Fuels, Volume 6, Issue 2 (June 2025) – 18 articles

This research delves into the co-pyrolysis of refuse-derived fuel (RDF) and oil shale (OS), utilizing a 50% weight ratio for each component. The study employs a fixed-bed reactor, augmented by electrical kiln heating, to conduct the co-pyrolysis process. A significant aspect of this research is the use of Aspen Plus software for process simulation, with the simulated results undergoing validation through experimental data. A commendable correlation was observed between the experimental outcomes and the model predictions, underscoring the reliability of the simulation approach. The investigation reveals distinct product yields from the pyrolysis of 100% RDF and 100% OS. Specifically, the pyrolysis of pure RDF yielded 45.26% gas, 20.67% oil, and 34.07% char by weight. In contrast, the pyrolysis of pure OS resulted in 14.51% gas, 8.32% liquid, and a significant 77.61% char by weight. The co-pyrolysis of RDF and OS in a 50% blend altered the product distribution to 31.98% gas, 12.58% liquid, and 55.09% char by weight. Furthermore, the Aspen Plus simulation model aligned closely with these findings, predicting yields of 31.40% gas, 11.9% oil, and 56.6% char by weight for the RDF-OS blend. This study not only elucidates the co-pyrolysis behavior of RDF and OS but also contributes valuable insights into the potential of these materials to address the pressing issue of plastic waste management and energy resource utilization. The findings underscore the efficacy of RDF and OS co-pyrolysis as a viable strategy for enhancing the value extraction from waste and underutilized energy resources, presenting a promising avenue for environmental and energy sustainability. Full article

The main motivation for this paper was the lack of studies and comparative analyses on the new generation of alternative fuels in the marine sector, such as methane, methanol, ammonia and hydrogen. Firstly, a review of international legislation and the status of these new fuels was carried out, highlighting the current situation and the different existing alternatives for reducing greenhouse gas (GHG) emissions. In addition, the status and evolution of the current order book for ships since the beginning of this decade were used for this analysis. Secondly, each fuel and its impact on the geometry and operation of the engine were evaluated in a theoretical engine called MW-1. Lastly, an economic analysis of the current situation of each fuel and its availability in the sector was carried out in order to select, using the indicated methodology, the most viable fuel at present to replace traditional fuels with a view to the decarbonization set for 2050. Full article

All modern process simulators rely on thermodynamic methods to estimate physical properties and calculate phase equilibria. The critical properties of individual components or pseudo-components, which represent undefined mixtures, play a crucial role in these calculations. However, the chemical compositions and characteristics of whole crude oils, petroleum fractions, and fuels, which are very complex mixtures of individual hydrocarbons, can vary significantly depending on the specific crude oil and the processing involved. For instance, straight-run petroleum fractions differ from those obtained through cracking processes due to differences in unsaturated hydrocarbon content. Consequently, effective methods for predicting critical temperature and pressure must account for a wide range of compositional scenarios. To address this challenge, we utilized a database of 176 individual hydrocarbons to evaluate the existing correlations for critical temperature and pressure calculations. Intercriteria analysis was performed to evaluate the relations between the different variables to be used for critical temperature and pressure predictions. Additionally, we proposed new correlations and ANN models for these properties and assessed their performance. Our study aims to provide robust predictive models that can accurately estimate critical properties across diverse petroleum fractions and compositions. Full article

The residue conversion processes, coking, visbreaking, and fluid catalytic cracking (FCC), have demonstrated that feedstock quality is the single factor that most affects process performance. While, for the FCC, it is known that the heavy oil conversion at a maximum gasoline yield point can vary between 50 and 85 wt. %, for the vacuum residue hydrocracking, no reports have appeared yet to reveal the dependence of conversion on the quality of vacuum residue being hydrocracked. In order to search for such a dependence, eight vacuum residues derived from medium, heavy, and extra heavy crude oils have been hydrocracked in a laboratory unit at different reaction temperatures. The current study has witnessed that the vacuum residue hydrocracking obeys the same rule as that of the other residue conversion processes, confirming that the feedstock quality has a great influence on the process performance. A conversion variation between 45 and 85 wt. % can be observed when the sediment content in the hydrocracked atmospheric residue is within the acceptable limit, guaranteeing the planned cycle length. An intercriteria analysis was performed, and it revealed that the vacuum residue conversion has negative consonances with the contents of nitrogen and metals. Correlations were developed which predict the conversion at constant operating conditions within the uncertainty of conversion measurement of 1.7 wt. % and correlation coefficient of 0.964. The conversion at constant hydrocracked atmospheric residue (HCAR) sediment content was predicted with a correlation coefficient of 0.985. The correlations developed in this work disclosed that the higher the contents of metals, nitrogen, and asphaltenes, and the lower the content of sulfur, the lower the conversion in the hydrocracking process is. It was also shown that vacuum residues, which have the same reactivity (the same conversion at identical operating conditions), can indicate significant difference in the conversion at the same HCAR sediment content due to their diverse propensity to form sediments in the process of hydrocracking. Full article

This study presents the development of a kinetic model for the gasification of biochar with carbon dioxide and compares the results obtained using a thermogravimetric analyzer (TGA) and a fluidized bed reactor (FBR). The kinetic experiments investigated the effects of the CO₂ partial pressure (0.33–1 atm), temperature (800–1000 °C), and CO₂/C ratio (3.5–10.5). Three structural models, the shrinking core model (SCM), volumetric model (VM), and power-law model (PLM), were evaluated for their ability to predict experimental results. The results demonstrated that increasing the temperature, CO₂ partial pressure, and CO₂/C ratio enhanced the gasification rate, reducing the time required for complete biochar conversion. The apparent activation energy for both reactors was similar (156–159 MJ/kmol), with reaction orders of 0.4–0.49. However, the kinetic models varied significantly between setups. In the TGA, the PLM provided the best fit to experimental data, with standard deviations of 2.6–9%, while in the FBR, the SCM was most accurate, yielding an average deviation of 1.5%. The SCM effectively described the layer-by-layer char consumption, where gasification slowed at high conversion levels. Conversely, the PLM for the TGA revealed a unique mathematical function not aligned with traditional models, indicating localized reaction behaviors. This study highlights the inability to directly extrapolate TGA-derived kinetic models to FBR systems, underscoring the distinct mechanisms governing char consumption in each reactor type. These findings provide critical insights for optimizing biochar gasification across diverse reactor configurations. Full article

Automation has transformed process optimization across industries by enhancing efficiency, safety, and reliability while minimizing human intervention. This paper presents a model-based optimization strategy tailored for automated drilling operations, focusing on maximizing performance while maintaining operational safety. The approach employs real-time control of key parameters, such as applied force and rotational speed, through a robust closed-loop control system. An adaptive detection algorithm is incorporated to dynamically adjust operational parameters when encountering changing conditions. This real-time adaptability ensures efficient performance under diverse scenarios while mitigating risks. In the simulation, the data used for modeling drillstring dynamics are sourced from a publicly available benchmarking dataset, which provides a reliable basis for evaluation. From the simulation results, it is clear that the drilling optimization framework is capable of achieving high performance with lower energy consumption while maintaining effective vibration mitigation and prevention. This balance is essential for ensuring operational efficiency and tool longevity in dynamic environments. The findings highlight the potential of this framework to enhance automated systems in energy, construction, and other sectors requiring precise control of dynamic mechanical processes. Full article

Digestate as a by-product of biogas production requires appropriate utilization methods to convert it into a valuable resource. This study investigated the feasibility of using digestate from a biogas plant as a sustainable feedstock for fuel pellet production. Digestate from an agricultural biogas plant was dried and pelletized, both with and without the addition of biochar. The resulting pellets were analyzed for their physicochemical properties, elemental composition, and calorific value. Samples of pellets were examined using a calorimeter and XRF analyzer. Results showed that digestate pellets exhibited promising fuel characteristics comparable to traditional wood pellets (17.07–17.11 MJ/kg). However, the addition of biochar, while increasing calorific value, led to high ash content and elevated concentrations of Cl, S, N, Ni, Zn, exceeding acceptable limits defined by ISO 17225-6. Consequently, biochar addition is not recommended due to potential environmental concerns upon combustion. The findings highlight that digestate with initial moisture content of 7–7.5% is the most suitable for pelletization in terms of mechanical durability and strength quality. Further research is recommended to fully assess the environmental and economic viability of digestate-based fuel pellets. This approach addresses two issues: it enables waste utilization and produces a valuable resource. Full article

The essence of coal spontaneous combustion lies in the existence of a large number of chemically active functional groups in the coal molecule, such as aldehyde group (-CHO) and methoxy group (-OCH₃) in the side chain structure of coal molecule, which can be easily oxidized, thus triggering the spontaneous combustion process. Retardant is a more widely used technology to prevent the spontaneous combustion of coal, but the research on the microscopic level of the mechanism of coal spontaneous combustion retardation has been weak for many years, so deepening the exploration in this field is crucial for the optimization of the retardation strategy. The inhibition effect of Li⁺, Na⁺, and K⁺ inhibitors was investigated through the programmed warming experiments, and the results showed that the carbon monoxide production and oxygen consumption of coal samples inhibited by Li⁺, Na⁺, and K⁺ inhibitors were reduced to different degrees compared with that of the original coal, which proved that it had an inhibitory effect on the spontaneous combustion of coal. In order to deeply investigate the interaction between the molecular structure properties of coal and alkali metal ions, the complexes formed by three typical alkali metal ions-Li⁺, Na⁺, and K⁺-with specific reactive groups (-CHO and -OCH₃) in coal were investigated with the help of the quantum chemical calculation software Gaussian 16W, and the following conclusions were made after analyzing the complexes: on the one hand, the complexes formed by Li⁺, Na⁺, and K⁺ with the reactive groups in coal can occupy the sites where the reactive groups bind with oxygen, reduce the chance of coal oxygen contact and inhibit its oxidation process; on the other hand, the coordinating action of alkali metal ions increases the maximum energy barrier that needs to be overcome for the reaction of the originally active groups, resulting in the coal molecules in the process of oxidation reaction, increasing the difficulty of the reaction, thus effectively curbing the tendency of spontaneous combustion of coal. Full article

An efficient adaptive modeling criterion for the polymer electrolyte membrane fuel cell (PEMFC) is proposed in this paper, which can facilitate its precise simulation, design, analysis and control. In this work, a number of state-of-the-art algorithms have been adapted to optimize the complex electrochemical PEMFC model. Investigations are carried out not only from the conventional perspective of modeling accuracy but also from a new perspective represented by the impact of process computational time. Here, a novel technique of PEMFC modeling is proposed based on a meta-heuristic optimization algorithm called the wild horse optimizer (WHO). The proposed technique is concerned with the impact of the computational time on dynamic PEMFC modeling. A comprehensive statistical analysis was performed on the results of competing meta-heuristic optimizers that were adapted to a common PEMFC modeling problem. Among them, the proposed WHO approach’s results showed a promising performance in terms of its accuracy and minimum computational time over the other state-of-the-art approaches. For further evaluation of the WHO approach, it was used to optimize additional commercial PEMFC stack models. The results of the WHO approach highlighted its superior performance from the point of view of a high accuracy with a low computational burden, which supports its suitability for online applications. Full article

The objective of this research is to examine the dynamics of parent/child well interaction in unconventional plays, an issue that has gained prominence as high-quality inventory reduces and the number of infill wells escalates. To achieve this, the research will identify and analyze the factors influencing the interaction between parent/child wells and quantify the impacts of time, distance, and geological formation within the context of the DJ basin. The short-term estimate, considered as the next 12 months of cumulative oil production, is forecasted using decline curve analysis (DCA), and the long-term estimates come from the estimated ultimate recovery (EUR) of oil. The impact of the interaction on the parent well is determined as the difference between the recovery of the pre-frac hit and the post-frac hit. The child wells are compared to unaffected wells from the same unit. The average distance between parent and child wells is kept constant, and the time gap between the pre-existing and infill wells is statistically compared to observe the impact of time. The same procedure is followed for distance, orientation, and formation. The findings indicate that stimulation of child wells can lead to a depletion-induced stress shadow around the parent wells, potentially resulting in asymmetrical fracture growth. Consequently, the proximity of parent wells may contribute to a decrease in the performance of the child wells. On the contrary, parent wells with frac hits experienced varied outcomes, including improved production, reduced production, or no noticeable change at all. When the distance between parent and child well decreases, the negative impact on child wells increases. Increasing the time gap between pre-existing wells and infill wells shows an adverse impact on child wells. The impact on child wells was not observed when the parent well had been producing for less than 5 months. An interesting pattern emerged when analyzing the orientation of wells; child wells drilled at a perpendicular angle to their parent wells did not exhibit changes in performance. Within the geological context, the Niobrara Formation was found to have a more substantial negative impact on well interactions than the Codell Formation. In conclusion, time and distance play a crucial role in parent/child well interaction. Despite the existence of studies on parent/child well interactions within the literature, a comprehensive and detailed analysis specifically targeting the DJ Basin—particularly focusing on the intricacies of well interactions within the Niobrara and Codell Formations—has not yet been undertaken. Full article

Hydrogen–methane gas mixtures are increasingly recognized as a viable path toward achieving carbon neutrality, leveraging existing natural gas infrastructure while reducing greenhouse gas emissions. This study investigates a novel static mixing device designed for blending hydrogen and methane, employing both experimental tests and three-dimensional computational fluid dynamics (CFD) simulations. Hydrogen was introduced into a methane flow via direct injection, with experimental mixtures ranging from 5% to 18% hydrogen. The mixture quality was assessed using a specialized gas chromatograph, and the results were compared against simulated data to evaluate the mixer’s performance and the model’s accuracy. The system demonstrated effective blending, maintaining uniform hydrogen concentrations across the outlet with minimal variations. Experimental and simulated results showed strong agreement, with an average accuracy error below 2%, validating the reliability of the CFD model. Smaller nozzles (0.4 mm) achieved greater mixing uniformity, while larger nozzles (0.6 mm) facilitated higher hydrogen throughput, indicating trade-offs between mixing precision and flow capacity. The mixing device proved compatible with existing pipeline infrastructure, offering a scalable solution for hydrogen integration into natural gas networks. These findings underscore the mixer’s potential as a practical component in advancing the hydrogen economy and achieving sustainable energy transitions. Full article

Hydrogen internal combustion engines (ICEs) have gained significant attention as a promising solution for achieving zero-carbon emissions in the transportation sector. This study investigates the conversion of a 2 L Diesel ICE into a lean hydrogen-powered ICE, focusing on key challenges such as hydrogen mixing, pre-ignition, combustion flame development, and NOx emissions. The novelty of this research lies in the specific modifications made to optimize engine performance and reduce emissions while utilizing the existing Diesel engine infrastructure. The study identifies several important design changes for the successful conversion of a Diesel engine to hydrogen, including the following: Intake port design: transitioning from a swirl to a tumble design to enhance hydrogen mixing; Injection and spark plug configuration: using a lateral injection system combined with a central spark plug to improve combustion; Piston design: employing a lenticular piston shape with adaptable depth to enhance mixing; Mitigating Coanda effect: preventing hydrogen issues at the spark plug using deflectors or caps; and Head design: maintaining a flat head design for efficient mixing, while ensuring adequate cooling to avoid pre-ignition. These findings highlight the importance of specific modifications for converting Diesel engines to hydrogen, providing a solid foundation for further research in hydrogen-powered ICEs, which could contribute to carbon emission reduction and a more sustainable energy transition. Full article

The power to weight ratio of power plants is an important consideration, especially in the design of Unmanned Aircraft System (UAS). In this paper, a UAS with an MTOW of 35.3 kg, equipped with a fuel cell as a prime power supply to provide electrical power to the propulsion system, is considered. A pressure vessel design that can estimate and determine the total size and weight of the combined power plant of a fuel cell stack with hydrogen and air/oxygen vessels and the propulsion system of the UAS for high-altitude operation is proposed. Two scenarios are adopted to determine the size and weight of the pressure vessels required to supply oxygen to the fuel cell stack. Different types of stainless-steel materials are used in the design of the pressure vessel in order to find an appropriate material that provides low size and weight advantages. Also, the design of a hydrogen pressure vessel and mass estimation are also considered. The estimated sizes and weights of the hydrogen and oxygen vessels of the power plant and propulsion system in this research offer a maximum of four hours of flying time for the UAS mission; this is based on a Horizon (H-1000) Proton Exchange Membrane (PEM) stack. Full article

The purpose of this study is to reveal the characteristics of a Pd/Cu membrane and Ni/Cr catalyst adopted in a biogas dry reforming (BDR) membrane reactor by the numerical simulation procedure. The commercial software COMSOL Multiphysics ver. 6.2 was adopted in the numerical simulation. COMSOL is one type of commercial software that can solve multiphysics phenomena, i.e., chemical reaction, fluid dynamics, heat transfer, etc. The impact of the initial reaction temperature and the thickness of the Pd/Cu membrane on the performance of the BDR membrane reactor using an Ni/Cr catalyst is also investigated. The initial reaction temperatures adopted were 400 °C, 500 °C, and 600 °C, and the thicknesses of the Pd/Cu membrane were varied at 20 μm, 40 μm, and 60 μm. It was discovered that when the initial reaction temperature was raised, the molar concentration of H₂ increased while the molar concentrations of CH₄ and CO₂ decreased. Because the penetration resistance of the Pd/Cu membrane decreased with the decrease in the thickness of the Pd/Cu membrane, the molar concentrations of H₂ remaining in the Pd/Cu membrane and sweep chamber rose with the decrease in the thickness of the Pd/Cu membrane. Full article

Low-temperature Fischer–Tropsch (LTFT) synthesis converts syngas to diesel/wax at 200–250 °C. The LTFT reaction has recently received renewed interest, as it can be used for converting syngas from renewable sources (biomass and waste) to high-value fuels and chemicals. Conventional LTFT reactors, such as fixed-bed and slurry reactors, are not entirely suitable for bio-syngas conversion due to their smaller scale compared to fossil fuel-based syngas processes. This review explores advancements in intensifying LTFT reactors suitable for bio-syngas conversion, enabling smaller scale and dynamic operation. Various strategies for enhancing heat and mass transfer are discussed, including the use of microchannel reactors, structured reactors, and other designs where either one or both the heat and mass transfer are intensified. These technologies offer improved performance and economics for small LTFT units by allowing flexible operation, with increased syngas conversion and reduced risk of overheating. Additionally, this review presents our outlook and perspectives on strategies for future intensification. Full article

This study presents an integrated strategy to optimize biofuel production from Chlorella sorokiniana (CSO) and Chlorella vulgaris (CVU) by combining salt-induced stress and thermal pretreatment. The microalgae were cultivated in anaerobic digestate effluent (ADE) under stress and non-stress conditions to evaluate nutrient availability’s impact on biomass composition. Salt stress significantly enhanced lipid accumulation, with CVU exhibiting a 51.6% increase. Thermal pretreatment of biomass at 90 °C for 10 h achieved the highest methane yield (481 mL CH₄/g VS), with CVU outperforming CSO. Milder pretreatment conditions (40 °C for 4 h) were more energy-efficient for CSO, achieving a yield of 2.67%. Fatty acid profiles demonstrated species-specific biodiesel properties, with CSO rich in oleic acid (33.47%) offering enhanced oxidative stability and cold flow performance, while CVU showed a higher polyunsaturated fatty acid content. This research highlights the economic viability of using ADE as a low-cost cultivation medium and the potential for scalable thermal pretreatments. Future research should focus on reducing energy demands of pretreatment processes and exploring alternative stress induction methods to further enhance biofuel yields. These findings offer valuable insights for tailoring cultivation and processing strategies to maximize lipid and methane production, supporting sustainable and economically viable dual biofuel production systems. Full article

In this study, Kerogen conversion and oil production laboratory modeling results in Bazhenov formation source rock samples (Western Siberia, Russia) are presented. Two samples from one well with a similar composition and immature type II kerogen, which were accumulated in the same deep-sea conditions, were used for this investigation. Hydrous pyrolysis was performed under 300 °C, with liquid products and a sample portion collected every 12 h to study kerogen parameters via pyrolysis and the synthetic-oil composition via GC–MS. The transformation of pyrolytic parameters was similar to the natural trend previously determined for Bazhenov source rocks with different maturities. The synthetic oils’ normal alkane composition and biomarker parameters transformed with time. Sedimentary conditions and lithology biomarker parameters presumed to be constant (Pr/Ph, Ph/C18, H29/H30, and DBT/Phen) changed depending on the heating duration. The oil maturation increased slightly. Differences between the samples were detected in hydrocarbon generation endurance (5 and 8 days), n-alkane composition, and C27/C29 and DBT/Phen. A hypothesis about the influence of kerogen variability and mineral matrix on oil production was made. This paper provides the basis for more detailed and accurate investigation of the factors affecting kerogen cracking and hydrocarbon formation. Full article

Direct methanol fuel cells (DMFCs) typically operate in passive mode, where methanol is distributed across the membrane electrode assembly through natural diffusion. Usual methanol concentrations range from 1% to 5% by weight (wt.%), although this can vary depending on the specific configuration and application. In this work, the effect of an additional pumping system to supply the methanol has been analyzed by varying the methanol flow rate within the pump’s range. To this end, a parametric experimental study was carried out to study the influence of temperature (25–40 °C), concentration (0.15–6 wt.% methanol in water), and the flow rate of methanol (1.12–8.65 g/s) on the performance of a single mini-direct methanol fuel cell (DMFC) operating in semi-passive mode with a passive cathode and an active anode. Open circuit voltage, maximum power density, and cell efficiency were analyzed. To this purpose, open circuit voltage and current–voltage curves were measured in different experimental conditions. Results indicate that temperature is the most decisive parameter to increase DMFC performance. For all methanol concentrations and flow rates, performance improves with higher operating temperatures. However, the impact of the concentration and flow rate depends on the other parameters. The operating optimal concentration was 1% wt. At this concentration, a maximum power of 14.2 mW was achieved at 40 °C with a methanol flow of 7.6 g/s. Under these same conditions, the cell also reached its maximum efficiency of 23%. The results show that switching from passive to semi-passive mode generally increases open-circuit voltage and maximum power, thus improving fuel cell performance, likely due to the enhanced uniform distribution of the reactant in semi-passive mode. However, further increases in flow rate led to a decrease in performance, probably due to the methanol crossover effect. An optimal methanol flow rate is observed, depending on methanol flow temperature and concentration. Full article