A conceptual design of an industrial production plant for activated carbon was developed to process 31.25 tons/day of industrial waste nutshells as the raw material and produce 6.6 ton/day of activated carbon using steam as an activation agent. The design considered the cost of the main equipment, the purchase price of the nutshells, basic services, and operation. A sensitivity analysis was developed, considering the price of the finished product and the volume of raw material processing varied up to ±25%. Furthermore, the total annual cost of the product was determined based on the production of 2100 tons/year of activated carbon. Two cash flows were developed and projected to periods of 10 years and 15 years of production, using a tax rate of 27%, a low discount rate (LDR) of 10% per year, and without external financing. For a 10-year production project, the net present value (NPV) was USD 2,785,624, the internal return rate (IRR) 21%, the return on investment (ROI) 25%, and the disc... [more]

To solve the problems of high specific energy consumption and excessive harmful ions in the water production of a small reverse osmosis (RO) plant, a desalination system coupling RO and membrane capacitive deionization (MCDI) is proposed in this study. Aiming at producing two cubic meters per day of fresh water with a salt concentration of less than 280 mg L−1, parameter matching optimization was carried out on two desalination system schemes of one-stage two-section RO and one-stage three-section RO coupled with MCDI. The results were compared with the parameter matching optimization results of the one-stage one-section RO and the one-stage two-section pure RO desalination system. The results show that compared with the pure RO desalination mode, the seawater desalination mode coupled with RO and MCDI reduces the specific energy consumption under the same effluent salt concentration. Moreover, it decreases the feed water pressure in front of the RO membrane, which can reduce the stand... [more]

The rheological characterization of fluids using a rheometer is an essential task in food processing, materials, healthcare or even industrial engineering; in some cases, the high cost of a rheometer and the issues related to the possibility of developing both electrorheological and magnetorheological tests in the same instrument have to be overcome. With that in mind, this study designed and constructed a low-cost rotational rheometer with the capacity to adapt to electro- and magneto-rheological tests. The design team used the method of continuous improvement through Quality Function Deployment (QFD) and risk analysis tools such as Failure Mode and Effect Analysis (FMEA) and Finite Element Analysis (FEA). These analyses were prepared in order to meet the customer’s needs and engineering requirements. In addition to the above, a manufacturing control based on process sheets was used, leading to the construction of a functional rheometer with a cost of USD $1500.

A new spray-drying system has been designed to overcome the limitations caused by existing designs. A key feature of the approach has been the systematic use of Computational Fluid Dynamics (CFD) to guide innovation in the design process. An example of an innovation is the development of a box-shaped transitional feature between the bottom of the main drying chamber and the entrance to the secondary chamber. In physical experiments, the box design performed better in all three representative operating conditions, including the current conditions, a higher feed solids concentration (30% solids rather than 8.8%), and a higher inlet drying temperature (230 °C rather than 170 °C). The current conditions showed a 3% increase in yield (solids recovery) while the 30% feed condition improved the yield by 7.5%, and the higher temperature test increased the yield by 13.5%. Statistical analysis showed that there were significant reductions in the wall flux at the high solids feed concentration. T... [more]

This paper deals with the scale-up of equipment for the mixing of suspensions. The measurement of just-suspended agitator speeds was carried out with standard, pitched, four-blade turbines and folded, four-blade turbines in three vessels (290 mm, 600 mm, and 800 mm in diameter) for several particle sizes and concentrations. The results of measurements confirmed that scale-up based on dimensionless Froude number dependence, on the relative particle size and concentration, can be used. On the basis of the results, a scale-up rule for agitator speeds in a given suspension and equipment geometry was recommended, and various conclusions reported by different investigators were discussed.

The spanwise distribution of impeller exit circulation (SDIEC) has a significant effect on the impeller performance, therefore, there is a need for its consideration in the optimization design of mixed-flow pumps. In this study, a combination optimization system, including a 3D inverse design method (IDM), computational fluid dynamics (CFD), Latin hypercube sampling (LHS) method, response surface model (RSM), and non-dominated sorting genetic algorithm (NSGA-Ⅱ) was used to improve the performance of the mixed-flow pump after considering the effect of SDIEC on the performance of the impeller. The CFD results confirm the accuracy and credibility of the optimization results because of the good agreement the CFD results established with the experimental measurements. Compared with the original impeller, the pump efficiency of the preferred impeller at 0.8Qdes, 1.0Qdes, and 1.2Qdes improved by 0.63%, 3.39%, and 3.77% respectively. The low-pressure region on the blade surface reduced by 96.9... [more]

Compared with the waste-to-heat and electricity-based hybrid refrigeration system, the innovative lab-scale refrigeration system integrated with the DC and AC cooling units that able to use solar and electricity as energy resources. Previous studies found that temperature control and uniform temperature distribution in refrigeration systems are both critical factors reducing vibrio growth on raw oysters and saving energy consumption. Therefore, this refrigeration system also equipped a specially designed divider and was used to test various air circulation strategies to achieve uniform temperature distribution in six individual compartments. The objective is to investigate and evaluate the effects of air circulation strategies and operating conditions on the cooling performance, including temperature distribution, standard deviation of compartment temperatures, and cooling time using a factorial design method. Results indicated the maximum temperature difference between the compartment... [more]

A classification method is proposed to classify dividing walls into 5 types. Each type of dividing wall has its unique structural characteristics which impact its total vapor duty, construction complexity and controllability. Based on this classification, a comprehensive guideline to draw optimal dividing wall columns for any n-component distillation is provided.

Traditional extraction processes of natural product are widespread, especially in regulated industries. Possibilities of extraction development and manufacturing optimization in regulated industries is limited. Regulatory approvals are often based on traditional preparations of phyto-pharmaceuticals. The dependence on traditional processes can result in sub-optimal extraction parameters causing unnecessary costs and product variability. Innovative methods like Quality-by-Design (QbD), including process analytical technology (PAT), open opportunities for manufacturers to cope with regulatory demanded, narrow batch-to-batch variability. In addition, such validated process models represent perfect digital twins which could be utilized for advanced process control and life cycle analysis.

Hydrodesulfurization (HDS) has been commercially employed for the production of ultra-low sulfur fuel oil. However, HDS is unable to remove sterically hindered sulfur-containing compounds such as dibenzothiophene (DBT) and benzothiophene (BT). An alternative way to remove sulfur is via extractive desulfurization system (EDS) using deep eutectic solvents (DES) as sustainable extractant. In this work, liquid polymer DES was synthesized using tetrabutylammonium chloride (TBAC) and poly(ethylene glycol) 400 (PEG) with different molar ratios. Response surface methodology (RSM) was applied to study the effect of independent variables toward extraction efficiency (EE). Three significant operating parameters, temperature (25−70 °C), DES molar ratio (1−3), and DES volume ratio (0.2−2.0), were varied to study the EE of sulfur from model oil. A quadratic model was selected based on the fit summary test, revealing that the extraction efficiency was greatly influenced by the amount of DES used, fol... [more]

In this study, the response surface methodology (RSM) and desirability function (DF) were utilized to optimize the recycling conditions of aluminum (AA6061) chips, in the presence of particulate alumina (Al2O3), to obtain a metal matrix composite of recycled aluminum (MMC-AlR) using hot press forging processes. The effects of temperature (430−530 °C) and holding time (60−120 min) were investigated. The introduction of 2.0 wt. % of Al2O3 to the aluminum matrix was based on preliminary research and some pilot tests. This study employed the 2k factorial design of experiments that should satisfy the operating temperatures (T) of 430 °C and 530 °C with holding times (t) of 60 min and 120 min. The central composite design (CCD) was utilized for RSM with the axial and center point to evaluate the responses to the ultimate tensile strength (UTS), elongation to failure (ETF), and microhardness (MH). Based on RSM, with the desirability of 97.6%, the significant parameters T = 530 °C and t = 120... [more]

Electrolyzed water (EW) shows great potential as a green and economical sanitation solution for the food industry. However, only limited studies have investigated the optimum electrolysis parameters and the bactericidal effect of acidic electrolyzed water (AcEW) and alkaline electrolyzed water (AlEW). Here, the Box−Behnken experimental design was used to identify the optimum parameters. The tests were conducted with different types of electrodes, electrical voltages, electrolysis times, and NaCl concentrations. There were no obvious differences observed in the physico-chemical properties of EW when different electrodes were used. However, stainless steel was chosen as it meets most of the selection criteria. The best-optimized conditions for AcEW were at 11.39 V, 0.65 wt.% NaCl, and 7.23 min, while the best-optimized conditions for AlEW were at 10.32 V, 0.6 wt.% NaCl, and 7.49 min. The performance of the optimum EW (AcEW and AlEW) compared with commercial cleaning detergents for the fo... [more]

Nanoparticle-based therapeutics have been used in pulmonary formulations to enhance delivery of poorly water-soluble drugs, protect drugs against degradation and achieve modified release and drug targeting. This review focuses on the use of spray drying as a solidification technique to produce microparticles containing nanoparticles (i.e., nanoparticle (NP) agglomerates) with suitable properties as dry powders for inhalation. The review covers the general aspects of pulmonary drug delivery with emphasis on nanoparticle-based dry powders for inhalation and the principles of spray drying as a method for the conversion of nanosuspensions to microparticles. The production and therapeutic applications of the following types of NP agglomerates are presented: nanoporous microparticles, nanocrystalline agglomerates, lipid-based and polymeric formulations. The use of alternative spray-drying techniques, namely nano spray drying, and supercritical CO2-assisted spray drying is also discussed as a... [more]

A comprehensive energy and exergoeconomic analysis of a novel transcritical refrigeration cycle (NTRC) is presented. A second ejector is introduced into the conventional refrigeration system for the utilization of the gas-cooler waste heat. The thermodynamic properties of the working fluid are estimated by the database of REFPROP 9, and a FORTRAN program is used to solve the system governing equations. Exergy, energy, and exergoeconomic analyses of the two cycles are carried out to predict the exergetic destruction rate and efficiency of the systems. The optimum gas cooler working pressure will be determined for both cycles. A comprehensive comparison is made between the obtained results of the conventional and the new cycles. An enhancement of approximately 30% in the coefficient of performance (COP) of the new cycle was found in comparison to the value of the conventional cycle. In addition, the results of the analysis indicated a reduction in the overall exergy destruction rate and... [more]

Up-flow Anaerobic Sludge Blanket (UASB) reactors are popular tools in wastewater treatment systems due to the ability to work with high feed rates and wastes with high concentration of organic contaminants. While full-scale industrial applications of UASB reactors are developed and described in the available literature, laboratory-scale designs utilized for treatability testing are not well described. The majority of published studies do not describe the laboratory UASB construction details or do use reactors that already had developed a trophic network in microbial consortia under laboratory environment and therefore are more stable. The absence of defined guidelines for geometry design, selection of materials, construction, operation rules, and, especially, the start-up conditions, significantly hamper researchers who desire to conduct treatability testing using UASB reactors in laboratory scale. In this article, we compiled and analyzed the information available in the refereed lite... [more]

Pharmaceutical manufacturing is evolving from traditional batch processes to continuous ones. The new global competition focused on throughput and quality of drug products is certainly the driving force behind this transition which, thus, represents the new challenge of pharmaceutical manufacturing and hence of lyophilization as a downstream operation. In this direction, the present review deals with the most recent technologies, based on spray freeze-drying, that can achieve this objective. It provides a comprehensive overview of the physics behind this process and of the most recent equipment design.

A compact heat integrated reactor system (CHIRS) of a steam reformer, a water gas shift reactor, and a combustor were designed for stationary hydrogen production from ethanol. Different reactor integration concepts were firstly studied using Aspen Plus. The sequential steam reformer and shift reactor (SRSR) was considered as a conventional system. The efficiency of the SRSR could be improved by more than 12% by splitting water addition to the shift reactor (SRSR-WS). Two compact heat integrated reactor systems (CHIRS) were proposed and simulated by using COMSOL Multiphysics software. Although the overall efficiency of the CHIRS was quite a bit lower than the SRSR-WS, the compact systems were properly designed for portable use. CHIRS (I) design, combining the reactors in a radial direction, was large in reactor volume and provided poor temperature control. As a result, the ethanol steam reforming and water gas shift reactions were suppressed, leading to lower hydrogen selectivity. On th... [more]

The aim of heat exchanger network synthesis is to design a cost-effective network configuration with the maximum energy recovery. Therefore, a nodes-based non-structural model considering a series structure (NNM) is proposed. The proposed model utilizes a simple principle based on setting the nodes on streams such that to achieve optimization of a heat exchanger network synthesis (HENS) problem. The proposed model uses several nodes to quantify the possible positions of heat exchangers so that the matching between hot and cold streams is random and free. Besides the stream splits, heat exchangers with series structures are introduced in the proposed model. The heuristic algorithm used to solve NNM model is a random walk algorithm with compulsive evolution. The proposed model is used to solve four scale cases of a HENS problem, the results show that the costs obtained by NNM model can be respectively lower 3226 $/a(Case 1), 11,056 $/a(Case 2), 2463 $/a(Case 3), 527 $/a(Case 4) than the... [more]

Laccase enzyme from white-rot fungi is a potential biocatalyst for the oxidation of emerging contaminants (ECs), such as pesticides, pharmaceuticals and steroid hormones. This study aims to develop a three-step platform to treat ECs: (i) enzyme production, (ii) enzyme concentration and (iii) enzyme application. In the first step, solid culture and liquid culture were compared. The solid culture produced significantly more laccase than the liquid culture (447 vs. 74 µM/min after eight days), demonstrating that white rot fungi thrived on a solid medium. In the second step, the enzyme was concentrated 6.6 times using an ultrafiltration (UF) process, resulting in laccase activity of 2980 µM/min. No enzymatic loss due to filtration and membrane adsorption was observed, suggesting the feasibility of the UF membrane for enzyme concentration. In the third step, concentrated crude enzyme was applied in an enzymatic membrane reactor (EMR) to remove a diverse set of ECs (31 compounds in six group... [more]

Aminoethers of boric acid, which are organoboron ionic liquids, were synthesized by using boric acid, triethanolamine, and triethylene glycol/diethylene glycol. Due to the formation of intermolecular complexes of borates, the structure of aminoethers of boric acid contains ion pairs separated in space, giving these compounds the properties inherent to ionic liquids. It is established that the thermal stability of aminoethers under normal atmospheric conditions increases with an increase in the size of the glycol. According to measurements of fast scanning calorimetry, density, dynamic viscosity, and electrical conductivity, water is involved in the structural organization of aminoethers of boric acid. The impact of the most thermostable organoboron ionic liquids on the phase equilibrium conditions of the vapor−liquid azeotropic ethanol−water mixture is studied. It is shown that the presence of these substances leads to increase in the relative volatility of ethanol. In general, the mag... [more]

In this work, a comprehensive experimental analysis on the performance of a 50 cm2 polymer electrolyte membrane (PEM) fuel cell is presented, including experimental results for a dedicated load cycling test. The harmonized testing protocols defined by the Joint Research Centre (JRC) of the European Commission for automotive applications were followed. With respect to a reference conditions representative of automotive applications, the impact of variations in the cell temperature, reactants pressure, and cathode stoichiometry was analyzed. The results showed that a higher temperature resulted in an increase in cell performance. A higher operating pressure also resulted in higher cell voltages. Higher cathode stoichiometry values negatively affected the cell performance, as relatively dry air was supplied, thus promoting the dry-out of the cell. However, a too low stoichiometry caused a sudden drop in the cell voltage at higher current densities, and also caused significant cell voltage... [more]

In recent times two or more desalination processes have been combined to form integrated systems that have been widely used to resolve the limitations of individual processes as well as producing high performance systems. In this regard, a simple integrated system of the Multi Effect Distillation (MED)/Thermal Vapour Compression (TVC) and Permeate Reprocessing Reverse Osmosis (PRRO) process was developed by the same authors and confirmed its validity after a comparison study against other developed configurations. However, this design has a considerable amount of retentate flowrate and low productivity. To resolve this issue, two novel designs of MED and double reverse osmosis (RO) processes including Permeate and Retentate Reprocessing designs (PRRP and RRRO) are developed and modelled in this paper. To systematically assess the consistency of the presented designs, the performance indicators of the novel designs are compared against previous simple designs of MED and PRRO processes a... [more]

Reactive distillation is a technical procedure that promotes material strengthening and its simulation plays an important role in the design, research, and optimization of reactive distillation. The solution to the equilibrium mathematical model of the reactive distillation process involves the calculation of a set of nonlinear equations. In view of the mutual influence between reaction and distillation, the nonlinear enhancement of the mathematical model and the iterative calculation process are prone to fluctuations. In this study, an improved Inside−Out method was proposed to solve the reaction distillation process. The improved Inside−Out methods mainly involved—(1) the derivation of a new calculation method for the K value of the approximate thermodynamic model from the molar fraction summation equation and simplifying the calculation process of the K value, as a result; and (2) proposal for an initial value estimation method suitable for the reactive distillation process. The alg... [more]

A novel process of membrane separation for H2/CO2 of shifted syngas coupled with gasoil hydrogenation (NMGH) is proposed. First, a new process, with two-stage CO2-selective and one-stage H2-selective membranes, was developed to substitute the conventional PSA separation devices to remove CO2 and purify H2 in coal gasification refineries to reduce energy consumption and investment costs. Then, the process was coupled with gasoil hydrogenation and the recycled H2 produced by the hydrogenation reactor could be further purified by the H2-selective membrane, which increased the H2 concentration of the hydrogenation reactor inlet by about 11 mol.% compared with the conventional direct recycling process, and the total system pressure was reduced by about 2470 kPa. At the same time, this additional membrane separation and purification prevented the accumulation of CO/CO2 in the recycled H2, which ensured the activity of the catalyst in the reactor and the long-term stable operation of the devi... [more]

Statistical-based study using response surface methodology (RSM) was conducted to study the effects of process parameters towards biomass hydrogenation. Using Malaysian oil palm empty fruit bunches (EFB) fibres as feedstock, the central composite design (CCD) technique was employed and 18 runs were generated by CCD when four parameters (mass ratio of binary catalyst, hydrogen pressure, temperature and mass ratio of catalyst to feedstock) were varied with two center points to determine the effects of process parameters and eventually to get optimum ethylene glycol (EG) yield. RSM with quadratic function was generated for biomass hydrogenation, indicating all factors except temperature, were important in determining EG yield. Analysis of variance (ANOVA) showed a high coefficient of determination (R2) value of >0.98, ensuring a satisfactory prediction of the quadratic model with experimental data. The quadratic model suggested the optimum EG yield should be >25 wt.% and the EG yield resu... [more]