authors":"Jiamin Huang,&nbsp;Jiawei Zhang,&nbsp;Lei Huang,&nbsp;Yi He,&nbsp;Zhuo Chen,&nbsp;Zhihan Xu,&nbsp;Xiaoping Ma,&nbsp;Yu Xin","doi":"10.1016/j.cep.2025.110313","DOIUrl":"10.1016/j.cep.2025.110313","url":null,"abstract":"<div><div>Developing an electrochemical degradation system with high catalytic efficiency and extended operational lifetime is crucial for practical industrial applications. In this study, a novel Sb, Ni-doped tin oxide-coated electrode, named A@SnO₂-Sb-Ni/SnO₂-Sb/Ti, featuring a high-resistance intermediate layer (HRIL) and surface active layer in combination with alternating thick and thin layers (ATTL) method was proposed to enhance both catalytic performance and stability. The potential divider effect of the SnO₂-Sb HRIL and fine cracks on the surface induced by alternating thick and thin active layer not only effectively reduce the dissolution rate of the active layer but also inhibit the direct dissipation of the Ti substrate by the electrolyte, which collaboratively increases the overall stability of the electrode. Accelerated life test results demonstrated that the stability of the A@SnO₂-Sb-Ni/SnO₂-Sb/Ti electrode showed a 110 % improvement in acidic environments compared to the traditional SnO₂-Sb-Ni/Ti electrode. At a constant current density of 10 mA cm⁻² applied to a 4.0 cm² electrode, nearly complete degradation of Rhodamine B (100 mL, 20 mg L⁻¹) was achieved within 15 min.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110313"},"PeriodicalIF":3.8,"publicationDate":"2025-04-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143820733","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":"Study on the combustion characteristics and pollutant formation behavior of semi coke micro-particles loaded with pesticide distillation residues","authors":"Qiansha Yang ,&nbsp;Zhikuan Lu ,&nbsp;Zhiming He ,&nbsp;Yingxu Liu ,&nbsp;Minjie Pei ,&nbsp;Zhanqi Song ,&nbsp;Haosong Qu ,&nbsp;Kai Zhang ,&nbsp;Yali Li","doi":"10.1016/j.cep.2025.110305","DOIUrl":"10.1016/j.cep.2025.110305","url":null,"abstract":"<div><div>To effectively promote the resource utilization of pesticide distillation residues, this study employs strong shear force to thoroughly mix the residues with semi-coke micro-particles, ensuring their uniform distribution on the surface of the microparticles. This approach allows for the exploration of the combustion characteristics and pollutant formation pathways of semi-coke micro-particles loaded with pesticide distillation residues. The results indicate that, when the heating rate is 10 °C/min, the ignition temperature decreases as the proportion of pesticide residue increases. Additionally, as the heating rate rises, both the ignition temperature and burnout temperature increase. During pollutant dissociation, the pyridine ring and its derivatives in the pesticide residue preferentially cleave the C<img>Cl bond to generate chlorine radicals, while organic components such as carbon-carbon triple bonds in the semi-coke also undergo cleavage and release heat, leading to the breakage of bonds in the pyridine ring. These cleavage products react with hydroxyl radicals and oxygen radicals to form unsaturated organic compounds such as C₄H₄ and C₂H₄, as well as small amounts of chlorine, sulfur, fluorine, carbon, and nitrogen compounds. As the oxygen concentration increases, the unsaturated bonds are oxidized. After cooling, the main products are CO₂, H₂O, HCl, HF, NO_x, and COS. Furthermore, the inorganic components in the semi-coke exhibit good fluorine and chlorine fixation effects. This study not only reveals the combustion characteristics and pollutant generation pathways of the semi coke particles loaded with pesticide distillation residues, but also foretells its broad application prospects in the field of organic hazardous waste resource utilisation.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110305"},"PeriodicalIF":3.8,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143820734","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":"Numerical simulation on electrical-intensified separator: The development of the flow field and its separation performance","authors":"Chen Huo ,&nbsp;Bao Yu ,&nbsp;Ling Chen ,&nbsp;Ye Peng ,&nbsp;Hong Yin ,&nbsp;Ping Ouyang ,&nbsp;Haifeng Gong","doi":"10.1016/j.cep.2025.110281","DOIUrl":"10.1016/j.cep.2025.110281","url":null,"abstract":"<div><div>Wastewater treatment for improving energy efficiency to promote water resource recycling is required globally. Centrifugation technology has been widely applied in industrial wastewater pretreatment. However, conventional hydrocyclones induce high breakage rate of droplets owing to the high shear force. Therefore, the electrical-intensified separator was designed. It provides preseparation and strengthened environments and applies electrical field to intensify separation effect. A simulation of the separator was conducted. The separation performance was investigated, and the reason for low energy loss was discussed. Simultaneously, the simulation was verified through experiment. The results show that the electrical-intensified separator not only increases efficiency by 20 % but also decreases dynamic energy loss by &gt;120 Pa under <em>V</em> = 5 m/s compared to the conventional hydrocyclone. And numerical results agree with experiment. The separator decreases the rate of droplet breakup and enhances separation due to the separation with progressive process, making the region distribution of tangential velocity wider and greater. Additionally, the role of electrical field intensifies the droplet migration, which is conducive to increase the movement of mixture in flow field. Therefore, the dynamic pressure loss of this separator is significantly lower than conventional hydrocyclone.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110281"},"PeriodicalIF":3.8,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143737964","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":"Comparative analysis of flow behavior during the nanofluid Phase transition at serpentine microchannel bends","authors":"Juhui Chen ,&nbsp;Hanchi Xu ,&nbsp;Dan Li ,&nbsp;Jin Guo ,&nbsp;Michael Zhuravkov ,&nbsp;Siarhel Lapatsin ,&nbsp;Wenrui Jiang","doi":"10.1016/j.cep.2025.110298","DOIUrl":"10.1016/j.cep.2025.110298","url":null,"abstract":"<div><div>With the growing demand for high-flux thermal management in electronics, understanding nanofluid flow dynamics during phase transitions in complex microchannel geometries remains a critical yet underexplored frontier. This study pioneers a comprehensive investigation into the flow characteristics of four nanofluids (Cu-water, Al₂O₃-water, Al-water, SiO₂-water) before and after liquid-vapor phase transitions in serpentine microchannel bends, integrating the Mixture model with the RNG k-ε turbulence model. The novelty lies in the coupled analysis of multiphase flow, flow behavior and geometric effects during the phase transition of nanoparticles at different Reynolds numbers (100–400), volume fractions (0.1 %–1.3 %) and heat fluxes (50–80kW/m²). Key findings reveal that the change of heat flux density in pre-phase transition has little effect on pressure drop, but escalates with Reynolds number and volume fraction, with Cu-water exhibiting the highest growth rates (66.91 % and 42.96 %, respectively). Post-phase transition, despite lower absolute pressure drops, growth rates surpass pre-transition values (Cu-water: 67.16 % and 43.15 %), driven by vapor-induced turbulence and altered flow resistance mechanisms. These insights challenge the traditional single-phase cooling paradigm by quantifying how phase transitions modulate the behavior of nanofluids within serpentine microchannels, and can provide theoretical references for fields such as high-power electronics and aerospace thermal management.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110298"},"PeriodicalIF":3.8,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143777479","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":"Reaction/distillation matrix algorithm development to cover sequences containing reactive dividing wall column: Validation in process of cumene production","authors":"Maedeh Jamshidi ,&nbsp;Ali Mallahzadeh ,&nbsp;Amirhossein Khalili-Garakani ,&nbsp;Norollah Kasiri","doi":"10.1016/j.cep.2025.110289","DOIUrl":"10.1016/j.cep.2025.110289","url":null,"abstract":"<div><div>The Reactive Dividing Wall Column (RDWC) offers a powerful approach to process intensification by combining chemical reactions and multi-component separations within a single unit, delivering significant economic and operational benefits. This study investigates various RDWC configurations for Cumene production generated through a modified Reaction/Distillation matrix-based algorithm. Rigorous simulations of both the conventional Reactive Distillation Column (RDC) and RDWC setups were conducted in Aspen Plus, while the Teaching-Learning-Based Optimization (TLBO) algorithm in MATLAB minimized total annual costs (TAC) and met product specifications. TLBO was chosen for its parameter-free nature, computational efficiency, and strong optimization performance, making it a robust tool for this case study. Comparative analysis revealed that the optimized RDWC configuration substantially outperformed the conventional RDC, reducing TAC by 27.62 % and total energy consumption by 27.98 %. Furthermore, the optimized RDWC configuration led to a 57.66 % decrease in capital costs and a 29.13 % reduction in operating costs by minimizing the required number of columns, condensers, and reboilers. These results demonstrate that the RDWC is a highly efficient and economically viable option for energy-intensive processes such as Cumene production, achieving substantial cost savings and enhanced operational efficiency.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"213 ","pages":"Article 110289"},"PeriodicalIF":3.8,"publicationDate":"2025-03-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143826290","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}