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]

Three types of organic Rankine cycles (ORCs): basic ORC (BORC), ORC with single regeneration (SRORC) and ORC with double regeneration (DRORC) under the same heat source have been simulated in this study. In the following, the energy and exergy analysis and the advanced exergy analysis of these three cycles have been performed and compared. With a conventional exergy analysis, researchers can just evaluate the performance of components separately to find the one with the highest amount of exergy destruction. Advanced analysis divides the exergy destruction rate into unavoidable and avoidable, as well as endogenous and exogenous, parts. This helps designers find more data about the effect of each component on other components and the real potential of each component to improve its efficiency. The results of the advanced exergy analysis illustrate that regenerative ORCs have high potential for reducing irreversibilities compared with BORC. Total exergy destruction rates of 4.13 kW (47%) a... [more]

The reverse osmosis (RO) process is one of the best desalination methods, using membranes to reject several impurities from seawater and brackish water. To systematically perceive the transport phenomena of solvent and solutes via the membrane texture, several mathematical models have been developed. To date, a large number of simulation and optimisation studies have been achieved to gauge the influence of control variables on the performance indexes, to adjust the key variables at optimum values, and to realise the optimum production indexes. This paper delivers an intensive review of the successful models of the RO process and both simulation and optimisation studies carried out on the basis of the models developed. In general, this paper investigates the scope and limitations of the RO process, as well as proving the maturity of the associated perspective methodologies.

Compared with conventional natural gas, liquefied natural gas has the advantages of easier storage and transportation, more safety, less indirect investment, better peak regulation, and environmental protection. This paper studies the large-scale cryogenic propane precooled mixed refrigerant (C3MR) liquefied natural gas (LNG) process. The phase equilibrium of the liquefaction process is calculated by the Peng-Robinsonstate equation using ASPEN. A numerical model for the thermal process simulation of the liquefaction process is established by MATLAB. Based on Active X technology, data invocation between software is realized, which overcomes the problem of process variable changes under limited degrees of freedom. The minimum sum of the propane precooling amount for the compressor energy consumption is used as the objective function, the control variate method is used to address the liquefaction process model, and the parameter sensitivity analysis is performed and combined with the exer... [more]

Hydrogen purification and CO2 capture are of great significance in refineries and pre-combustion power plants. A dual membrane separator offers an alternative approach for improving H2/CO2 separation efficiency. In this work, H2/CO2/CH4 ternary gas mixtures separation can be achieved by a dual membrane separator with an integrated polyimide (PI) membrane and polydimethylsiloxane/polyetherimide (PDMS/PEI) composite membrane. A hollow fiber dual membrane separation equipment is designed and manufactured. Through the self-designed device, the effects of stage cut, operating temperature, operating pressure, and membrane area ratio on separation performance of dual membrane separator have been studied. The results indicate that, at a high stage cut, a dual membrane separator has obvious advantages over a single membrane separator. Operating temperature has a significant impact on gas permeation rates. At 25 °C, a dual membrane separator can obtain the highest purity of H2 and CO2. By increa... [more]

This paper explores a possible waste-based economy transition strategy. Digestate from the organic fraction of municipal solid waste (OFMSW) is considered, as well as a low-added value product to be properly valorized. In this regard, air gasification may be used to produce syngas. In this work, the production of methanol, hydrogen, or electricity from digestate-derived syngas was assessed by ChemCAD process simulation software. The process scheme of methanol production comprises the following parts: water gas shift (WGS) with carbon capture and storage units (CCS), methanol synthesis, and methanol purification. In the case of hydrogen production, after WGS-CCS, hydrogen was purified from residual nitrogen by pressure swing absorption (PSA). Finally, for electricity production, the digestate-derived syngas was used as fuel in an internal combustion engine. The main objective of this work is to compare the proposed scenarios in terms of CO2 emission intensity and the effect of CO2 stora... [more]

In nature bio-composites such as nacre show remarkable mechanical properties due to their complex hierarchical structure and high-volume fraction of its hard component. These composites are highly interesting for structural applications in different branches of industries for mechanical engineering and process technology. The aim of this work was to provide a scalable method for the production of highly filled composites by mimicking the structure of bio-composites. Therefore, composites from iron oxide (Fe2O3) and SBC-polymer (styrene-butadiene block copolymer) were fabricated by using a miniaturized spouted bed with an innovative fluidization gap design. Small iron oxide particles (25−45 μm) were fluidized in the spouted bed and coated with a polymer solution via a bottom spray nozzle. Afterwards the coated granules were hot-pressed and the mechanical properties of the obtained composites were tested. By this method composites with a bending strength of up to 6 MPa were fabricated. A... [more]

PET/PTT bicomponent filaments yarn is produced by two polymers: the polyethylene terephthalate (PET) and the polytrimethylene terephtalate (PTT) extruded side by side. This yarn is known for its high mechanical properties in particular elasticity and elastic recovery. However, differences between physical and chemical properties of the two components make the dyeing step of this yarn complicated. The aim of this work is the development of a dyeing process for bicomponent filaments without altering their physical and chemical properties. Different techniques such as SEM, FTIR, and differential scanning calorimetry (DSC) were used to characterize the studied yarn. For dyeing, three different disperse dyes CI Disperse Red 167.1, CI Disperse Yellow 211, and CI Disperse Red 60 with different energy classes were studied. The influence of dyeing conditions in particular dyeing temperature, pH of dye bath, dyeing time, and carrier concentration in the dye bath was evaluated. Responses analyzed... [more]