Kombucha is a traditional, fermented beverage made with an essential biomaterial known as SCOBY (symbiotic culture of bacteria and yeast). Three different tea types, namely black, green, and oolong, were compared in kombucha fermentation in terms of pH dynamics, the formation of SCOBY biomass, and the production of acetic acid. The rational, exponential, and polynomial models described pH dynamics with good fit, R2 > 0.98. The formation of SCOBY biomass and the production of acetic acid were modelled using sigmoidal functions, with three-parameter logistic and Gompertz models and four-parameter Boltzmann and Richards models. The F-test indicated that the three-parameter models were statistically adequate; thus, the Gompertz model was modified to present the biological meaning of the parameters. The SCOBY biomass formation rates ranged from 7.323 to 9.980 g/L-day, and the acetic acid production rates ranged from 0.047 to 0.049% acid (wt/vol)/day, with the highest values from the non-con... [more]

Contains 134 original peer-reviewed research articles and 10 extended abstracts submitted to FOCAPD 2024. Subject categories include Invited Plenary and Keynote Submissions, Advances in PSE Design, Design and Emerging Fields, Design and Energy Transitions, Design and Sustainability, and Design Education and Future of Design. The scope is process design as it applies to process systems engineering in chemical engineering, energy systems engineering, and related fields.

At Procter and Gamble, innovation is based on a framework of Irresistible Superiority [1] that utilizes five complementary components – Products, Packages, Communication, Retail Execution, and Value. Increasing-ly, the computational techniques heavily leveraged with-in the Process Systems Engineering community are play-ing a leading role in delivering these five vectors, and they become increasingly valuable as we aim to deliver products in more exploratory consumer spaces – where combining high-volume data, advanced modeling, and quantified uncertainty will allow us to discover and deliv-er better products faster than ever before...

Some educators place an emphasis on the commonalities between engineering mathematics with process control, among others and this helps students see the bigger picture of what is being taught. Traditionally, some of the concepts such as diffusion and heat transfer are taught with a mathematical point of view. Now-a-days, Machine Learning (ML) has emerged as topic of greater interest to both educators and learners and new and disparate modules are sometimes introduced to teach the same. With the emergence of these new topics, some students (falsely) believe that ML is a new field that is somehow different and not linked to engineering mathematics. In this work, we show the link between the different topics from engineering mathematics, that are traditionally taught in UG education, with ML. We hope that educators and learners will appreciate the treatise and think differently, and we further hope that this will further increase the interest to improve ML models.

Equation-oriented (EO) modeling has the potential to enable the effective design and optimization of the operation of advanced energy systems. However, advanced modeling of energy systems results in a large number of variables and non-linear equations, and it can be difficult to search through these to identify the culprit(s) responsible for convergence issues. The Institute for the Design of Advanced Energy Systems Integrated Platform (IDAES-IP) contains a tool to identify poorly scaled constraints and variables by searching for rows and columns of the Jacobian matrix with small L2-norms so they can be rescaled. A further singular value decomposition can be performed to identify degenerate sets of equations and remaining scaling issues. This work presents an EO model of a flowsheet developed for post-combustion carbon capture using a monoethanolamine (MEA) solvent system as a case study. The IDAES diagnostics tools were successfully applied to this flowsheet to identify problems to im... [more]

In this work, we propose a Mixed Integer Nonlinear Programming (MINLP) model to determine the optimal sustainable design of a poly(hydroxyalkanoate)s (PHAs) production plant configuration and its heat exchanger network (HEN). The superstructure-based optimization model considers different carbon sources as raw material: glycerol (crude and purified), corn starch, cassava starch, sugarcane sucrose and sugarcane molasses. The PHA extraction section includes four alternatives: the use of enzymes, solvent, surfactant-NaOCl or surfactant-chelate. Model constraints include detailed capital cost for equipment, mass and energy balances, product specifications and operating bounds on process units. To assess the feasibility of the PHA plant, we considered the Sustainability Net Present Value (SNPV) as the objective function, a multi-criteria sustainability metric that considers economic, environmental and social pillars. The Net Present Value (NPV) was also calculated. SNPV metric provides usef... [more]

The oil and gas energy sector uses billions of gallons of water for hydraulic fracturing each year to extract oil and gas. The water injected into the ground for fracturing along with naturally occurring formation water from the oil wells surfaces back in the form of produced water. Produced water can contain high concentrations of total dissolved solids and is unfit for reuse outside the oil and gas industry without desalination. In semi-arid shale plays, produced water desalination for beneficial reuse could play a crucial role in alleviating water shortages and addressing extreme drought conditions. In this paper we co-optimize the design and operation of desalination technologies along with operational decisions across produced water networks. A multi-period produced water network model with simplified split-fraction-based desalination nodes is developed. Rigorous steady-state desalination mathematical models based on mechanical vapor recompression are developed and embedded at the... [more]

Plastic packaging plays a fundamental role in the food industry, avoiding food waste and facilitating food access. The increasing plastic production and the lack of appropriate plastic waste management technologies represent a threat to the environmental and human welfare. Therefore, there is an urgent need to identify sustainable packaging solutions. Circular economy (CE) promotes reducing waste and increasing recycling practices to achieve sustainability. In this work, we propose a CE framework based on multi-objective optimization, considering both economic and environmental impacts, to identify optimal packaging designs and waste management technologies. Using mixed-integer linear programming (MILP), techno-economic analysis (TEA), and life cycle assessment (LCA), this work aims to build the first steps in packaging design, informing about the best packaging alternatives and the optimal technology or technologies to process packaging waste. For the economic analysis, we consider th... [more]

Modern mechanical recycling infrastructure for plastic is capable of processing only a small subset of waste plastics, reinforcing the need for parallel disposal methods such as landfilling and incineration. Emerging pyrolysis-based chemical technologies can “upcycle” plastic waste into high-value polymer and chemical products and process a broader range of waste plastics. In this work, we study the economic and environmental benefits of deploying an upcycling infrastructure in the continental United States for producing low-density polyethylene (LDPE) and polypropylene (PP) from post-consumer mixed plastic waste. Our analysis aims to determine the market size that the infrastructure can create, the degree of circularity that it can achieve, the prices for waste and derived products it can propagate, and the environmental benefits of diverting plastic waste from landfill and incineration facilities it can produce. We apply a computational framework that integrates techno-economic analy... [more]

Plastics are widely used for their affordability and versatility across many consumer and industrial applications. However, the end-of-life (EoL) management stage can often lead to releasing hazardous chemical additives and degradation products into the environment. The increasing demand for plastics is expected to increase the frequency of material releases throughout the plastic EoL management activities, creating a challenge for policymakers, including ensuring proper material segregation and disposal management and increasing recycling efficiency and material reuse. This research designed a Python-based EoL plastic management tool to support decision-makers in analyzing the holistic impacts of potential plastic waste management policies. The constructed tool was developed to reduce the complexity of material flow analysis calculations, estimating material releases, and environmental impacts. The utility of the tool was tested through the hypothetical nationwide adoption of an exten... [more]

Initial design stages are inherently complex and often lack comprehensive information, posing challenges in evaluating sustainability metrics. Machine Learning (ML) emerges as a valuable solution to address these challenges. ML algorithms, particularly effective in predicting environmental impacts of new chemicals with limited data, enable more informed decisions in sustainable design. This study focuses on employing ML for predicting the environmental impacts related to human health, ecosystem quality, climate change, and resource utilization to aid in early-stage environmental impact assessment of chemical processes. The effectiveness of the ML algorithm, eXtreme Gradient Boosting (XGBoost) tested using a dataset of 350 points, divided into training, testing, and validation sets. The study also includes a practical application of the model in a cradle-to-cradle LCA of N-Methylpyrrolidone (NMP), demonstrating its utility in sustainable chemical process design. This approach signifies... [more]

The transition to net-zero greenhouse gas emissions requires a rapid redesign of energy systems. However, the redesign may shift environmental impacts to other categories than climate change. To assess the sustainability of the resulting impacts, the planetary boundaries framework provides absolute limits for environmental sustainability. This study uses the planetary boundaries framework to assess net-zero sector-coupled energy system designs for absolute environmental sustainability. Considering Germany as a case study, we extend the common focus on climate change in sustainable energy system design to seven additional Earth-system processes crucial for maintaining conditions favorable to human well-being. Our assessment reveals that transitioning to net-zero greenhouse gas emissions reduces many environmental impacts but is not equivalent to sustainability, as all net-zero designs transgress at least one planetary boundary. However, the environmental impacts vary substantially betwe... [more]

Water-gas shift membrane reactors (WGS-MRs) offer a pathway to affordable blue H2 generation/purification from gasified feedstock or reformed fuels. To exploit their cost benefits for blue hydrogen production, WGS-MRs’ performance needs to be optimized, which includes navigating the multidimensional design space (e.g., temperature, feed pressures, space velocity, membrane permeance and selectivity, catalytic performance). This work describes an equation-oriented modeling framework for WGS-MRs in the Pyomo ecosystem, with an emphasis on model scaling and multi-start initialization strategies to facilitate reliable convergence with nonlinear optimization solvers. We demonstrate, through sensitivity analysis, that our model converges rapidly (< 1 CPU second on a laptop computer) under a wide range of operating parameters (e.g., feed pressures of 1-3 MPa, reactor temperatures of 624-824 K, sweep-to-feed ratios of 0-0.5, and steam/carbon ratios of 1-5). Ongoing work includes (1) validat... [more]

Cyclic adsorption processes attain a cyclic-steady state (CSS) condition by undergoing repeated cycles in time, owing to their transient and modular nature. Mathematically, solving a set of underlying nonlinear partial differential equations iteratively for different steps in a cycle until the CSS condition is attained presents a computational challenge, making the simulation and optimization of cyclic adsorption processes time-consuming. This paper focuses on expediting the CSS convergence in adsorption process simulations by implementing two vector-based acceleration methods that offer quadratic convergence akin to Newton’s methods. These methods are straightforward to implement, requiring no prior knowledge of the first derivatives (or Jacobian). The study demonstrates the efficacy of accelerated convergence by considering two adsorption processes that exhibit complex dynamics, namely, a four-step vacuum swing adsorption and a six-step temperature swing adsorption cycles for post-co... [more]

Maintaining product integrity in multi-product oil pipelines is crucial for efficiency and profit. This study presents a strategy combining design and process improvement to enhance flushing protocols, addressing the challenge of residual batch contamination. A pilot plant, mirroring industrial operations through dimensionless residence time distribution, was developed to identify and rectify bottlenecks during product transition. The pilot plant’s success in replicating industrial operations paves the way for targeted experiments and modelling to enhance optimized flushing, ensuring product quality and operational excellence.

Sustainability and circular economy enclose initiatives to achieve economic systems and industrial value chains by improving resource use, productivity, reuse, recycling, pollution prevention, and minimizing disposed material. However, shifting from the traditional linear economic production system to a circular economy is challenging. One of the most significant hurdles is the absence of sustainable end-of-life (EoL)/manufacturing loops for recycling and recovering material while minimizing negative impacts on human health and the environment. Overcoming these challenges is critical in returning materials to upstream life cycle stage facilities such as manufacturing. Chemical flow analysis (CFA), sustainability evaluation, and process systems engineering (PSE) can supply chemical products and processes performances from environmental, economic, material efficiency, energy footprint, and technology perspectives. These holistic evaluation techniques can improve productivity, source mate... [more]

This work presents an overview of the path towards the use of renewable and nonconventional resources for a sustainable chemical and process industry. The aim is not only to lead the way to meet the sustainable development goals but also to maintain the style and quality of life achieved by the technologies and products developed within this sector. Alternative raw materials are to be used and processed differently while a new paradigm for utilities is to be established. The development of technologies and their deployment faces several barriers that we as process engineers can help overcome by providing insight into the alternatives, the thresholds to achieve to become competitive, and strategic analyses.

The piloted and the spontaneous ignition of low and high molecular weight (LMW and HMW) polymethyl methacrylate are simulated using a one-dimensional condensed-gas phase model for constant heat fluxes in the range of 25−150 kW/m2. Purely thermal (nitrogen) and thermo-oxidative (air) decomposition is considered, described by a single and four-step kinetics for the low and high molecular weight polymer, respectively. Different optical properties are also examined. The same trends of the ignition time and other ignition parameters are always observed. Due to a more significant role of the chemical kinetics, the effects of the sample molecular weight and reaction atmosphere are higher at low heat fluxes. Times are shorter for the black HMW samples and thermo-oxidative kinetics. For piloted ignition, factors are around 2.8−1.6, whereas for thermal decomposition, they are 1.3−1.2. The corresponding figures are 1.8−1.3 and 1.3−1.1, in the same order, for the spontaneous ignition. Overall, the... [more]

This paper researches the heat transfer equation and thermal balance equation of a shell-and-tube evaporator; constructs an accurate mathematical model for the evaporator; and derives equations including detailed and accurate calculation methods for all heat transfer coefficients, such as the refrigerant side heat transfer coefficient, water side heat transfer coefficient, refrigerant kinematic viscosity, density, and specific enthalpy. Adopting this approach involves fitting the relationships between the density, thermal conductivity, kinematic viscosity, and enthalpy of R134a refrigerants in saturated vapor and liquid states. The relationships between superheated gas enthalpy, density, and temperature were also assessed, and heat transfer coefficients were obtained through calculation methods and microelement heat transfer relationships in both the single-phase and two-phase zones, matching empirical formulas concerning the relationship between superheated enthalpy and temperature. N... [more]

This study examined the convective drying of red cabbage at temperatures ranging from 50 to 90 °C. Mathematical modeling was used to describe isotherms, drying kinetics and rehydration process. The effects of drying conditions on energy consumption and microstructure were also evaluated. The Halsey model had the best fit to the isotherm data and the equilibrium moisture was determined to be 0.0672, 0.0490, 0 0.0379, 0.0324 and 0.0279 g water/g d.m. at 50, 60, 70, 80 and 90 °C, respectively. Drying kinetics were described most accurately by the Midilli and Kuçuk model. Also, the diffusion coefficient values increased with drying temperature. Lower energy consumption was found for drying at 90 °C and the rehydration process was best described by the Weibull model. Samples dehydrated at 90 °C showed high water holding capacity and better maintenance of microstructure. These results could be used to foster a sustainable drying process for red cabbage.

The current research trend is not only focused on advanced techniques to intensify the extraction of bioactive compounds from plants, but also on the optimization process. The objective of this work was the implementation of the multiple criteria analysis using navigation on Pareto sets to determine the optimal parameters for the microwave-assisted extraction of Levisticum officinale WDJ Koch roots in order to obtain the maximum efficiency of the antioxidant potential of the extracts. The optimized parameters were extraction time, microwave power, and plant biomass/solvent ratio, while the evaluation criteria were based on the total phenols, flavonoids, reducing sugars, and antioxidant capacity. It was shown that the process parameters analyzed, i.e., biomass/solvent ratio, process time, and microwave power, determined the extraction efficiency of total phenolic content (TPC). A different observation was made for the analysis of total flavonoid content (TFC) and total antioxidant poten... [more]

The overarching goal of limiting the increase in global temperature to ≤ 2.0˚ C likely requires both decarbonization and defossilization efforts. Direct air capture (DAC) and CO2 electrolysis stand out as promising technologies for capturing and utilizing atmospheric CO2. In this effort, we explore the details of designing and operating an integrated DAC-electrolysis process by examining some key parameters for economic feasibility. We evaluate the gross profit and net income to find the most appropriate capacity factor, average electricity price, syngas sale price, and CO2 taxes. Additionally, we study an optimistic scenario of CO2 electrolysis and perform a sensitivity analysis of the CO2 capture price to elucidate the impact of design decisions on the economic feasibility. Our findings underscore the necessity of design improvements of the CO2 electrolysis and DAC processes to achieve reasonable capacity factor and average electricity price limits. Notably, CO2 taxes and tax credits... [more]

The present work studies the convective drying of a granular porous medium in a bed of olive pomace. The experimental tests were conducted in a closed convection drying loop of hot air. The experimental tests measured the mass loss over time. Tests were carried out for five temperature values: 60 ± 0.1 °C, 70 ± 0.1 °C, 80 ± 0.1 °C, 90 ± 0.1 °C and 100 ± 0.1 °C, respectively. Moreover, three values of velocities of the drying air, 1 ± 0.01 ms−1, 1.5 ± 0.01 ms−1 and 2 ± 0.01 ms−1, were considered. The effects of initial humidity, bed thickness and pomace composition on the drying process were studied. The results show that the moisture content decreases when the temperature and the velocity of the drying air increase. In addition, the composition of olive pomace (pulp, pits and raw pomace) significantly affects the drying time. A characteristic drying curve and its equation were determined. Seven thin layer drying models were tested, and the Midilli et al.’s model produced the best agree... [more]

A semi-analytical approach is developed for predicting pyrolysis front temperature in a charring solid undergoing thermal decomposition. The pre-reaction heating stage is described using an analytical formulation and invoking the concept of thermal penetration depth. The solution for the solid conversion stage accounts for decomposition enthalpy, the convective flow of volatiles, and a reaction front characterized by a uniform temperature that progresses toward the inner layers. This method incorporates empirical relations into the analytical model. Two scenarios are considered. First, the solution of the pyrolysis model combined with the data of conversion time versus external heat flux leads to an algebraic expression that reveals the existence of a maximum pyrolysis-front temperature. Explicit relations are derived for both the extremum pyrolysis temperature and optimum applied heat flux. In the second case, an expression is derived for the ignition temperature of a solid fuel (e.g.... [more]

Nanofiltration is well suited to separate monovalent ions from multivalent ions, such as the separation of Li+ and Mg2+ from seawater, a potential lithium source for the production of lithium-ion batteries. To the best of our knowledge, there is no existing work on the optimization of a multi-stage membrane plant that differentiates between different ions and that is based on a validated transport model. This study presents a method for modeling predefined membrane interconnections using discretization along the membrane length and across the membrane thickness. The solution-diffusion−electromigration model was used as the transport model in a fundamental membrane flowsheet, and the model was employed to optimize a given flowsheet with a flexible objective function. The methodology was evaluated for three distinct separation tasks, and optimized operating points were found. These show that permeances and feed concentrations might cause negative rejections and positive rejections (espec... [more]