Lactic acid is an important chemical with numerous commercial applications that can be fermentatively produced from biological feedstocks. Producing lactic acid from corn grain could complement the use of already existing infrastructure for corn grain-based ethanol production with a higher value product. The objective of this study was to evaluate the techno-economic feasibility of producing 100,000 metric tons (t) of lactic acid annually from corn grain in a biorefinery. The study estimated the resources (equipment, raw materials, energy, and labor) requirements and costs to produce lactic acid from bacteria, fungi and yeast-based fermentation pathways. Lactic acid production costs were $1181, $1251 and $844, for bacteria, fungi and yeast, respectively. Genetically engineered yeast strains capable of producing lactic acid at low pH support significantly cheaper processes because they do not require simultaneous neutralization and recovery of lactic acid, resulting in lower requirement... [more]

Olive stones are an abundant lignocellulose material in the countries of the Mediterranean basin that could be transformed to bioethanol by biochemical pathways. In this work, olive stones were subjected to fractionation by means of a high-temperature dilute-acid pretreatment followed by enzymatic hydrolysis of the pretreated solids. The hydrolysates obtained in these steps were separately subjected to fermentation with the yeast Pachysolen tannophilus ATCC 32691. Response surface methodology with two independent variables (temperature and reaction time) was applied for optimizing D-xylose production from the raw material by dilute acid pretreatment with 0.01 M sulfuric acid. The highest D-xylose yield in the liquid fraction was obtained in the pretreatment at 201 °C for 5.2 min. The inclusion of a detoxification step of the acid prehydrolysate, by vacuum distillation, allowed the fermentation of the sugars into ethanol and xylitol. The enzymatic hydrolysis of the pretreated solids was... [more]

Reducing the mass of vehicles is an effective way to improve energy efficiency and mileage. Therefore, hot stamping is developed to manufacture lightweight materials used for vehicle production, such as magnesium and aluminum alloys. However, in comparison with traditional cold stamping, hot stamping is a high-energy-consumption process, because it requires heating sheet materials to a certain temperature before forming. Moreover, the process parameters of hot stamping considerably influence the product forming quality and energy consumption. In this work, the energy-economizing indices of hot stamping are established with multiobjective consideration of energy consumption and product forming quality to find a pathway by which to obtain optimal hot stamping process parameters. An energy consumption index is quantified by the developed models, and forming quality indices are calculated using a finite element model. Response surface models between the process parameters and energy-econom... [more]

Layout problems are an engineering task that heavily relies on project experience. During the design of a plant, various factors need to be considered. Most previous efforts on industrial layout design have focused on the arrangement of facilities in a plant. However, the area-wide layout was not thoroughly studied and the relationship between plant layout and area-wide layout was rarely mentioned. In this work, the key plant that has the greatest impact on the industrial area is figured out first, and then the coupling relationships between the key plant and the industrial area are studied by changing the occupied area and length-width ratio of the key plant. Both of them are achieved by changing the floor number. A hybrid algorithm involving the genetic algorithm (GA) and surplus rectangle fill algorithm (SRFA) is applied. Various constraints are considered to make the layout more reasonable and practical. In the case study, a refinery with 20 plants is studied and the catalytic crac... [more]

Alkylate produced by catalyzed reaction of isobutane and olefin-rich streams is a desired component for gasoline blending. Fractionation of the alkylation reactor effluent is energy demanding due to the presence of close boiling point components and solutions cutting its energy intensity; expenses associated with this process are investigated intensely nowadays. This paper presents a novel conceptual design and techno-economic analysis of alkylation reaction effluent fractionation revamp to reach a cut in energy costs of the fractionation process without the need to revamp the rectification columns themselves, providing thus an alternative approach to a more sustainable alkylation process. Two cases are considered—A. additional steam turbine installation or B. combustion engine-driven heat pump-assisted rectification. Mathematical modeling of the considered system and its revamp is applied using the “frozen technology” approach. Real system operation features and seasonal variations ar... [more]

Callicarpa candicans (Burm. f.) Hochr. (Callicarpa cana L.) is a medicinal plant that is distributed mainly in the tropics and subtropics of Asia and finds a wide range of uses in traditional medicine. In this study, we attempted and optimized the microwave-assisted hydro-distillation (MAHD) process to obtain essential oil from the leaves of C. candicans. In addition, the obtained oil was analyzed for volatile composition by gas chromatography−mass spectrometry (GC-MS) and assayed for bioactivity against several bacteria and cancer cell lines. To optimize the extraction process, response surface methodology (RSM) in combination with central composite design (CCD) was adopted. Experimental design and optimization were carried out with respect to three experimental factors including the ratio of water to raw material, extraction time, and microwave power. The optimal extraction conditions were obtained as follows: water to raw material ratio of 6/1 (v/w), extraction time 42 min, and micr... [more]

The aim of the study was to examine the effect of fresh vegetable addition on processing efficiency, and to ascertain the energy and water consumption during production of potato-based snack pellets. The extrusion-cooking process with a modified single screw extruder was applied at variable screw speeds and amounts of vegetable additives. A mixture of potato flakes, potato grits and starch was used as a basic recipe. The potato composition was supplemented with fresh pulp of onion, leek, kale and carrot in amounts of 2.5−30.0% as replacement of a related amount of potato starch. The water consumption, as well as processing indicators: the production efficiency, the specific mechanical energy (SME), and the total SME requirements during snack pellets processing at the laboratory scale were evaluated. As a result of this work, we found that the amount of applied vegetable additives had little impact on both processing efficiency and SME depending on the screw speeds applied. Moreover, we... [more]

Agriculture is one of the leading sectors on the global level contributing to greenhouse gas (GHG) emissions increase. With the utilization of biogas production technology within the agriculture sector, ecological benefits could be achieved, with immediate economic profit. Therefore, to retain economic profit and environmental sustainability, implementation of bioeconomy principles is of key importance. This paper examines four options of digestate treatment, which is identified as one of the highest operational cost for the biogas plant. A simple and robust model in Excel Solver was developed to determine the best solution for minimising GHG emissions and maximise profit for the biogas plant operator, through an upgrade of the plant with digestate treatment technologies. The model was implemented on a case of a Croatian biogas plant and the best solution in terms of GHG reduction and profit increase proved to be fertilizer production (Option 1), through a crystallization process of st... [more]

Offshore floating hybrid wind and wave energy is a young technology yet to be scaled up. A way to reduce the total costs of the energy production process in order to ensure competitiveness in the sustainable energy market is to maximize the farm’s efficiency. To do so, an energy generation and costs calculation model was developed with the objective of minimizing the technology’s Levelized Cost of Energy (LCOE) of the P80 hybrid wind-wave concept, designed by the company Floating Power Plant A/S. A Particle Swarm Optimization (PSO) algorithm was then implemented on top of other technical and decision-making processes, taking as decision variables the layout, the offshore substation position, and the export cable choice. The process was applied off the west coast of Ireland in a site of interest for the company, and after a quantitative and qualitative optimization process, a minimized LCOE was obtained. It was then found that lower costs of ~73% can be reached in the short-term, and th... [more]

Biochar obtained from sewage sludges are adopted for biogas cleaning. Sewage sludges are treated considering temperature, dwell time, activating agent, heating, and flow rate. The best performances achieved are registered considering the char produced at 400 °C using CO2 as an activating agent with a dwell time of 2 h. The adsorption capacity for the biogas cleaning CH4/CO2/H2S (20 ppm(v)) increased from 1.3 mg/g to 5.9 mg/g with the bed height. Future research with chemical activation processes will be made to improve the adsorption capacity achieved to produce cheaper sorbents than commercial ones.

Biopharmaceuticals are currently becoming one of the fastest growing segments of the global pharmaceutical industry, being used in practically all branches of medicine from disease treatment to prevention. Virus-like particles (VLP) hold tremendous potential as a vaccine candidate due to their anticipated immunogenicity and safety profile when compared to inactivated or live attenuated viral vaccines. Nevertheless, there are several challenges yet to be solved in the development and manufacturing of these products, which ultimately can increase time to market. Suchlike virus-based products, the development of a platform approach is often hindered due to diversity and inherent variability of physicochemical properties of the product. In the present work, a flow-through chromatographic purification strategy for hepatitis C VLP expressed using the baculovirus-insect cell expression system was developed. The impact of operational parameters, such as residence time and ionic strength were s... [more]

Unprecedented advances and innovation in technology and short lifespans of electronic devices have resulted in the generation of a considerable amount of electronic waste (e-waste). Polymeric components present in electronic waste contain a wide range of organic materials encompassing a significant portion of carbon (C). This source of carbon can be employed as a reducing agent in the reduction of oxides from another waste stream, i.e., steelmaking slag, which contains ≈20 wt%−40 wt% iron oxide. This waste slag is produced on a very large scale by the steel industry due to the nature of the process. In this research, the polymeric residue leftover from waste printed circuit boards (PCBs) after a physical-chemical recycling process was used as the source of carbon in the reduction of iron oxide from electric arc furnace (EAF) slag. Prior to the recycling tests, the polymer content of e-waste was characterized in terms of composition, morphology, thermal behavior, molecular structure, ha... [more]

The purpose of this study was to attempt the encapsulation of lemongrass (Cymbopogon citratus) essential oil utilizing spray drying technique. An array of process parameters including concentration of wall (15−30%), type of wall materials (maltodextrin, maltodextrin and gum Arabic mixture), and concentration of essential oil (0.5−2.0%) were thoroughly investigated. The results show that the use of sole maltodextrin as encapsulant gave microcapsules characteristics comparable to that of powder produced using maltodextrin and gum Arabic mixture. The encapsulation process that was performed with maltodextrin at the concentration of 30% as wall material and lemongrass essential oil at the concentration of 1.5% as core material showed highest drying yield (84.49%), microencapsulation yield (89.31%) and microencapsulation efficiency (84.75%). Encapsulated essential oils retained most of their major constituents in comparison with the bare essential oils without any significant compromise in... [more]

Anaerobic digestion has been widely employed in waste treatment for its ability to capture methane gas released as a product during the digestion. Certain wastes, however, cannot be easily digested due to their low nutrient level insufficient for anaerobic digestion, thus co-digestion is a viable option. Numerous studies have shown that using co-substrates in anaerobic digestion systems improve methane yields as positive synergisms are established in the digestion medium, and the supply of missing nutrients are introduced by the co-substrates. Nevertheless, large-scale implementation of co-digestion technology is limited by inherent process limitations and operational concerns. This review summarizes the results from numerous laboratory, pilot, and full-scale anaerobic co-digestion (ACD) studies of wastewater sludge with the co-substrates of organic fraction of municipal solid waste, food waste, crude glycerol, agricultural waste, and fat, oil and grease. The critical factors that infl... [more]

Effective cooling of the internal combustion (I. C.) engines is of utmost importance for their improved performance. Automotive heat exchangers used as radiator with low efficiency in the industry may pose a serious threat to the engines. Thus, thermal scientists and engineers are always looking for modern methods to boost the heat extraction from the engine. A novel idea of using nanofluids for engine cooling has been in the news for some time now, as they have huge potential because of better thermal properties, strength, compactness, etc. Nanofluids are expected to replace the conventional fluids such as ethylene glycol, propylene glycol, water etc. due to performance and environmental concerns. Overall performance of the engine cooling system depends on several input parameters and therefore they need to be optimised to achieve an optimum performance. This study is focussed on developing a nanofluid engine cooling system (NFECS) where Al2O3 nanoparticles mixed with ethylene glycol... [more]

A framework is introduced for the systematic development of preparative chromatographic processes. It is intended for the optimal design of conventional and advanced concepts that exploit strategies, such as recycling, side streams, bypasses, using single or multiple columns, and combinations thereof. The Python-based platform simplifies the implementation of new processes and design problems by decoupling design tasks into individual modules for modelling, simulation, assertion of cyclic stationarity, product fractionation, and optimization. Interfaces to external libraries provide flexibility regarding the choice of column model, solver, and optimizer. The current implementation, named CADET-Process, uses the software CADET for solving the model equations. The structure of the framework is discussed and its application for optimal design of existing and identification of new chromatographic operating concepts is demonstrated by case studies.

Anti-solvent crystallization is frequently applied in pharmaceutical processes for the separation and purification of intermediate compounds and active ingredients. The selection of optimal solvent types is important to improve the economic performance and sustainability of the process, but is challenged by the discrete nature and large number of possible solvent combinations and the inherent relations between solvent selection and optimal process design. A computational framework is presented for the simultaneous solvent selection and optimization for a continuous process involving crystallization and distillation for recycling of the anti-solvent. The method is based on the perturbed-chain statistical associated fluid theory (PC-SAFT) equation of state to predict relevant thermodynamic properties of mixtures within the process. Alternative process configurations were represented by a superstructure. Due to the high nonlinearity of the thermodynamic models and rigorous models for dist... [more]

The demand on biologics has been constantly rising over the past decades and has become crucial in modern medicine. Promising approaches to cope with widespread diseases like cancer and diabetes are gene therapy, plasmid DNA, virus-like particles, and exosomes. Due to progress that has been made in upstream processing (USP), difficulties arise in downstream processing and demand for innovative solutions. This work focuses on the integration of precipitation using a quality by design (QbD) approach for process development. Selective precipitation is achieved with PEG 4000 resulting in an HCP depletion of ≥80% respectively to IgG. Dissolution was executed with a sodium phosphate buffer (pH = 5/50 mM) reaching an IgG recovery of ≥95%. However, the central challenge in process development is still an optimal process design, which is transferable for a broad molecular variety of new products. This is where rigorous modeling becomes vital in order to generate digital twins to support early-s... [more]

Tunnel Boring Machines (TBMs) are a cutting-edge excavating equipment, but are barely applied in underground coal mines. For TBM excavation projects involving the Zhangji coal mine, the surrounding rock properties, stress field, cross section geometry, as well as the excavation-induced stress path of TBM-excavated coal mine roadways are different from those of traditional tunnels or roadways. Consequently, traditional roadway supporting technologies and experiences cannot be relied on for this project. In order to research an appropriate supporting pattern for a TBM-excavated coal mine roadway, first of all, the constitutive model of roadway surrounding rocks was derived, and a rock failure criterion was proposed based on rock mechanical tests. Secondly, a three-dimension finite element model was established and computer simulations under three different supporting patterns were conducted. Stress redistribution, roadway convergence, and excavation damage zone ranges of surrounding rock... [more]

This paper presents a multi-objective particle swarm optimization (MOPSO) method for optimal sizing of the standalone photovoltaic (SAPV) systems. Loss of load probability (LLP) analysis is considered to determine the technical evaluation of the system. Life cycle cost (LCC) and levelized cost of energy (LCE) are treated as the economic criteria. The two variants of the proposed PSO method, referred to as adaptive weights PSO ( A W P S O c f ) and sigmoid function PSO ( S F P S O c f ) , are implemented using MATLAB software to the optimize the number of PV modules in (series and parallel) and number of the storage battery. The case study of the proposed SAPV system is executed using the hourly meteorological data and typical load demand for one year in a rural area in Malaysia. The performance outcomes of the proposed A W / S F P S O c f methods give various configurations at desired levels of LLP values and the corresponding minimum cost. The perform... [more]

The power-to-ammonia process requires flexible operation due to intermittent renewable energy supply. In this work, we analyse three-bed autothermal reactor systems for design and off-design performance for power-to-ammonia application. The five reactor systems differ in terms of inter-stage cooling methods, i.e., direct cooling by quenching (2Q), combination of indirect and direct cooling (HQ and QH) and indirect cooling (2H) with variations. At optimum nominal operation conditions, the inter-stage indirect cooling (2H) reactor systems result in the highest NH3 production. For off-design performance analysis, NH3 production is minimised or maximised by varying one of the following process variables at a time: inert gas, feed flow rate or H2-to-N2 ratio. For each variation, the effect on H2 intake, recycle stream load and recycle-to-feed ratio is also analysed. Among the three process variables, the H2-to-N2 ratio provided ca. 70% lower NH3 production and 70% lower H2 intake than at no... [more]

The peel of Gac fruit (Momordica cochinchinensis Spreng.), which is considered as waste of Gac processing, has been found to possess high levels of carotenoids and other antioxidants. This study aimed at determining the optimal conditions of an ultrasound-assisted extraction for recovering carotenoids and antioxidant capacity from Gac peel. A response surface methodology using the Box−Behnken design was employed to investigate the impact of extraction time, temperature and ultrasonic power on the recovery of total carotenoid and antioxidant capacity. The results showed that an extraction time of 76 min, temperature of 50 °C and ultrasonic power of 250 W were the optimal conditions for the extraction. The experimental carotenoid yield and antioxidant capacity obtained under the optimal extraction conditions were validated as 269 mg/100 g DW (dry weight) and 822 µM TE (Trolox equivalent)/100 g DW, respectively. These values were not significantly different from the values predicted by th... [more]

The performance of cross-flow ultrafiltration is greatly influenced by permeate flux behavior, which depends on many factors, including solution properties, membrane characteristics, and operating conditions. Currently, most research focuses on improving membrane performance, both in terms of permeability and selectivity. Only a few studies have paid attention to how the membrane module is configured and operated. In this study, the geometric design and operating conditions of a membrane module are considered as multivariable optimization variables. The objective function is the annual cost. The cost consists of a capital investment depending on the plant scale and an operating expense associated with energy consumption. In the optimization problem, the channel dimensions (width × length × height), and operating conditions (the inlet pressure and recirculation flow rate) were considered as decision variables. The operating configuration of the membrane plant is assumed to be feed and b... [more]

The traditional two-column reactive distillation (RD) process is used for the production of butyric anhydride, which is synthesized with butyric acid and acetic anhydride via a reversible reaction. In this work, a novel process with a single RD column (SRDC) is designed for the production of butyric anhydride, where the second distillation column for separating excess reactant is removed based on the boiling point profile of the reaction system. Two applications of the proposed SRDC process, namely SRDC with excess butyric acid or acetic anhydride circulating internally, are economically optimized, and the results show that both SRDC processes have a lower total annual cost (TAC) than the traditional two-column process. Furthermore, from the perspective of TAC, the application with an excess feed of butyric acid is better than the application with excess acetic anhydride. The developed technique may also be applied to retrofit other traditional two-column RD processes, where the overhe... [more]

Efficiency is a critical consideration in the design of hydro turbines. The crossflow turbine is the cheapest and easiest hydro turbine to manufacture and so is commonly used in remote power systems for developing countries. A longstanding problem for practical crossflow turbines is their lower maximum efficiency compared to their more advanced counterparts, such as Pelton and Francis turbines. This paper reviews the experimental and computational studies relevant to the design of high efficiency crossflow turbines. We concentrate on the studies that have contributed to designs with efficiencies in the range of 88⁻90%. Many recent studies have been conducted on turbines of low maximum efficiency, which we believe is due to misunderstanding of design principles for achieving high efficiencies. We synthesize the key results of experimental and computational fluid dynamics studies to highlight the key fundamental design principles for achieving efficiencies of about 90%, as well as future... [more]