This paper proposes T-shaped ribs as obstacles attached to the heat absorber plate in a rectangular solar air heater to promote heat transfer. The thermal and aerodynamic performance of the solar heater was numerically evaluated using three-dimensional Reynolds-averaged Navier−Stokes equations with the shear stress transport turbulence model. A parameter study was performed using the ratios of rib height to channel height, rib width to channel width, and rib width to rib height. The area-averaged Nusselt number and friction factor were selected as the performance parameters of the solar air heater to evaluate the heat transfer and friction loss, respectively. In addition, the performance factor was defined as the ratio of the area-averaged Nusselt number to the friction factor. The maximum area-averaged Nusselt number was found at h/e = 0.83 for a fixed rib area. Compared with triangular ribs, the T-shaped ribs showed up to a 65 % higher area-averaged Nusselt number and up to a 49.7% h... [more]

Internal Quenching is an innovative heat treatment method for difficult to access component sections. Especially, the microstructure, as well as the residual stress state at inner surfaces, of thick-walled tubes can be adjusted with the presented flexible heat treatment process. Based on multiphysical FE-models of two different steels, a simulative optimization study, considering different internal quenching strategies, was performed in order to find the optimal cooling conditions. The focus hereby was on the adjustment of a martensitic inner surface with high compressive residual stresses. The simulatively determined optimal cooling strategies were carried out experimentally and analyzed. A good agreement of the resulting hardness and residual stresses was achieved, validating the presented Fe-model of the Internal Quenching process. The shown results also indicate that the arising inner surface state is very sensitive to the transformation behavior of the used steel. Furthermore, the... [more]

Hydro energy is a kind of typical renewable energy, which can be converted by hydraulic machinery. However, tip leakage vortex (TLV) has a significant negative influence on the flow pattern and energy performance of hydraulic machinery. In this paper, a bending shrinkage groove (BSG) is proposed to suppress the TLV and improve the energy performance of a hydrofoil first, and then a parametric optimization design method is briefly introduced and applied to determine the optimal configuration of the groove. The main geometric parameters of the groove are selected as optimized variables and three different groove configurations are selected from the optimization result. Finally, the performance improvement of the hydrofoil with groove, the sensitivity analysis of the optimization variables, and the groove impacts on the TLV and flow patterns are investigated. The results demonstrate that the preferred groove reduces the non-dimensional Q criterion vortex isosurfaces area (Qarea = 2 × 107)... [more]

Air infiltration into the combustion chambers of industrial furnaces is an unwanted phenomenon causing loss of thermal efficiency, fuel consumption increase, and the subsequent increase in operating costs. In this study, a novel design for a rotary tilting furnace door with improved construction features is proposed and tested experimentally in a laboratory-scale furnace, aimed at air infiltration rate reduction by decreasing the gap width between the static furnace door and the rotating body. Temperatures in the combustion chamber and oxygen content in the dry flue gas were measured to document changes in the combustion process with the varying gap width. Volumetric flow values of infiltrating air calculated based on measured data agree well with results of numerical simulations performed in ANSYS and with the reference calculation procedure used in relevant literature. An achievable air infiltration reduction of up to 50% translates into fuel savings of around 1.79 to 12% of total na... [more]

In this study, continuous transesterification of refined palm oil by using radiation-induced kenaf denoted as anion exchange kenaf catalyst in a packed-bed reactor was developed. The application of full factorial design and response surface methodology (RSM) based on the central composite design (CCD) was used to design the process and analyzed the effect of reactor operating variables such as packed bed height, the molar ratio of oil to ethanol and volumetric flow rate on the production of fatty acid ethyl ester (FAEE). The statistical analysis results showed that all three operating parameters affect the reaction efficiency significantly. The optimum conditions were determined to be 9.81 cm packed bed height, a molar ratio at 1:50, and a volumetric flow rate of 0.38 mL min−1. Three tests were carried out to verify the optimum combination of process parameters. The predicted and actual values of molar conversion fatty acid ethyl ester (FAEE) molar conversion were 97.29% and 96.87%, re... [more]

Due to the harmful effects and depletion of non-renewable energy resources, the major concerns are focused on using renewable energy resources. Among them, the geothermal energy has a high potential in volcano regions such as the Middle East. The optimization of an organic Rankine cycle with a geothermal heat source is investigated based on a genetic algorithm having two stages. In the first stage, the optimal variables are the depth of the well and the extraction flow rate of the geothermal fluid mass. The optimal value of the depth of the well, extraction mass flow rate, and the geothermal fluid temperature is found to be 2100 m, 15 kg/s, and 150 °C. In the second stage, the efficiency and output power of the power plant are optimized. To achieve maximum output power as well as cycle efficiency, the optimization variable is the maximum organic fluid pressure in the high-temperature heat exchanger. The optimum values of energy efficiency and cycle power production are equal to 0.433 M... [more]

Phase transfer catalysed (PTC) reactions are used in several pharmaceutical and fine chemical industrial processes. We have developed a novel stirred tank reactor (Yadav reactor) to conduct batch and continuous liquid−liquid−liquid (L-L-L) PTC reactions. The reactor had a provision of using three independent stirrers for each phase, thereby having complete control over the rate of mass transfer across the two interfaces. In the continuous mode of operation, the top and bottom phases were continuously fed into the reactor while the middle phase was used as a batch. All three stirrers were used independently, thereby having independent control of mass transfer resistances. The reactor in a batch mode showed higher conversion and selectivity compared to a conventional batch reactor. L-L-L PTC reaction in the continuous mode was successfully performed without loss of the middle catalyst phase and with steady conversion and selectivity. The reaction of guaiacol with epichlorohydrin was cond... [more]

In this research, we performed energy and exergy assessments of a solar driven power plant. Supercritical carbon dioxide (S-CO2) Brayton cycle is used for the conversion of heat to work. The plant runs on solar energy from 8 a.m. to 4 p.m. and to account for the fluctuations in the solar energy, the plant is equipped with an auxiliary heater operating on hot combustion gases from the combustion chamber. The capital city of Saudi Arabia (Riyadh) is chosen in this study and the solar insolation levels for this location are calculated using the ASHRAE clear-sky model. The solar collector (central receiver) receives solar energy reflected by the heliostats; therefore, a radially staggered heliostat field is generated for this purpose. A suite of code is developed to calculate various parameters of the heliostat field, such as optical efficiencies, intercept factors, attenuation factors and heliostat characteristic angles. S-CO2 Brayton cycle is simulated in commercial software, Aspen HYSYS... [more]

Biopharmaceuticals are often lyophilized to improve their storage stability. Controlling ice nucleation during the freezing step of the lyophilization process is desired to increase homogeneity of product properties across a drug product batch and shorten the primary drying time. The present communication summarizes the process optimization of the freezing process when using vacuum-induced surface freezing to control ice nucleation, in particular for amorphous samples. We characterized freeze-dried samples for solid state properties, and compared these to uncontrolled nucleated samples using bovine serum albumin (BSA) as a model protein. Freezing parameters were optimized to obtain complete nucleation, adequate cake resistance during the subsequent lyophilization cycle, and elegant cakes. We highlight the challenges associated with vacuum-induced surface freezing and propose optimized freezing parameters to control ice nucleation, enabling manufacturing of amorphous samples.

Water disinfection and potential sterilization in continuous flow was achieved in a hybrid reactor with a broadband hydrodynamic emitter combined with ultrasonic vibrations at different frequencies and with excess pressure. Such a combination showed synergistic effects by increasing the acoustic power in the reactor vortex flow. The present combined physical treatment, compared with sonication alone, could increase microorganism inactivation by 15−20%.

The integration of membranes inside a catalytic reactor is an intensification strategy to combine separation and reaction steps in one single physical unit. In this case, a selective removal or addition of a reactant or product will occur, which can circumvent thermodynamic equilibrium and drive the system performance towards a higher product selectivity. In the case of an inorganic membrane reactor, a membrane separation is coupled with a reaction system (e.g., steam reforming, autothermal reforming, etc.), while in a membrane bioreactor a biological treatment is combined with a separation through the membranes. The objective of this article is to review the latest developments in membrane reactors in both inorganic and membrane bioreactors, followed by a report on new trends, applications, and future perspectives.

The increased levels of carbon dioxide in the environment have incited the search for breakthrough technologies to lessen its impact on climate. The CO2 capture from a mixture of CO2/N2 was studied using a molecular sieve (MS) and silica gel type-III. The breakthrough behavior was predicted as a function of temperature, superficial velocity, and CO2 partial pressure. The breakpoint time reduced significantly with increased temperature and increased superficial velocity. The CO2 adsorption capacity increased appreciably with decreased temperature and increased CO2 pressure. The saturation CO2 adsorption capacity from the CO2/N2 mixture reduced appreciably with increased temperature. The molecular sieve contributed to higher adsorption capacity, and the highest CO2 uptake of 0.665 mmol/g was realized for MS. The smaller width of the mass transfer zone and higher column efficiency of 87.5% for MS signify the efficient use of the adsorbent; this lowers the regeneration cost. The findings s... [more]

Anaerobic digestion is an efficient technology for a sustainable conversion of various organic wastes such as animal manure, municipal solid waste, agricultural residues and industrial waste into biogas. This technology offers a unique set of benefits, some of which include a good waste management technique, enhancement in the ecology of rural areas, improvement in health through a decrease of pathogens and optimization of the energy consumption of communities. The biogas produced through anaerobic digestion varies in composition, but it consists mainly of carbon dioxide methane together with a low quantity of trace gases. The variation in biogas composition are dependent on some factors namely the substrate type being digested, pH, operating temperature, organic loading rate, hydraulic retention time and digester design. However, the type of substrate used is of greater interest due to the direct dependency of microorganism activities on the nutritional composition of the substrate. T... [more]

Diverse and abundant applications of the eutectic solvents have appeared in the last years. Their promising tunable properties, eco-friendly character and the possibility of being prepared from numerous compounds have led to the publication of numerous papers addressing their use in different areas. Terpenes and terpenoids have been employed in the formulation of eutectic solvents, though they also have been applied as solvents in extraction processes. For their hydrophobic nature, renewable character, low environmental impact, cost and being non-hazardous, they have also been proposed as possible substitutes of conventional solvents in the separation of organic compounds from aqueous streams, similarly to hydrophobic eutectic solvents. The present work reviews the application of eutectic solvents in liquid−liquid extraction and terpenes and terpenoids in extraction processes. It has been made a research in the current state-of-the-art in these fields, describing the proposed applicati... [more]

There is a growing awareness of the need to mitigate greenhouse gas emissions and the inevitable depletion of fossil fuel. With the market pull for the growth in sustainable and renewable alternative energy, the challenge is to develop cost-effective, large-scale renewable energy alternatives for all energy sectors, of which transport fuels are one significant area. This work presents a summary of novel methods for integrating kraft mills with a hydrothermal liquefaction process. The application of these methods has resulted in a proposed kraft mill-integrated design that produces a liquid fuel and could provide net mitigation of 64.6 kg CO2-e/GJ, compared to conventional petrol and diesel fuels, at a minimum fuel selling price of 1.12−1.38 NZD/LGE of fuel, based on the case study. This paper concludes that a hydrothermal liquefaction process with product upgrading has promising economic potential and environmental benefits that are significantly amplified by integrating with an existi... [more]

In the manufacturing processes, process optimization tasks, to optimize their product quality, can be performed through the following procedures. First, process models mimicking functional relationships between quality characteristics and controllable factors are constructed. Next, based on these models, objective functions formulating process optimization problems are defined. Finally, optimization algorithms are applied for finding solutions for these functions. It is important to note that different solutions can be found whenever these algorithms are independently executed if a unique solution does not exist; this may cause confusion for process operators and engineers. This paper proposes a confidence interval (CI)-based process optimization method using second-order polynomial regression analysis. This method evaluates the quality of the different solutions in terms of the lengths of their CIs; these CIs enclose the outputs of the regression models for these solutions. As the CIs... [more]

It is paramount to optimize the performance of a chemical process in order to maximize its yield and productivity and to minimize the production cost and the environmental impact. The various objectives in optimization are often in conflict, and one must determine the best compromise solution usually using a representative model of the process. However, solving first-principle models can be a computationally intensive problem, thus making model-based multi-objective optimization (MOO) a time-consuming task. In this work, a methodology to perform the multi-objective optimization for a two-reactor system for the production of acrylic acid, using artificial neural networks (ANNs) as meta-models, is proposed in an effort to reduce the computational time required to circumscribe the Pareto domain. The performance of the meta-model confirmed good agreement between the experimental data and the model-predicted values of the existent relationships between the eight decision variables and the n... [more]

SuperPro Designer® is a process simulator software used for analyzing the techno-economic feasibility of large-scale bioprocesses. Its predetermined built-in features allow for easy implementation by non-experts, but a lack of examples limits its appropriation. This study aims to validate the implementation of SuperPro Designer® by non-experts for the techno-economic analysis of anaerobic digestion in Colombia, using vinasse as feedstock. These results demonstrate the financial feasibility of such a process when a processing flow rate of 25 m3/h is ensured. Additionally, this study validates the manageability of the tool for assessing the economic feasibility of a technology, a key practice during technology development regardless of the area of expertise.

This paper deals with three-objective optimization, using machine-learning-based surrogate modeling to improve the hydraulic performances of a two-vane pump for wastewater treatment. For analyzing the internal flow field in the pump, steady Reynolds-averaged Navier-Stokes equations were solved with the shear stress transport turbulence model as a turbulence closure model. The radial basis neural network model, which is an artificial neural network, was used as the surrogate model and trained to improve prediction accuracy. Three design variables related to the geometry of blade and volute were selected to optimize concurrently the objective functions with the total head and efficiency of the pump and size of the waste solids. The optimization results obtained by using the model showed highly accurate prediction values, and compared with the reference design, the optimum design provided improved hydraulic performances.

Carbon capture and utilization (CCU) may offer a response to climate change mitigation from major industrial emitters. CCU can turn waste CO2 emissions into valuable products such as chemicals and fuels. Consequently, attention has been paid to petrochemical industries as one of the best options for CCU. The largest industrial CO2 removal monoethanol amine-based plant in Iran has been simulated with the aid of a chemical process simulator, i.e., Aspen HYSYS® v.10. The thermodynamic properties are calculated with the acid gas property package models, which are available in Aspen HYSYS®. The results of simulation are validated by the actual data provided by Kermanshah Petrochemical Industries Co. Results show that there is a good agreement between simulated results and real performance of the plant under different operational conditions. The main parameters such as capture efficiency in percent, the heat consumption in MJ/kg CO2 removed, and the working capacity of the plant are calculat... [more]

The use of seawater desalination technology to solve water shortages in energy- and resource-scarce regions has attracted widespread attention worldwide. In this paper, the performance of a closed-cycle humidification−dehumidification desalination system with a heat pump was experimentally investigated. The system is a closed-cycle system, which includes humidifiers, a heat pump, dehumidifiers, and an air heat exchanger. The heat pump is used by the system to carry energy. The effects of different parameters on the system performance were studied. Scale and economic analyses of the system were conducted to explore the application prospects of the system. The maximum gained output ratio of the system was 4.82. The maximum freshwater production was 960 kg/h, and the cost per kilogram of freshwater was USD 0.03, which are more considerable compared with other systems. This system provides an effective way to save energy in remote areas with energy shortages and freshwater resource shortag... [more]

In this paper, a method based on the partial similarity principle is presented to improve the aerodynamic design with low cost and high accuracy for a 1-1/2 axial compressor. By means of this method, during the process of a similar design, the machine Mach number and flowrate coefficient are maintained. The flow similarity between the prototype and its large-scaled alternative was observed, according to a detailed analysis of flow fields of rotor and stator. As well, the relative discrepancies of isentropic efficiency and pressure ratio between two models are 1.25% and 0.4% at design point, respectively. Besides, their performance curves agreed very well in the whole operating range. Moreover, it was also found that the flow similarity between the two models can be maintained under unsteady working conditions. Thereafter, in order to investigate the impact of stability optimization method on the similarity principle, casing treatment with single circumferential groove was applied to th... [more]

The accompanying model for the paper 'Optimal design and operation of a waste tire feedstock polygeneration system' is presented. The model is written using the GOSSIP software platform and modeling language.

In this study, we constructed a new algorithm to determine the optimal parameters for friction stir welding including rotational speed, welding speed, axial force, tool pin profile, and tool material. The objective of welding is to maximize the ultimate tensile strength of the welded aluminum. The proposed method combines the response surface method and the modified differential evolution algorithm (RSM-MDE). RSM-MDE is a method that involves both experimental and simulation procedures. It is composed of four steps: (1) finding the number of parameters and their levels that affect the efficiency of the friction stir welding, (2) using RSM to formulate the regression model, (3) using the MDE algorithm to find the optimal parameter of the regression model obtained from (2), and (4) verifying the results obtained from step (3). The optimal parameters generated by the RSM-MDE method were a rotation speed of 1417.68 rpm, a welding speed of 60.21 mm/min, an axial force of 8.44 kN, a hexagon-... [more]

Here, we report a successfully modified Czochralski process system by introducing the cooling system and subsequent examination of the results using crystal growth simulation analysis. Two types of cooling system models have been designed, i.e., long type and double type cooling design (LTCD and DTCD) and their production quality of monocrystalline silicon ingot was compared with that of the basic type cooling design (BTCD) system. The designed cooling system improved the uniformity of the temperature gradient in the crystal and resulted in the significant decrease of the thermal stress. Moreover, the silicon monocrystalline ingot growth rate has been enhanced to 18% by using BTCD system. The detailed simulation results have been discussed in the manuscript. The present research demonstrates that the proposed cooling system would stand as a promising technique to be applied in CZ-Si crystal growth with a large size/high pulling rate.