Chemical Engineering and Processing - Process Intensification最新文献

{"title":"Numerical study on improving corrugated plate gas–liquid separator performance by integrating baffle and hook designs","authors":"Maha Ahmed ,&nbsp;Michael Mansour ,&nbsp;Mohamed Salem ,&nbsp;Abouelmagd Abdelsamie","doi":"10.1016/j.cep.2025.110514","DOIUrl":"10.1016/j.cep.2025.110514","url":null,"abstract":"<div><div>Steam–water separators are critical in industrial applications, especially in thermal and nuclear power plants and thermo-chemical hydrogen production. These devices enhance system efficiency by removing water droplets from steam, ensuring dry steam delivery to downstream equipment. The performance of steam–water separators depends on structural design and operating conditions. This study numerically investigates the performance of corrugated plate steam separators with various baffle and hook configurations to optimize separation efficiency and pressure drop. Six designs (Shape-I to Shape-VI) were evaluated using CFD simulations incorporating the <span><math><mrow><mi>k</mi><mo>−</mo><mi>ϵ</mi></mrow></math></span> turbulence model, the Discrete Phase Model (DPM), and the Discrete Random Walk (DRW) model to capture fluid dynamics and droplet behavior. Velocity distribution, pressure drop, and separation efficiency were analyzed. Results showed that Shape-V (baffles and double hooks) and Shape-VI (staged hooks) offered the highest performance. Shape-VI achieved 99.8% separation efficiency at high inlet velocity but with a higher pressure drop. In contrast, Shape-V achieved slightly lower efficiency with a 48% reduction in pressure drop, making it more suitable when minimizing pressure loss is essential. These findings support the design of more efficient and cost-effective separators, contributing to improved energy system performance and operational reliability.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110514"},"PeriodicalIF":3.9,"publicationDate":"2025-08-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144895250","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":"Unveiling the role of mixing enhancement in oxygen vacancy concentration and particle size during high-throughput synthesis of ZnO photocatalyst in a microreactor","authors":"Hao-Tian Tong ,&nbsp;Yan-Jiang Liu ,&nbsp;Shi-Xiao Wei ,&nbsp;Hua Yang ,&nbsp;Ting-Liang Xie ,&nbsp;Shuang-Feng Yin","doi":"10.1016/j.cep.2025.110518","DOIUrl":"10.1016/j.cep.2025.110518","url":null,"abstract":"<div><div>Oxygen vacancy (O_v) concentration and particle size (<em>d</em>) are critical to the performance of metal oxide photocatalysts. Here, taking advantage of strong chaotic mixing performance in a four-stage oscillating feedback microreactor (FOFM), the ZnO with small <em>d</em> and high O_v concentration were controllably prepared. First, dye-tracer experiments and Villermaux-Dushman reactions were used to investigate the macroscopic and micromixing performance within FOFM. Then, ZnO was prepared using FOFM at different flow rates, and the role of mixing enhancement in <em>d</em> and O_v concentration of ZnO was unveiled. The results indicate that increasing flow rates would enhance chaos intensity of fluids, thereby obtaining products with smaller <em>d</em> and higher O_v concentration. Photocatalytic tests indicate that ZnO prepared with small <em>d</em> has excellent photocatalytic performance for methyl orange degradation. DFT calculations prove that O_v can reduce adsorption energy of ZnO-*O₂ and enhance bonding strength between Zn and *O, thereby promoting adsorption of O₂.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110518"},"PeriodicalIF":3.9,"publicationDate":"2025-08-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144895247","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":"Optimization of dual-fluid wafer cleaning system through CFD simulation and dimensional analysis of dynamic liquid film behavior","authors":"Bingxu Yao ,&nbsp;Runkai Song ,&nbsp;Jingyi Wu ,&nbsp;Jiancheng Zhou ,&nbsp;Bin Hua ,&nbsp;Zhen Jiao","doi":"10.1016/j.cep.2025.110519","DOIUrl":"10.1016/j.cep.2025.110519","url":null,"abstract":"<div><div>As semiconductor devices continue to scale down, wafer cleaning is a critical step for manufacturing yield and device reliability. This study presents a framework integrating Computational Fluid Dynamics with experimental validation to investigate dual-fluid wafer cleaning by examining liquid film dynamics on rotating wafers. CFD simulations, coupling the Volume of Fluid and Discrete Phase Model approaches, modeled droplet impact, liquid film evolution, and key hydrodynamic parameters. These CFD predictions were validated through physical cleaning experiments using SiO₂ nanoparticles. The validation demonstrated a correlation between simulated wall shear stress and experimentally measured wafer cleaning efficiency, and also between simulated film uniformity and experimental cleaning uniformity. Key findings indicate that while an increasing Reynolds number enhances turbulence and shear stress, it may compromise liquid film uniformity. Increasing the Weber number not only contributes to higher cleaning efficiency but also promotes more uniform liquid film coverage. An empirical equation derived from Re and We offers a predictive tool for liquid film thickness, intended for scalable cleaning process optimization. This work provides an experimentally validated theoretical and practical foundation for optimizing semiconductor wafer cleaning, contributing to considerations of efficiency and process scalability.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110519"},"PeriodicalIF":3.9,"publicationDate":"2025-08-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144895248","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":"Synergistic role of Cyanex 272 saponification and acetate buffering in selective Co(II)/Ni(II) separation via Green Emulsion Liquid Membrane (GELM)","authors":"Farzin Sadehlari,&nbsp;Stevan Dubljevic","doi":"10.1016/j.cep.2025.110504","DOIUrl":"10.1016/j.cep.2025.110504","url":null,"abstract":"<div><div>This study explores the selective extraction of cobalt and nickel ions from acidic solutions using a Green Emulsion Liquid Membrane (GELM) system. Corn oil was selected as a green diluent based on shake-out tests. The membrane phase was formulated by dissolving Cyanex 272 (as extractant) and a binary surfactant system (Span 80 and Tween 80) in corn oil, then emulsified with sulfuric acid (H₂SO₄) as the internal stripping agent. Partial saponification of Cyanex 272 enhanced extraction efficiency, while sodium acetate served as a buffering agent to improve selectivity. Equilibrium studies validated the extraction mechanism. An optimized surfactant blend of 4% v/v (80% Span 80, 20% Tween 80) provided superior emulsion stability. Key operational parameters were optimized, including extractant concentration (25% v/v, 30% saponified), sodium acetate concentration (1.5 M), feed pH (5), treatment ratio (5:1), stirring speed (200 rpm), time (20 min), phase ratio (2:3), and stripping agent (1 M H₂SO₄). Under these conditions, cobalt extraction reached 95.0%, with minimal nickel co-extraction (3.8%), yielding a high separation factor. The membrane phase was successfully recycled twice with minimal loss in performance, demonstrating the feasibility of this sustainable approach for selective metal separation.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110504"},"PeriodicalIF":3.9,"publicationDate":"2025-08-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144895251","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":"A CFD-assisted UV- H2O2 advanced oxidation process intensification in a novel photoreactor through reflector shape optimization","authors":"Mohammad Mohammadrezaei,&nbsp;Hossein Khosravi,&nbsp;Farshad Kowsary,&nbsp;Alireza Jalali","doi":"10.1016/j.cep.2025.110517","DOIUrl":"10.1016/j.cep.2025.110517","url":null,"abstract":"<div><div>Incorporating reflectors in advanced oxidation processes offers advantages in both the maintenance and performance of novel reactors when compared to conventional ones. A Monte Carlo radiation simulation was developed for a novel photoreactor and integrated into a genetic algorithm to optimize the shape of reflectors for maximum radiation absorption on the effluent pipe. To assess the overall performance of photoreactors with optimized and non-optimized reflectors, as well as conventional photoreactors, the fluid flow, radiation distribution, and chemical reactions were simulated using a well-validated computational fluid dynamics (CFD) model. The flow rate, radiative power, and pollutant concentration at the inlet were held constant across the three photoreactor designs to compare the degradation efficiency of model pollutants, namely Tributyl Phosphate (TBP), Tri 2-Chloroethyl Phosphate (TCEP), and Tri 2-Butoxyethyl Phosphate (TBEP). At a flow rate of 10 gallons per minute (GPM), the photoreactor with optimized reflectors showed 14.12 %, 5.96 %, and 8.37 % higher degradation of TBP, TCEP, and TBEP, respectively, compared to the conventional photoreactor. When compared to the photoreactor with non-optimized reflectors, the degradation rates improved by 4.33 %, 2.52 %, and 2.1 %, respectively.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110517"},"PeriodicalIF":3.9,"publicationDate":"2025-08-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144895249","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":"Micro-mechanism and process study of green deep eutectic solvents in water/γ-valerolactone separation","authors":"Ying Zhao,&nbsp;Xiaohong Wang,&nbsp;Weibin Zhang,&nbsp;Zenglin Jiang,&nbsp;Chen Li,&nbsp;Ruitong Guo,&nbsp;Yugang Li","doi":"10.1016/j.cep.2025.110516","DOIUrl":"10.1016/j.cep.2025.110516","url":null,"abstract":"<div><div>The current industrial production processes of γ-valerolactone (GVL) generate GVL-containing wastewater, which requires treatment to prevent environmental pollution and resource waste. In this paper, the overall performance of various organic solvents and hydrophobic deep eutectic solvents (HDESs) was evaluated based on the COSMO-SAC model. The extractants suitable for GVL/water separation were preliminarily screened. Quantum chemical calculations and molecular dynamics simulations analyzed the microscopic interaction mechanisms between HDESs and GVL aqueous solutions. Experimental validation further confirmed the separation effect of toluene and Thy-Oct as optimal extractants. The study used toluene and Thy-oct as the optimal organic extractants and optimal HDESs for the process design. It was optimized with the objective of the lowest total annual cost, accounting for the harmful gas emissions. The results showed that the total annual cost and harmful gas emission of the extraction-distillation separation process using Thy-Oct were reduced by 40.38 % and 32.26 %, respectively, compared with that using toluene, which verified the economic and environmental advantages of the extraction-distillation process with HDESs as the extractants, and provided a strong basis for the separation of the same kind of substances.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110516"},"PeriodicalIF":3.9,"publicationDate":"2025-08-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144904412","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 influence of premixed volume on methane explosion dynamics under semi-confined conditions","authors":"Jing Guoxun,&nbsp;Sun Yue,&nbsp;Liu Chuang","doi":"10.1016/j.cep.2025.110515","DOIUrl":"10.1016/j.cep.2025.110515","url":null,"abstract":"<div><div>Gas explosion accidents are highly destructive, and the gas dispersion range significantly affects the explosion intensity. This study combines experiments and simulations in a semi - enclosed pipe to explore how different premixed volumes affect methane - air explosion dynamics and energy release efficiency. Results show that as the premixed volume increases, the average flame propagation velocity rises linearly, the time for the flame front to reach its farthest distance increases, and the peak explosion overpressure changes logarithmically. Expansion waves from the opening create negative pressure inside the pipe, gathering residual flammable gases. This allows unreacted fuel to mix with air again and participate in the explosion, providing energy for multi - peak fluctuations in explosion pressure. At 10vol% conditions, the explosion energy release coefficient correlates positively with the premixed volume. This research offers a theoretical basis for assessing gas explosion accidents and predicting losses.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110515"},"PeriodicalIF":3.9,"publicationDate":"2025-08-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144886622","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":"Influence and correlation analysis of urea injection method and mixer combination on SCR performance","authors":"Jianbin Luo ,&nbsp;Zongfa Jia ,&nbsp;Song Xu ,&nbsp;Guiguang Chen ,&nbsp;Haiguo Zhang ,&nbsp;Chunmei Jiang","doi":"10.1016/j.cep.2025.110513","DOIUrl":"10.1016/j.cep.2025.110513","url":null,"abstract":"<div><div>As emission standards have been tightened globally, reducing nitrogen oxide (NO_x) emissions is a strict challenge for the internal combustion engine industry. In this paper, it aims to explore the effects of different urea injection methods and mixer combinations on the performance of the selective catalytic reduction (SCR) system, as well as to perform correlation analysis by using the computational fluid dynamics (CFD) method. Firstly, the total SCR system model including a urea injection device and mixer has been built after the numerical simulation method was validated by comparing the results of the experimental data. Secondly, the effects of different injection methods and mixer configurations on turbulence energy, ammonia (NH₃) distribution uniformity, pressure drop, and NO_x reduction (de-NO_x) efficiency were analyzed. It is revealed that the mixer combination can significantly improve turbulence energy and NH₃ uniformity. The center injection method can provide better NH₃ uniformity and lower pressure drop compared to the wall injection method. Among the double mixers, the T-E type mixer is demonstrated to have superior de-NO_x efficiency, while the E-type mixer excels in turbulence generation and mixing. Finally, the Analytic Hierarchy Process (AHP) has been used to assign weights to performance indicators, and the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) identified Case D1 as the optimal configuration. For the T-E type mixer, de-NO_x efficiency can be improved by over 10 %. For the center injection method, the pressure drop is reduced by 15 % and NH₃ uniformity is enhanced by 20 %. It is highlighted that the urea injection method and mixer combination play a critical role in optimizing SCR system performance and efficiency. At the same time, it also provides a systematic approach to solving problems by comprehensively considering the coordinated coupling actions between various components of the entire SCR system.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110513"},"PeriodicalIF":3.9,"publicationDate":"2025-08-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144890502","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 liquid film flow turbulence characteristics of corrugated baffle-type plate under high Reynolds number","authors":"Liang Wang","doi":"10.1016/j.cep.2025.110511","DOIUrl":"10.1016/j.cep.2025.110511","url":null,"abstract":"<div><div>The stability of falling film flow is an important research problem in the vertical falling film evaporation flow.In this paper, the vertical falling film device with corrugated baffles is proposed, corrugated baffles are added to the structure of the traditional flat falling film device.The falling film device is simulated by fluent, and the effects of wave height, wavelength and inlet flow rate on the measurement results are analyzed. The results show that compared with the traditional flat plate liquid film falling device, the corrugated plate baffle has smaller turbulence intensity and greater resistance liquid film thickness. The higher wave height is, the turbulence intensity of the corrugated baffle is greater. However, the thickness of liquid film varies greatly. The smaller wavelength is, the turbulence intensity of the corrugated plate is smaller, but the change of liquid film thickness is also very small. The maximum deviation between the empirical formula of the fitting curve between the liquid film thickness and Reynolds number and the calculated value is 14.93 %. The maximum deviation of average liquid film thickness is 2.32 %, the maximum standard deviation(SD)is 0.27 mm, and the maximum relative standard deviation(RSD)is 0.061.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110511"},"PeriodicalIF":3.9,"publicationDate":"2025-08-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144892145","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":"Next-Gen Bioprocessing: Sustainable Scale-Up of Triple Algal Co-culture System","authors":"Buse Dincoglu,&nbsp;Bahar Aslanbay Guler,&nbsp;Zeliha Demirel,&nbsp;Esra Imamoglu","doi":"10.1016/j.cep.2025.110512","DOIUrl":"10.1016/j.cep.2025.110512","url":null,"abstract":"<div><div>In recent years, microalgae have attracted considerable interest because of their diverse uses in sustainable biotechnology. The role of microalgae in industrial biotechnology is steadily increasing; however, limitations (e.g. cost, operations and maintenance) encountered during scaling-up processes necessitate the development of more efficient methods. The co-culture approach offers numerous advantages, including enhanced productivity, sustainability, product diversity, cost-effective operations, and eco-friendly processing. In this study, a triple algal co-culture of <em>Haematococcus pluvialis Chlorella vulgaris</em>, and <em>Spirulina platensis</em> was scaled up in air-lift photobioreactors (ALPBRs) from 2 L to 8 L using constant power consumption per unit volume as the scale-up strategy. The results indicated that scaling-up increased productivity (approximately 1.3-fold increase), with significant improvements in production parameters observed in the 8 L ALPBR<strong>.</strong> Biomass productivity showed a 1.75-fold increase when scaling from 2 L to 8 L. Protein, chlorophyll and carotenoid productivities increased 1.5-fold, 1.2-fold, and 1.1-fold, respectively, compared to the 2 L ALPBR. These results demonstrate that the triple algal co-culture system enhances both energy and product efficiency, confirming the effectiveness of scale-up using a constant power consumption per unit volume strategy and highlighting its potential for more sustainable and efficient microalgal production processes through increased biomass and bioactive product yields.</div></div>","PeriodicalId":9929,"journal":{"name":"Chemical Engineering and Processing - Process Intensification","volume":"217 ","pages":"Article 110512"},"PeriodicalIF":3.9,"publicationDate":"2025-08-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144879931","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}