The overarching goal of process design (Figure 1) is to find technologically feasible, operable, economically attractive, safe and sustainable processing pathways and process configurations with specifications for the connectivity and design of unit operations that perform a set of tasks using selected functional materials (e.g., catalysts, solvents, sorbents, etc.) to convert a set of feed-stocks or raw materials into a set of products with desired quality at a scale that satisfies the demand. Process synthesis and integration can further screen, optimize and improve these pathways for given techno-econo-environmental targets or objectives. These objectives may include, but are not limited to, minimizing the overall investment and processing costs, minimizing the energy consumption, minimizing the emissions or wastes, maxim-zing the profit, and enhancing the safety, operability, controllability, flexibility, circularity, and sustainability, among others... (ABSTRACT ABBREVIATED)

As a promising electricity storage system, Liquid Air Energy Storage (LAES) has the main advantage of being geographically unconstrained. LAES has a considerable potential in energy efficiency improvement by utilizing compression heat and integrating with other systems. In this work, the Stirling Engine (SE) is introduced to improve the energy efficiency of the LAES system. Three LAES-SE systems are modelled in Aspen HYSYS and optimized by the Particle Swarm Optimization (PSO) algorithm. The studied systems include (i) the LAES system with 3 compressors and 3 expanders (3C+3E) using an SE to recover the compression heat, (ii) the 3C+3E LAES system with LNG regasification and SE, and (iii) the 3C+3E LAES system with solar energy and SE. The optimization results show that the Round-Trip Efficiencies (RTEs) of the LAES-SE system and the LNG-LAES-SE systems are 68.2% and 73.7%, which are 3.2% and 8.7% points higher than the basic 3C+3E LAES-ORC system with an RTE of 65.0%. For the Solar-LA... [more]

Thermal separation processes, such as distillation, play a pivotal role in the chemical and petrochemical sectors, constituting a substantial portion of the industrial energy consumption. Consequently, owing to their huge application scales, these processes contribute significantly to greenhouse gas (GHG) emissions. Decarbonizing distillation units could mitigate carbon emissions substantially. Heat Pumps (HP), that recycle lower quality heat from the condenser to the reboiler by electric work present a unique opportunity to electrify distillation systems. In this research we try to answer the following question in the context of multi-component distillation – Do HPs actually reduce the effective fuel consumption or just merely shift the fuel demand from chemical industry to the power plant? If they do, what strategies consume minimum energy? To address these inquiries, we construct various simplified surrogate and shortcut models designed to effectively encapsulate the fundamental phy... [more]

A novel process system which integrates an isopropanol-based chemical heat pump with a post-combustion carbon capture unit was proposed, designed, and analyzed. The system uses low-quality waste heat (~80°C) produced through the CO2 adsorption step of a carbon capture process and upgrades that heat to a higher temperature (~150°C) using the chemical heat pump. The chemical heat pump is powered mostly by the waste heat and requires only a small amount of electricity. The higher temperature heat produced can be used in the desorption stage of the CO2 capture process, displacing a portion of the existing fossil energy required. The energy and exergy performance characteristics of the chemical heat pump were computed using the results of a steady state simulation in a systems analysis. Using exergy cost correlations, the profitability of the chemical heat pump concept was estimated. It was found that for this particular configuration, the fossil energy load of desorption could be reduced b... [more]

In July 2023, the International Maritime Organization (IMO) presented an updated strategy for decarbonizing maritime transport and achieving net-zero greenhouse gas emissions by 2050. It is therefore imperative to explore innovative solutions to achieve a blue economy and maximize energy efficiency on-board ships. For this reason, the current study aims to integrate the organic Rankine cycle (ORC) and thermoelectric generator (TEG) on board a container ship to generate electrical energy and reduce fuel consumption. The combined system will benefit from the waste heat of a marine diesel engine installed on board. The current study uses R245fa as the organic liquid and analyzes the effects of varying the evaporation pressure on the energetic and economic performance indicators by modeling the combined system in Engineering Equation Solver (EES) software. The results show that the energy efficiency of the ORC system increases from 12.3% at 3.5 bar to 17.3% at 8 bar. In comparison, the ene... [more]

This study aims to enhance energy efficiency by reducing parasitic losses in the engine cooling system through a new drive strategy involving a two-stage water pump and a variable electro-fan. The fuel consumption gain analysis focused on a vehicle with average characteristics typical of 1.0L hatchbacks in the Brazilian market and urban driving conditions. The methodology implemented aims to minimize power absorbed by the forced water circulation and thermal rejection, thereby reducing parasitic losses, particularly during low-speed urban driving, without causing air-side heat exchanger saturation. The results show a potential decrease of up to 80% in power absorbed by the cooling system, leading to an estimated fuel consumption saving of approximately 1.4% during urban driving cycles.

In engineering, cost minimization, especially in Computer Numerical Control (CNC) machining like pocket milling, is crucial. Existing tool path definition software often lacks optimization, particularly at critical starting and ending points. This study optimizes CNC machine tool paths for energy-efficient multi-pocket milling, utilizing the Symbolic Discrete Control Synthesis (SDCS) method for formal correctness. In our work, the tool path generation is formulated as a traveling salesman problem. We introduce a modeling framework to adapt SDCS to multi-pocket-milling processes, aiming to enhance precision and efficiency for potential cost savings, including energy and time, in engineering applications. This study reports experimental and comparative results, where comparative evaluations were made using metaheuristic algorithms. Our proposed approach improves CNC machining processes for multi-pocket milling. We experimentally evaluate our control algorithms and demonstrate and validat... [more]

This study explores the existing literature on specific energy consumption (SEC) use for paddy drying and consolidates all relevant data for comparisons across technologies. Energy consumption data for a range of drying technologies are consolidated from published literature and normalized to enable comparison. A large proportion of the source data are generated from operational performance in industrial or laboratory settings, while the remainder is derived from computer simulations. The SEC of paddy drying is driven primarily by technology type; however, operational factors (such as the system size, temperature, and airflow) and external factors (such as the local climate and paddy moisture content) also heavily influence system energy use. The results of our analysis show that the industrial drying technologies explored in this study have an average SEC of 5.57 ± 2.21 MJ/kg, significantly lower than the 20.87 ± 14.97 MJ/kg observed in a laboratory setting, which can potentially be a... [more]

Nitrogen fixation, the conversion of atmospheric nitrogen into biologically useful compounds, is crucial for sustaining biological processes and industrial productivity. Recent advances have explored plasma-assisted processes as an innovative approach to facilitate nitrogen fixation. This review offers a comprehensive summary of the development, current state of the art, and potential future applications of plasma-based nitrogen fixation. The analysis encompasses fundamental principles, mechanisms, advantages, challenges, and prospects associated with plasma-induced nitrogen fixation.

Industrial process heating furnace operations consume considerable energy in the U.S. manufacturing sector, making it crucial to identify energy efficient strategies due to the growing need to minimize energy usage and emissions. It is important to identify the potential impact of these factors to enable process engineers to operate process heating systems at the maximum possible efficiency. This study examines and identifies the key impact factors that influence the efficiency of process heating systems using MEASUR (v1.4.0), the DOE software tools such as the insulation effectiveness, the burner stoichiometry, cooling medium, thermal storage, and atmospheric gases. Data from a two-fuel-fired heat treatment furnace and an electric arc furnace (EAF) for steelmaking were employed to establish the baseline heat balance models in MEASUR. The fractional factorial design experiment was developed with two-level parameter values and energy efficiency strategies for the heat input into industr... [more]

Despite renewable energy source integration being a well-established requirement in international policies, energy systems still face some unresolved issues, including the intermittence of production. To tackle this problem, a viable solution could comprise the off-peak storage of electricity production excess, to be consumed later during peak-load hours. The transition from the diffuse pattern of centralized generation to the distributed model, involving energy communities, suggests an additional aspect to manage: the spatial constraints of systems for domestic applications. Compressed-air energy storage represents a promising Power-to-Power technology for small-scale energy integration. This study proposes the application of a gas−liquid energy storage system (GLES) in a residential building, using renewable energy excess from a photovoltaic (PV) array. The performance of the proposed system, whose operation involves the compression of the gaseous mass through a piston operated by mi... [more]

In the contemporary era, conventional energy sources like oil, coal, and natural gas overwhelmingly contribute 89.6% to global CO2 emissions, intensifying environmental challenges. Recognizing the urgency of addressing climate concerns, a pivotal shift towards renewable energy, encompassing solar, wind, and biofuels, is crucial for bolstering environmental sustainability. Bioethanol, a globally predominant biofuel, offers a versatile solution, replacing gasoline or integrating into gasoline−ethanol blends while serving as a fundamental building block for various valuable compounds. This review investigates the dynamic landscape of biomass generations, drawing insightful comparisons between the first, second, third, and fourth generations. Amid the drive for sustainability, the deliberate focus on the initial generation of biomass, particularly corn, in bioethanol production is grounded in the current dependence on edible crops. The established utilization of first-generation biomass, e... [more]

Industrial manufacturing processes have evolved and improved since the disruption of the Industry 4.0 paradigm, while energy has progressively become a strategic resource required to maintain industrial competitiveness while maximizing quality and minimizing environmental impacts. In this context of global changes leading to social and economic impact in the short term and an unprecedented climate crisis, Digital Twins for Energy Efficiency in manufacturing processes provide companies with a tool to address this complex situation. Nevertheless, already existing Digital Twins applied for energy efficiency in a manufacturing process lack a flexible structure that easily replicates the real behavior of consuming machines while integrating it in complex upper-level environments. This paper presents a combined multi-paradigm approach to industrial process modeling developed and applied during the GENERTWIN project. The tool allows users to predict energy consumption and costs and, at the sa... [more]

The research presented aimed to address the treatment of fluid waste with significant environmental impact by utilizing plasma technology, specifically plasma arc flow (PAF). The goal was to develop a novel purification material based on graphene for industrial applications and to optimize the treatment process. Analysis and monitoring of a submerged arc plasma reactor were the main goals of this research. This entailed a careful examination of the incoming wastewater that needed to be treated with the goal of identifying its precise composition characteristics with the relative tolerances needed for the reactions that were to follow in the reactor. The focus of the analysis was on input-parameter optimization, production of characteristic curves, and analysis of the factors affecting hydrogen evolution in syngas. Additionally, the study investigated how to determine the best viscosity for a particular input matrix by carrying out an evaluation study. The effects of this parameter were... [more]

The paper presents an innovative concept of the fluidization of an adsorption bed carried out under low-pressure conditions. Additionally, different bed mixes were used to test the effects of the bed composition on fluidization. Fluidization was caused by the pressure difference and the velocity of the flowing water vapor. These features make the research presented in this article significantly different from other studies known in the literature and constitute the main novelty of the paper. Silica gel with a particle diameter of 200−250 µm (Geldart group B) with aluminum and carbon nanotube additives was fluidized under reduced pressure (10−25 mbar). The pressure difference results in the flow of water vapor and, consequently, induces fluidization. The pressure in the evaporator was approx. 10 mbar, while in the reaction chamber it was approx. 25 mbar. The pressure difference of about 10−15 mbar allows for a flow of water vapor between the evaporator and the reaction chamber. During t... [more]

This study aims to investigate the impact of ICT capital services on economic growth and energy efficiency in China at both national and industrial levels during the period 2000−2020. To achieve this aim, this study introduces a measurement method for capital services, explores ICT’s contributions to economic growth, and analyzes the impact of ICT on energy efficiency. The empirical results of this study indicate that although the ICT capital services scale is relatively small, accounting for only 8.87% of the total in 2020, its growth rate is faster than that of non-ICT capital services, and the distribution of ICT capital services varies widely among different industries. Additionally, based on the economic growth decomposition framework, this study finds that the contribution of ICT capital services to economic growth is 6.95% on average. It is significantly higher in certain industries, such as Financial industry; Information transmission, software and information technology servic... [more]

The environmental factors of greenhouses affect crop growth greatly and are mutually coupled and spatially distributed. Due to the complexity of greenhouse climate modeling, the current optimal control of greenhouse crop growth rarely considers the spatial distribution issues of environmental parameters. Proper Orthogonal Decomposition (POD) is a technique to reduce the order of a model by projecting it onto an orthogonal basis. In this paper, POD is used to extract environmental features from Computational Fluid Dynamics (CFD) simulations, and a low-dimensional feature subspace is obtained by energy truncation. With multi-dimensional interpolation, fast and low-dimensional reconstruction of the dynamic variation of greenhouse climates is achieved. On this basis, a rolling-horizon optimal control scheme is proposed. For each finite horizon, the external meteorological data are updated, and the response of the greenhouse environment is quickly calculated by the POD model. With the perfo... [more]

Effective implementation of renewable energy sources (RES) is one of the main challenges in regard to the organization of local energy microgrids with buildings. One of the solutions is the use of dynamic building façades with photovoltaic (PV) panels, in particular the innovative perovskite solar cells (PSCs). This paper describes a case study performed on a pilot installation of perovskite PV panels located in Poland, Central-Eastern Europe. Results of preliminary measurements on this installation are provided in terms of verifying its energy efficiency and the possibility of selecting settings for the façade dynamics control system. Our experiments have considered the sun-tracking mechanism and its energy consumption as well as the impact of weather conditions at different times of the year. The energy efficiency results for the PV system, with average levels below 10%, are rather low. Therefore, even small energy savings in the operation of the PV system itself are significant. Cha... [more]

This paper applied the advocacy coalition framework to explore and explain the political processes creating policies to enhance energy efficiency of European Union (EU) industry. The paper used legislation on energy audits and energy management systems as a proxy for EU policy on energy efficiency in industry. Based on qualitative text analysis of EU policy documents, including a proposal to recast the energy efficiency directive, amendments to the proposal suggested by Member States, the Council and the European Parliament, and reports from negotiations, the paper identified four advocacy coalitions with different core beliefs, spanning from those that want few companies to implement energy audits or energy management systems, and that recommendations from audits should not be mandatory to implement, to those that advocate that many companies implement energy audits and management systems and that it should be mandatory to implement measures recommended in audits. It was further found... [more]

Promoting energy efficiency is a key element of the strategic commitment of the European Community. Prominent among the binding measures established by the 2012 Energy Efficiency Directive to further this vision is the requirement for large companies to conduct energy audits every four years. After receiving the second cycle of energy audit reports in December 2019, a new description of the energy situation of Italian companies was made available. This presented the previously inaccessible possibility of comparing the two situations reported in 2015 and 2019 to assess the development of energy efficiency practices in organizations subject to the legislative obligation of energy audits in the country. To this end, in collaboration with the Italian National Agency for New Technologies, Energy and Sustainable Economic Development (ENEA), a project was initiated with the aim of developing the tools and methodologies necessary to assess in more detail the evolution that has occurred in the... [more]

In order to achieve China’s carbon peaking and carbon neutrality (double carbon) targets and to advance ecological conservation and high-quality development in the Yellow River Basin, it is essential that China reduces its energy intensity and increases its energy efficiency. This research developed an evaluation index system for energy efficiency and green development in the Yellow River Basin based on panel data collected from 64 of its prefecture-level cities and covering the period from 2011 to 2020. Each city’s energy efficiency and green development level index was calculated, and was analyzed together with the characteristics of its spatial pattern progression. The STIRPAT model was then used to investigate the influence mechanism of energy efficiency on green development. The final step in the analysis was to assess the process by which technical innovation influences the rise in energy efficiency from a green development point of view. The findings of this study indicate that:... [more]

In light of energy and climate targets, free cooling unlocks a major resource-saving potential compared to refrigeration. To fill the knowledge gap in quantifying this saving potential, we aim to specify the physical and technical limits of cooling tower applications and provide comprehensive data on electricity and water consumption. For this purpose, we distinguish six types of package-type cooling towers: dry, closed wet, open wet, and three types of hybrid systems; defining one generalized system for all types enables comparability. Subsequently, we collect data from 6730 system models of 27 manufacturers, using technical information from data sheets and additional material. The analysis reveals, for example, specific ranges of electricity demand from 0.01 to 0.06 kW/kW and highlights influencing factors, including type and operating point. Refrigeration systems would consume approximately ten times more electricity per cooling capacity. Furthermore, the evaluation demonstrates the... [more]

The petrochemical industry is a pillar industry for the development of the national economy affecting people’s daily living standards. Crude distillation process is the core and leading unit of the petrochemical industry. Its energy consumption accounts for more than 20% of the total energy consumption of the whole plant, which is the highest energy consumption link. A model based on the long short-term memory network (LSTM) is proposed in this paper to predict and analyze energy efficiency. This model extracts the complex relationship between many process variables and predicts the energy efficiency of the crude distillation process. Firstly, the process simulation of crude distillation is carried out. By adding random disturbance, the data set in different working conditions is obtained, and the difference between the working conditions is expressed with the distance-coded heat map. Secondly, the Savitzky−Golay (SG) filter is used to smooth the data, which preserves the original char... [more]

The growing attention towards environmental sustainability in the pharmaceutical industry and increased awareness of the potential for improving energy performance are justified by the fact that the sector is energy intensive. However, the variety of the processes and the lack of data about production and energy consumption make it difficult to calculate Energy Performance Indicators (EnPIs) as much as to list Energy Performance Improvements Actions (EPIAs). This work elaborates data, such as final energy consumption and site characteristics, from 84 mandatory Italian Energy Audits (EAs) to calculate the mean and standard deviation of site-level EnPIs. Additionally, the suggested and implemented EPIAs are analyzed to describe achieved and potential savings. The results show what follows. In the typical pharmaceutical plant, around 70% of energy is used in auxiliary services, and its use is not related to production. For this reason, EnPIs calculated both with respect to mass production... [more]

The ERTMS/ETCS is the newest automatic train protection system. This is a system that supports the driver in driving the train. It is currently being implemented throughout the European Union. This system’s latest specifications also provide additional functions to increase the energy efficiency of train driving in the form of ATO (automatic train operation). These functions of the ETCS will be valuable, provided they operate without failure. To achieve errorless configuration of the ETCS, a methodology for automatic system verification using the IMDS (Integrated Model of Distributed Systems) formalism and the temporal tool Dedan was applied. The main contribution is asynchronous and timed verification, which appropriately models the distributed nature of the ETCS and allows the designer not only to analyze time dependencies but also to define the range of train velocities in which the operational scenario is valid. Additionally, the novelties of the presented verification methodology... [more]