ChemEngineering — Open Access Journal

Spray drying of whey protein-based emulsions is a common task in food engineering. Lipophilic, low molecular weight emulsifiers including lecithin, citrem, and mono- and diglycerides, are commonly added to the formulations, as they are expected to improve the processing and shelf life stability of the products. During the atomization step of spray drying, the emulsions are subjected to high stresses, which can lead to breakup and subsequent coalescence of the oil droplets. The extent of these phenomena is expected to be greatly influenced by the emulsifiers in the system. The focus of this study was therefore set on the changes in the oil droplet size of whey protein-based emulsions during atomization, as affected by the addition of low molecular weight emulsifiers. Atomization experiments were performed with emulsions stabilized either with whey protein isolate (WPI), or with combinations of WPI and lecithin, WPI and citrem, and WPI and mono- and diglycerides. The addition of lecithin promoted oil droplet breakup during atomization and improved droplet stabilization against coalescence. The addition of citrem and of mono- and diglycerides did not affect oil droplet breakup, but greatly promoted coalescence of the oil droplets. In order to elucidate the underlying mechanisms, measurements of interfacial tensions and coalescence times in single droplets experiments were performed and correlated to the atomization experiments. The results on oil droplet breakup were in good accordance with the observed differences in the interfacial tension measurements. The results on oil droplet coalescence correlated only to a limited extent with the results of coalescence times of single droplet experiments. Full article

The oxidative dehydrogenation (ODH) of butene has been recently developed as a viable alternative for the synthesis of 1,3-butadiene due to its advantages over other conventional methods. Various catalytic reactors for this process have been previously studied, albeit with a focus on lab-scale design. In this study, a multi-tubular reactor model for the butadiene synthesis via ODH of butene was developed using computational fluid dynamics (CFD). For this, the 3D multi-tubular model, which combines complex reaction kinetics with a shell-side coolant fluid over a series of individual reactor tubes, was generated using OpenFOAM^®. Then, the developed model was validated and analyzed with the experimental results, which gave a maximum error of 7.5%. Finally, parametric studies were conducted to evaluate the effect of thermodynamic conditions (isothermal, non-isothermal and adiabatic), feed temperature, and gas velocity on reactor performance. The results showed the formation of a hotspot at the reactor exit, which necessitates an efficient temperature control at that section of the reactor. It was also found that as the temperature increased, the conversion and yield increased whilst the selectivity decreased. The converse was found for increasing velocities. Full article

Online detection of product defects using fast spectroscopic measurements is beneficial for producers in the dairy industry since it allows readjustment of product characteristics or redirection of product streams during production. Raman spectroscopy has great potential for such application due to the fast and simple measurement. Its suitability as online sensor for process control was investigated at typical control points in consumer milk production being raw milk storage, standardization, and heat treatment. Additionally, the appropriateness of Raman spectroscopy to act as indicator for product application parameters was investigated using the example of barista foam. To assess the suitability of a pure online system, the merit of Raman spectra was evaluated by a principal component analysis (PCA). Thereby, proteolytic spoilage due to the presence of extracellular enzymes of Pseudomonas sp. was detected and samples based on the applied heat treatment (extended shelf life (ESL) and ultra-high temperature (UHT)) could be separated. A correlation of the content of free fatty acids and foam stability with spectra of the respective milk samples was found, allowing a prediction of the technofunctional quality criterion “Barista” suitability of a UHT milk. The results underlined the suitability of Raman spectroscopy for the detection of deviations from a defined product standard of consumer milk. Full article

Three new crosslinked polystyrene nanoparticles covalently attached with low lattice energy lithium salt moieties were synthesized: poly(styrene lithium trifluoromethane sulphonyl imide) (PSTFSILi), poly(styrene lithium benzene sulphonyl imide) (PSPhSILi), and poly(styrene lithium sulfonyl-1,3-dithiane-1,1,3,3-tetraoxide) (PSDTTOLi). A series of solid polymer electrolytes (SPEs) were formulated by mixing these lithium salts with high molecular weight poly(ethylene oxide), poly(ethylene glycol dimethyl ether), and lithium bis(fluorosulfonyl)imide. The crosslinked nano-sized polymer salts improved film strength and decreased the glass transition temperature (T_g) of the polymer electrolyte membranes. An enhancement in both ionic conductivity and thermal stability was observed. For example, the SPE film containing PSTFSILi displayed ionic conductivity of 7.52 × 10⁻⁵ S cm⁻¹ at room temperature and 3.0 × 10⁻³ S cm⁻¹ at 70 °C, while the SPE film containing PSDTTOLi showed an even better performance of 1.54 × 10⁻⁴ S cm⁻¹ at room temperature and 3.23 × 10⁻³ S cm⁻¹ at 70 °C. Full article

A new porous activated carbon (AC) material with very high specific surface area (3193 m² g⁻¹) was prepared by the carbonization of a colloidal silica-templated melamine–formaldehyde (MF) polymer composite followed by KOH-activation. Several electrical double-layer capacitor (EDLC) cells were fabricated using this AC as the electrode material. A number of organic solvent-based electrolyte formulations were examined to optimize the EDLC performance. Both high specific discharge capacitance of 130.5 F g⁻¹ and energy density 47.9 Wh kg⁻¹ were achieved for the initial cycling. The long-term cycling performance was also measured. Full article

The emerging need for high-performance lithium–sulfur batteries has motivated many researchers to investigate different designs. However, the polysulfide shuttle effect, which is the result of dissolution of many intermediate polysulfides in electrolyte, has still remained unsolved. In this study, we have designed a sulfur-filled dual core–shell spindle-like nanorod structure coated with manganese oxide ([email protected]@MnO₂) to achieve a high-performance cathode for lithium–sulfur batteries. The cathode showed an initial discharge capacity of 1661 mA h g⁻¹ with 80% retention of capacity over 70 cycles at a 0.2C rate. Furthermore, compared with the nanorods without any coating ([email protected]), the MnO₂-coated material displayed superior rate capability, cycling stability, and Coulombic efficiency. The synergistic effects of the nitrogen-doped hollow carbon host and the MnO₂ second shell are responsible for the improved electrochemical performance of this nanostructure. Full article

In this paper, a sensitivity analysis of a continuous stirred tank bioreactor (CSTBR) was conducted to determine a parametrically sensitive regime. The growth of a lactic acid bacterium, namely, Lactobacillus casei, in a pH-controlled CSTBR was considered as a process model. Normalized objective sensitivities of the minimum pH were determined with respect to input parameters. A generalized criterion for sensitivity was defined for determining the parametric range of three input variables, i.e., dilution rate base stream (θ), base concentration (R), and initial pH (pH₀) for maintaining optimal pH range in the reactor. The system exhibits sensitive behavior for θ, R, and pH₀, from 0.095 to 0.295, 0 to 0.865, and 4.42 to 4.77, respectively. The critical values of θ, R, and pH₀ are 0.0195, 0.48, and 4.6, respectively. The mathematical model can also be used to determine a parametrically sensitive regime for other important parameters, namely, temperature, the concentration of metabolites, and other byproducts. The mathematical tool can also be used in bioreactor design and the improvement of control strategies. Full article

Manganese-containing anode sludge is a common side-product in the electrowinning of zinc. The anode sludge consists mainly of oxidized manganese, but also lesser amounts of lead, calcium, and other minor metals. The impurities present in the anode sludge mandate new recycling strategies for its efficient use. This work demonstrates a novel method for selective manganese recovery from lead- and calcium-bearing manganese oxide solid residue. Leaching with sulfuric acid in the presence of a selected reducing agent, such as hydrogen peroxide or citric acid, yields a concentrated MnSO₄ solution with high selectivity over calcium and lead. Manganese yields up to 98% can be obtained. Minimization of calcium and lead in final manganese product can be accomplished with the correct choice of leaching conditions. Alongside manganese sulfate solution, leaching residue with high content of lead and silver was also formed. Full article

Layered Double Hydroxide (LDH)/TiO₂ nanocomposites with photocatalytic properties were synthesized by both impregnation and the direct coprecipitation of LDH matrices using a colloidal suspension of TiO₂ nanoparticles. While the two methods led to an efficient TiO₂ nanoparticle immobilization, the direct coprecipitation allowed us to tune the amount of immobilized TiO₂ within the materials. The LDH/TiO₂ nanocomposites obtained were deeply characterized by chemical analysis (ICP-AES), Powder X-ray diffraction (XRD), Fourier Transformed Infra-Red (FTIR), Thermogravimetric analysis (TGA), and High-Resolution Transmission Electron Microscopy (HRTEM). Clearly, the immobilization of TiO₂ by direct coprecipitation promoted a modification of the textural properties and a net increase in the surface area. The crystallized TiO₂ nanoparticles can be distinctly visualized by HRTEM at the surface of the layered material. Several parameters, such as the nature of the chemical composition of LDH (ZnAl and MgAl), the method of immobilization and the amount of TiO₂, were shown to play a crucial role in the physicochemical and photocatalytic properties of the nanocomposites. The photocatalytic efficiency of the different LDH/TiO₂ nanocomposites was investigated using the photodegradation of a model pollutant, the Orange II (OII), and was compared to a pure TiO₂ colloidal solution. The degradation tests revealed that the nanocomposite obtained from MgAl LDH at a low MgAl LDH/TiO₂ ratio was the most efficient for the photodegradation of OII leading to complete mineralization in 48 h. Full article

The focus of our study is to identify physical properties of different impact-resistant/toughened structural adhesives and identify/develop an elastic-viscoelastic-plastic model as a function of loading rate by using Ludwik-type equations to be able to predict adhesive behavior at higher loading rates and to make cars more crashworthy. For this purpose, we first characterized eight different commercial toughened epoxy structural adhesives to provide detailed information about their constituents using X-ray diffraction (XRD), differential thermal analysis (DTA), thermogravimetric analysis (TGA), scanning electron microscope (SEM) and energy dispersive x-ray spectrometer (EDS). Most (but not all) of the model adhesives contained organic tougheners in the form of carboxyl terminated butadiene acrylonitrile (CTBN) copolymer, as well as polyurethane adducts. The main crystalline inorganic phases were found as calcite (CaCO₃), wollastonite (CaSiO₃) or calcium silicate (CaSiO₃), talc (Mg₃Si₄O₁₀ (OH)₂), zeolite which is an alumina silicate based mineral and has many different elements in its composition (M₂/nO·Al₂O₃·xSiO₂·yH₂O, M can be Mg, Na, Ca, K, Li). The total amount of inorganic fillers was found to be different in each adhesive. Material behavior of the model adhesives were determined via tensile tests and Single Lap Joint (SLJ) tests in shear. Split Hopkinson pressure bar (SHPB) was also used to measure the strain and stress values at higher strain rates in the order of 10² s⁻¹, which is generally encountered in impact related loading situations. Toughness values in the range ~0.5 to ~1.35 MJ/m³ were observed with the model adhesives tested in tensile mode within the ~3 × 10⁻³ to 0.18 m/m/s strain rate range. The softening behavior of the elastic moduli at higher strain rates observed during tensile testing was also observed with SHPB testing. It is remarkable that, overall, the modulus magnitudes seem to be similar between the tensile test and SHPB specimens within this softening range of the initial bilinear elastic behavior observed. When the results from bulk (tensile) and bonded (shear) specimens were compared, it was clearly seen that the toughness responses of the adhesives to (tensile/shear) strain rates in the bulk and bonded forms, respectively, were different, with the bonded shear toughness values in the ~25 to ~120 MJ/m³ range within ~1.25 to ~25 mm/mm/s shear strain range. The model adhesive which included just inorganic fillers had the lowest tensile toughness at the lowest tensile strain rate, but the highest slope in its tensile toughness regression line, exhibited the second highest bonded shear toughness. When tested at the extension rates of 25 mm/min and 100 mm/min in bonded lap shear, the same adhesive exhibited limited interfacial failure areas, however the dominant failure mode was cohesive failure. When the extension rate increased further, transition to interfacial (adhesive) failure was observed revealing that interfacial failures do not necessarily diminish adhesive bond toughness. Our observations point to the fact that cohesive deformation/failure processes indicating interfacial separations, inter-particle interactions as well as polymer matrix deformation in high deformation loading scenario as in bonded shear loadings may provide the highest toughness. Apparently, a large inorganic filler weight fraction is not necessary to obtain high shear toughness in bonded form since the highest bonded shear toughness was obtained with the adhesive which had the least amount of inorganic fillers among the model adhesives with 14.72 wt %. Full article

Accurate prediction of the hydrodynamic profile is important for circulating fluidized bed (CFB) reactor design and scale-up. Multiphase computational fluid dynamics (CFD) simulation with interphase momentum exchange is key to accurately predict the gas-solid profile along the height of the riser. The present work deals with the assessment of six different drag model capability to accurately predict the riser section axial solid holdup distribution in bench scale circulating fluidized bed. The difference between six drag model predictions were validated against the experiment data. Two-dimensional geometry, transient solver and Eulerian–Eulerian multiphase models were used. Six drag model simulation predictions were discussed with respect to axial and radial profile. The comparison between CFD simulation and experimental data shows that the Syamlal-O’Brien, Gidaspow, Wen-Yu and Huilin-Gidaspow drag models were successfully able to predict the riser upper section solid holdup distribution with better accuracy, however unable to predict the solid holdup transition region. On the other hand, the Gibilaro model and Helland drag model were successfully able to predict the bottom dense region, but the upper section solid holdup distribution was overpredicted. The CFD simulation comparison of different drag model has clearly shown the limitation of the drag model to accurately predict overall axial heterogeneity with accuracy. Full article

Targets to reduce CO₂ emissions by 75% and NO_x emissions by 90% by 2050 in aviation have been set by The Advisory Council for Aviation Research and Innovation in Europe. Sustainable fuels, e.g., emulsified biofuel, have demonstrated promise in reducing emissions and greenhouse gases. The aim of this project is to investigate the stability of a water in oil emulsion using sunflower oil. The primary objective is to achieve an emulsion which is stable for at least 4 days, and the secondary objective is to investigate how altering the emulsification parameter values of the surfactant hydrophilic-lipophilic balance (HLB), energy density and sonotrode depth in an ultrasonication procedure can impact the stability. The stability of each emulsion was measured over a period of 14 days. The main outcome is that two of the 14 emulsions made remained stable for at least 14 days using a surfactant HLB of five, which proved to be the optimum value from those tested. The results also show that, by using the sonotrode in a higher starting position, emulsions achieved a greater stability. Furthermore, over-processing of the emulsion was determined, with the point of over-processing lying between an energy density of 75 and 200 W.s/mL. Full article

Many powders are produced in spray-drying processes from liquid concentrates. Self-agglomeration can be performed in a fluidised bed where the spray-dried powder is agglomerated using the liquid concentrate as the binder material. This has advantages over traditional wet agglomeration in fluid beds using liquid binders (such as water or sugar solutions). These include thermal energy savings and no additional non-aqueous binder components added. The work presented has two parts. The first part is experimental, which investigated the self-agglomeration of whey protein isolate (WPI) powder as a case-study. It showed that satisfactory agglomeration was achieved with a great improvement in the wettability of the powder. The second part of the work performed thermal energy analysis to estimate the energy saving potential of self-agglomeration, and how this is influenced by binder to powder ratio and binder solids concentration. For the WPI case-study, the analysis showed there is potential for a 19% saving in thermal energy requirement for self-agglomeration in comparison to traditional agglomeration using a water binder. Full article

Significant energy savings can be made in aerobic stirred tank batch bioreactors by the manipulation of agitator power (Pag) and air flowrate per unit working volume (vvm). Control is often implemented to maintain the oxygen concentration in the bioreaction liquid (C_OL) at a constant value. This work used model simulations to show that controlling the Pag and vvm continuously over time, such that it is operated at or near the impeller flooding constraint results in the minimum energy requirement for oxygen transfer (strategy Cmin); however, this might prove impractical to control and operate in practice. As an alternative, the work shows that dividing the bioreaction time into a small number of constant Pag time segments (5–10), where a PID controller is used to control vvm to maintain C_OL constant in each segment, can achieve much of the energy saving that is associated with Cmin. During each time segment, vvm is increased and a sudden decrease in C_OL is used to detect the onset of flooding, after which there is a step increase in Pag. This sequence of Pag step increases continues until the bioreaction is completed. This practical control approach was shown to save most of the energy that is associated with Cmin. Full article

The Special Issue “Progress in Thermal Process Engineering” contains a total of eight articles, seven research papers and a review article. The topics of the individual articles reflect the variety of current research in the field of thermal process engineering. The contributions address important issues such as modularization, digitization, new equipment and simulation techniques. It becomes clear that efficiency efforts are an essential feature of current research in the mentioned field. Efficiency in the sense of energy efficiency as well as in the sense of more efficient, i.e., more flexible, production. The authors of the articles originate from the USA, Russia, Switzerland and Germany. Full article

To stop blood loss and accelerate wound healing, conventional wound closure techniques such as sutures and staples are currently used in the clinic. These tissue-piercing wound closure techniques have several disadvantages such as the potential for causing inflammation, infections, and scar formation. Surgical sealants and tissue adhesives can address some of the disadvantages of current sutures and staples. An ideal tissue adhesive will demonstrate strong interfacial adhesion and cohesive strength to wet tissue surfaces. Most reported studies rely on the liquid-to-solid transition of organic molecules by taking advantage of polymerization and crosslinking reactions for improving the cohesive strength of the adhesives. Crosslinking reactions triggered using light are commonly used for increasing tissue adhesive strength since the reactions can be controlled spatially and temporally, providing the on-demand curing of the adhesives with minimum misplacements. In this review, we describe the recent advances in the field of naturally derived tissue adhesives and sealants in which the adhesive and cohesive strengths are modulated using photochemical reactions. Full article

In process engineering, optimization is usually carried out without the simultaneous consideration of material and process. This issue is addressed in the following contribution. A model-based optimization is presented to improve the performance of adsorption heat pumps. Optimization is carried out in two steps. First, we optimize the operational parameters, the cycle time, and the thickness of the adsorbent for a given adsorption material. In a second step we use a material model to predict heat and mass transfer and adsorption capacity from structural material parameters. This allows us to vary the structural material parameters and calculate the optimal operational parameters for each adsorbent. The two-step optimization thus identifies optimal material properties together with corresponding optimal operational parameters. As constraints, a minimum specific cooling power (SCP) and the passive mass of heat transfer pipes are used. The coefficient of performance (COP) is taken as the objective function. We exemplarily demonstrate the approach for a two-bed adsorption chiller, carbide-derived carbon as the adsorbent, methanol as the sorptive and boron-nitrate as additive to improve heat conductivity. The approach can be easily extended to multi-bed installations and more sophisticated material models. Full article

Viscoelastic bonds intended for Discrete Multiphysics (DMP) models are developed to allow the study of viscoelastic particles with arbitrary shape and mechanical inhomogeneity that are relevant to the pharmaceutical sector and that have not been addressed by the Discrete Element Method (DEM). The model is applied to encapsulate particles with a soft outer shell due, for example, to the partial ingress of moisture. This was validated by the simulation of spherical homogeneous linear elastic and viscoelastic particles. The method is based on forming a particle from an assembly of beads connected by springs or springs and dashpots that allow the sub-surface stress fields to be computed, and hence an accurate description of the gross deformation. It is computationally more expensive than DEM, but could be used to define more effective interaction laws. Full article

The physical properties, like density and viscosity, of alkanolamine + H₂O (water) + CO₂ (carbon dioxide) mixtures receive a significant amount of attention as they are essential in equipment sizing, mathematical modelling and simulations of amine-based post-combustion CO₂ capture processes. Non-linear models based on artificial neural networks (ANNs) were trained to correlate measured densities and viscosities of monoethanol amine (MEA) + H₂O, MEA + H₂O + CO₂, and 2-amino-2-methyl-1-propanol (AMP) + MEA + H₂O + CO₂ mixtures and results were compared with conventional correlations found in literature. For CO₂-loaded aqueous amine mixtures, results from the ANN models are in good agreement with measured properties with less than 1% average absolute relative deviation (AARD). The ANN-based methodology shows much better agreement (R² > 0.99) between calculated and measured values than conventional correlations. Full article