Processes

Nowadays, the proportional–integral–derivative (PID) controller dominates industrial process control. Because of the compromise between parameters, its tuning is still a challenge for practitioners. A reference model (RM)-based PID controller—the desired dynamic equational (DDE) PID controller—is regarded as a viable alternative since it can readily eliminate the compromise. However, how to design its desired dynamic equation remains an unsolved problem which limits the application of DDE PID controllers in large-scale industrial systems. Therefore, this paper studies the desired dynamic selection of DDE PID controllers and proposes a simple and practical selection procedure without using the accurate plant model. Simulations, experiments and filed tests demonstrate the convenience and advantages of the proposed method, thus making DDE PID an effective controller type which is specifically appealing to engineers. Moreover, the successful application of DDE PID controllers to a high-pressure (HP) heater in a coal-fired power plant shows their promising prospects in the future power industry with the increasing demand to integrate more renewables into the grid. Full article

Limited-entry fracturing (LEF) technology is a widely used method to realize the simultaneous propagation of multiple fractures in horizontal wells. The key of this technology is to create high perforation friction to maintain the high treatment pressure in the wellbore and realize the uniform fluid entry of multi-fractures; however, high perforation friction cannot be effectively maintained due to the serious perforation erosion effect. Considering that the current laboratory studies mostly used small fluid injection flowrate, low injection pressure, and small proppant dosage, this study has developed a field-scale flow system to investigate the effect of various factors on perforation erosion under real field conditions. The filed-scale flow system uses the real fracturing trucks, proppant, and perforated wellbore, the fluid flow rate through perforation could reach 200 m/s and the injection pressure could reach 105 MPa. The effects of different parameters, such as injection flow rates, proppant concentration, proppant type, proppant size, and carrying fluid viscosity, on the perforation erosion were investigated. The experimental results show that: (1) The perforation friction during erosion goes through two stages, i.e., the roundness erosion stage and the diameter erosion stage. The reduction of perforating friction mainly occurred in the first stage, which was completed after injecting 1 m³ proppant. (2) After erosion, the perforation changes from the original circular shape to a trumpet shape, the inner diameter is much larger than the outer diameter. (3) The more serious perforation erosion is caused by the conditions of high injection flow rate, large proppant size, using ceramic proppant, and low viscosity fluid. The findings of this study can help for a better understanding of perforation erosion during the limited-entry fracturing in the horizontal wells, and also could promote the establishment of a theoretical model of perforation erosion under the field-scale conditions. Full article

The main objective of this study is to develop a novel green-nanofluid from Sapindus Saponaria for its application in enhanced oil recovery (EOR) processes. The bio-nanofluid is composed of a green active compound (AGC), bio-ethanol, and commercial surfactant (SB) at a low concentration. The AGC was obtained from soapberry “Sapindus Saponaria” using the alcoholic extraction method and characterized by Fourier transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), and critical micellar concentration (CMC) to verify the content of saponins as active agents with surface-active behavior. Three types of silica-based nanoparticles were used and characterized by FTIR, TGA, and dynamic light scattering (DLS) analysis. Two commercial nanoparticles (SiO₂-C₁ and SiO₂-C₂) were evaluated, and a third one (SiO₂-RH) was synthesized from rice husks as an ecological nanomaterial alternative. The performance of the adjusted systems was evaluated by capillary number (effective interfacial tension (${\sigma }_e$), wettability and viscosity) and finally with coreflooding tests under reservoir conditions. The FTIR results confirm the presence of saponins in the AGC. In addition, according to the TGA, the AGC is stable under the reservoir temperature of interest. Regarding nanoparticles, siloxane and silanol groups were observed in all samples. For SiO₂-C₁ and SiO₂-C₂ samples, the weight loss was lower than 5% for temperatures up to 700 °C. Meanwhile, SiO₂-RH had a weight loss of 12% at 800 °C, and 8% at reservoir temperature. Results show a decrease in the interfacial tension (IFT) of up to 83% of the tuned system with only 100 mg·L⁻¹ of rice husk nanoparticles compared to the system without nanoparticles, reaching values of 1.60 × 10⁻¹ mN·m⁻¹. In the coreflooding test, increases of up to 13% of additional crude oil were obtained using the best bio-nanofluid. This work presents an excellent opportunity to include green alternatives to improve conventional techniques with added value during the injection of chemicals in chemical-enhanced oil recovery (CEOR) processes. Full article

Ceramic/fiber composite armor is a hot research topic of bulletproof equipment. The lightweight design of ceramic materials and structures has attracted much attention. In this work, in the light of the remarkable performance of ceramic against elastic and oblique penetration, a novel honeycomb ceramic panel with a hexagonal prism and spherical body was designed. The splicing ceramic/fiber composite plate was bonded with a PE plate. The splicing ceramic/fiber composite was prepared, and the target test of the composite was conducted. The results show that the bulletproof performance of the hexagonal prism spherical crown ceramic/fiber composite plate is better than that of the conventional ceramic/fiber composite plate of the same thickness. The honeycomb spherical crown structure of the ceramic surface can convert the nominal forward penetration into the actual oblique penetration. This surface structure provides an effective lightweight design of ceramic/fiber composite armor. Full article

Protective coal seam mining can not only effectively prevent coal and gas outbursts in mines, but also provide stress unloading space for the protected coal seam. The coal body in the protected coal seam might undergo deformation, internal damage and structural damage, which changes its gas seepage characteristics. This study aims to explore the variations of permeability of the coal body in the protected coal seam under axial unloading. With the coal body from the outburst coal seam in the Huaibei mining area as the research object, experiments were conducted to explore the gas seepage characteristics of axially unloaded coal body under different confining pressures and gas pressures, using the TAWD-2000 coal-rock mechanics-seepage experimental system. According to the results, with respect to the gas seepage, the variations of permeabilities of axially unloaded coal samples are closely related to their deformation and damage. As the confining pressure and gas pressure rise, the difference between the permeability at the final failure point and the initial permeability rises at a decreasing rate. The experiments fully demonstrate that the protective coal seam is technically important for the unloaded gas drainage and the coal and gas outburst prevention of the protected coal seam. Under different confining pressures and gas pressures, the permeability of axially unloaded coal varies to different extents and at different rates. The mining scheme for the protective coal seam should be designed in accordance with its confining pressure and gas pressure. This study is of guiding significance for the prevention and control of coal and gas outbursts in coal seam groups. Full article

In order to improve the pump device efficiency of the frequent operating condition of the extra-low head pumping station, the energy performance of the front-positioned shaft tubular pump device at two guide vane inlet angles has been researched. Based on the function of the guide vane in the pump device, the guide vane blades are divided into three parts: the inlet section, the middle section, and the outlet section. Combining numerical simulation and model tests, the energy performance of the pump device with the inlet section angle adjusted to 0° and −12° were studied and compared, respectively. The research results indicate that the inlet section angle of the guide vane has a significant effect on the energy performance of the pump device. When the guide vane inlet section is adjusted clockwise, the pump device efficiency of the optimal operating point—while the efficiency of the pump device at a low head and large discharge that deviate from the optimal operating point—will be improved. The farther the working condition deviates from the optimal operating point, the greater the influence. Within the scope of the working conditions studied in this paper, the pump device efficiency of the optimal operating point is reduced by about 2%, and the pump device efficiency in the low head and high flow conditions is increased by 5% at the maximum. Adjusting the inlet section angle of the guide vane, the flow pattern in the guide vane will be improved, and the hydraulic loss of the guide vane will be decreased, thus the pump device efficiency is increased. The numerical calculation results of the energy performance agree with the model test results; the maximum error of the pump device efficiency is less than 7%. Adjusting the angle of the inlet section of the guide vane has great significance to the hydraulic design and engineering application of the extra-low head pump device. Full article

The ongoing pandemic of coronavirus disease (COVID-19) stimulated an unprecedented international collaborative effort for rapid diagnosis, epidemiologic surveillance, clinical management, prevention, and treatment. This review focuses on the current and new therapeutical approaches, summarizing the viral structure and life cycle, with an emphasis on the specific steps that can be interfered by antivirals: (a) inhibition of viral entry with anti-spike monoclonal antibodies; (b) inhibition of the RNA genome replication with nucleosidic analogs blocking the viral RNA polymerase; (c) inhibition of the main viral protease (Mpro), which directs the formation of the nonstructural proteins. An overview of the immunomodulatory drugs currently used for severe COVID-19 treatment and future therapeutical options are also discussed. Full article

The bi-reforming of methane (BRM) is a promising process which converts greenhouse gases to syngas with a flexible H₂/CO ratio. As there are many factors that affect this process, the coupled effects of multi-parameters on the BRM product are investigated based on Gibbs free energy minimization. Establishing a reliable model is the foundation of process optimization. When three input parameters are changed simultaneously, the resulting BRM products are used as the dataset to train three artificial neural network (ANN) models, which aim to establish the BRM prediction model. Finally, the trained ANN models are used to predict the BRM products when the conditions vary in and beyond the training range to test their performances. Results show that increasing temperature is beneficial to the conversion of CH₄. When the molar flow of H₂O is at a low level, the increase in CO₂ can enhance the H₂ generation. While it is more than 0.200 kmol/h, increasing the CO₂ flowrate leads to the increase and then decrease in the H₂ molar flow in the reforming products. When the numbers of hidden layer neurons in ANN models are set as (3, 3), (3, 6) and (6, 6), all the correlation coefficients of training, validation and test are higher than 0.995. When these ANN models are used to predict the BRM products, the variation range of the prediction error becomes narrower, and the standard deviation decreases with the increase in neuron number. This demonstrates that the ANN model with more neurons has a higher accuracy. The ANN model with neuron numbers of (6, 6) can be used to predict the BRM products even when the operating conditions are beyond the training ranges, demonstrating that this model has good extension performance. This work lays the foundation for an artificial intelligent model for the BRM process, and established ANN models can be further used to optimize the operating parameters in future work. Full article

To obtain local flow velocity and holdup for oil–water in a near-horizontal well, array probes were adopted in the cross section of the wellbore. In this study, a fluid flow imaging logging tool called the single-probe multi-position measurement fluid imager (SPFI) was developed, which consisted of only a single turbine flowmeter and a single capacitance holdup probe. Most importantly, it could collect local velocity and holdup information at different locations along the vertical direction of the wellbore diameter. Firstly, in the large-diameter multi-phase flow simulation test loop, the instrument was placed at five different positions along the wellbore cross section to perform simulated measurements in different wellbore deviation angles and oil–water flowrates. Secondly, the experiment data was analyzed, and the experiment flow pattern chart, instrument response coefficient, and rule of the instrument response were obtained. At the same time, the calculation methods of local holdup and local velocity were derived. Thirdly, by combining the interpolation algorithm, velocity imaging and holdup imaging were implemented, and the stratified flow model was used to calculate the flowrate of each phase. Finally, this study provides technology support for production profile data interpretation using the fluid flow imaging tool for oil–water in a near-horizontal well. Full article

Proteases that can remain active under extreme conditions such as high temperature, pH, and salt concentration are widely applicable in the commercial sector. The majority of the proteases are rendered useless under harsh conditions in industries. Therefore, there is a need to search for new proteases that can tolerate and function in harsh conditions, thus improving their commercial value. In this study, 142 bacterial isolates were isolated from diverse alkaline soil habitats. The two highest protease-producing bacterial isolates were identified as Bacillus subtilis S1 and Bacillus amyloliquefaciens KSM12, respectively, based on 16S rRNA sequencing. Optimal protease production was detected at pH 8, 37 °C, 48 h, 5% (w/v) NaCl for Bacillus subtilis S1 (99.8 U/mL) and pH 9, 37 °C, 72 h, 10% (w/v) NaCl for Bacillus amyloliquefaciens KSM12 (94.6 U/mL). The molecular weight of these partially purified proteases was then assessed on SDS-PAGE (17 kDa for Bacillus subtilis S1 and 65 kDa for Bacillus amyloliquefaciens KSM12), respectively. The maximum protease activity for Bacillus subtilis S1 was detected at pH 8, 40 °C, and for Bacillus amyloliquefaciens KSM12 at pH 9, 60 °C. These results suggest that the proteases secreted by Bacillus subtilis S1 and Bacillus amyloliquefaciens KSM12 are suitable for industries working in a highly alkaline environment. Full article

Background: Green extraction involves using green solvents, such as water, to reduce energy consumption, avoid health and environmental hazards and induce the quality and quantity of the extract. Date palm fruits are a vital source of food and medicinal activities, as they contain a high diversity of phytochemicals, mainly phenolic and flavonoid compounds. The main aim of this study is to investigate the use of water as a green solvent, when assisted by different ultrasonic frequencies, in the extraction of four different cultivars of date palm fruits, by evaluating the phenolic and flavonoid composition as well as the antioxidant capacity of the extract. Methods: Four date palm fruits’ cultivars (Agwa, Anbarah, Khalas, and Reziz) were extracted using conventional methods (by water and ethanol) and by ultrasonic means, using two frequencies, 28 and 40 kHz, and applying temperatures (30, 45, and 60 °C), also measuring extraction times (20, 40, 60 min.). Response surface methodology was used for the statistical analysis, applying three factors (temperature, time, and ultrasonic frequency), four responses (total phenolic content, total flavonoid content, FRAP, and ABTS), and four cultivars (categories). Results: Conventional water extraction obtained minimal phenolic and flavonoid compounds (up to 52% of ethanol extraction). This percent improved to reach 60% when heat was utilized. The application of ultrasonic frequencies significantly enhanced the extraction of phenolics/flavonoids and the antioxidant ability of the extract to nearly 90% and 80%, respectively. The use of 40 kHz ultrasonic power managed to extract more phenolic and flavonoid components; however, the antioxidant capacities of the extract were less than when the 28 kHz power was utilized. Agwa and Khalas demonstrated themselves to be the best cultivars for ultrasonic-assisted extraction, depending on the results of the optimized responses. Conclusion: This study could be implemented in the industry to produce date palm fruits’ enriched extracts with phenolic and flavonoid components and/or antioxidants. Full article

The increasing demand for renewable energy sources and demand-oriented electricity provision makes anaerobic digestion (AD) one of the most promising technologies. In addition to energy crops, the use of lignocellulosic residual and waste materials from agriculture is becoming increasingly important. However, AD of such feedstocks is often associated with difficulties due to the high content of lignocellulose and its microbial persistence. In the present work, the effect of hydrothermal pretreatment (HTP) on the digestibility of wheat straw is investigated and evaluated. Under different HTP temperatures (160–180 °C) and retention times (15–45 min), a significant increase in biomethane potential (BMP) can be observed in all cases. The highest BMP (309.64 mL CH4 g⁻¹ volatile solid (VS) is achieved after pretreatment at 160 °C for 45 min, which corresponds to an increase of 19% of untreated wheat straw. The results of a multiple linear regression model show that the solubilization of organic materials is influenced by temperature and time. Furthermore, using two different first-order kinetic models, an enhancement of AD rate during hydrolysis due to pretreatment is observed. However, the increasing intensity of pretreatment conditions is accompanied by a decreasing trend in the conversion of intermediates to methane. Full article

Volatile markets and increasing demands for quality and fast availability of specialty chemical products have motivated the rise of small-scale, integrated, and modular continuous processing plants. As a significant unit operation used for product isolation and purification, cooling crystallization is part of this trend. Here, the small-scale and integrated quasi-continuous filter belt crystallizer (QCFBC) combines cooling crystallization, solid-liquid separation, and drying on a single apparatus. This contribution shows the general working principle, different operation modes, and possibilities of temperature control with the modular setup. For precise temperature control in cooling crystallization, Peltier elements show promising results in a systematic study of different operation parameters. Sucrose/water was used as a model substance system. The results confirm that seed crystal properties are the most important parameter in crystallization processes. Additionally, an oscillating temperature profile has a narrowing effect on the crystal size distribution (CSD). The integrated, small-scale, and modular setup of the QCFBC offers high degrees of flexibility, process control, and adaptability to cope with future market demands. Full article

Chemical accidents are the biggest factor that hinders the development of the chemical industry. Issuing an emergency evacuation order is one of effective ways to reduce human casualties that may occur due to chemical accidents. The present study proposes a machine learning-based decision making model for faster and more accurate decision making for the issuance of an emergency evacuation order in the event of a chemical accident. To implement the decision making model, supervised learning by the 1-Dimension Convolutional Neural Network based model was carried out using the HSEES and NTSIP data of ATSDR in the United States. An action—victim matrix was devised to determine the validity of emergency evacuation orders and the decision making model was made to learn the matrix so that the decision making model could recommend whether to execute the emergency evacuation orders or not. To make the decision making model learn the chemical accident situations, the embedding technique used in text mining was applied, and weighted learning was carried out considering the fact that learning data are asymmetric. The AUROC value for the results of the decision making by the model is 0.82, which is at a reliable level. Establishing such an emergency response decision making model using the method proposed in the present study in the mitigation stage will help the process. Among the chemical accident emergency management stages, constructing a database for the model, and using the model as a tool for quick decision making for an emergency evacuation order, is also thought to be helpful in the establishment and implementation of emergency response plans for chemical accidents. Full article

The practice of odorant analysis can often be very challenging because odorants are usually composed of a host of volatile organic compounds (VOCs) at low concentrations. Preconcentration with solid phase microextraction (SPME) is a conventional technique for the enrichment of these volatile compounds before analysis by headspace gas chromatography-mass spectrometry (GC-MS). However, commercially available SPME products usually bear the defects of weak mechanical strength and high cost. In this work, novel SPME fibers were prepared by a one-pot synthesis procedure from divinylbenzene (DVB), porous carbon powder (Carbon) and polydimethylsiloxane (PDMS). Factors that influence the extraction efficiency, such as extraction temperature, extraction time, salting effects, pH, stirring rate, desorption temperature and time, were optimized. VOCs in landfills pose a great threat to human health and the environment. The new SPME fibers were successfully applied in the analysis of VOCs from the leachate of a cyanobacteria landfill. Quantification methods of major odor contributors were established, and a good linearity (r > 0.998) was obtained, with detection limits in the range of 0.30–0.50 ng/L. Compared to commercial SPME fibers, the new material has higher extraction efficacy and higher precision. Hence, it is suitable for the determination of hazardous odorants of various sources. Full article

As a traditional processing method, the Nine-Steam-Nine-Bask method has been widely used in the special processing of Chinese medicinal materials. With the highly integrated design and innovation of infiltrating equipment, steaming equipment, drying equipment, and other equipment, a new type of integrated equipment for the Nine-Steam-Nine-Bask method was finally developed and successfully applied in Polygonatum cyrtonema processing. Moreover, seven new processes were explored. The longer the steaming time was, the more steaming and drying cycles, the lower the product recovery rate and the higher the energy consumption. The higher the steaming pressure was, the lower the product recovery rate, the higher the energy consumption and the shorter the drying time. The longer the drying time was, the lower the product recovery rate and polysaccharide content, and the higher the energy consumption. The best new process was XGY1, which had the highest overall score. The steaming process was the most time-consuming and energy-intensive production process, followed by the drying process. The obtained results can provide knowledgeable guidance for the further optimization of the integrated equipment of the Nine-Steam-Nine-Bask method and the development and application of technology for processing characteristic Chinese medicinal materials. Full article

In this paper, a set of novel adaptive control strategies based on an advanced G-L (proposed by Ge-Li-Tam, called GLT) fuzzy system is proposed. Three main design points can be summarized as follows: (1) the unknown parameters in a nonlinear dynamic system are regarded as extra nonlinear terms and are further packaged into so-called nonlinear terms groups for each equation through the modeling process, which reduces the complexity of the GLT fuzzy system; (2) the error dynamics are further rearranged into two parts, adjustable membership function and uncertain membership function, to aid the design of the controllers; (3) a set of adaptive controllers change with the estimated parameters and the update laws of parameters are provided following the current form of error dynamics. Two identical nonlinear dynamic systems based on a Quantum-CNN system (Q-CNN system) with two added terms are employed for simulations to demonstrate the feasibility as well as the effectiveness of the proposed fuzzy adaptive control scheme, where the tracking error can be eliminated efficiently. Full article

Biodiesel is considered a renewable, green fuel as it is derived from renewable living resources like animal fats or vegetable oils. This research is utilized to investigate the possibility of using Solvay wastewater as a source of biodiesel catalyst, which is CaO. CaCl₂ from Solvay wastewater reacts with CO₂ to produce CaCO₃. CaCO₃ is then heated to produce pure CaO. Waste cooking oil, wastewater, and CO₂, which are considered dangerous materials to the environment, are used to produce valuable products. This research has environmental and economic benefit benefits of using waste materials as a replacement for raw materials. The selected experimental parameters for the CaCO₃ production step are stirring rate (500–1300) rpm, CO₂ gas flow rate (900–2000) mL/min, amount of ammonia (15–35) mL, and glycerol volume (0–25) mL. The selected experimental parameters for the biodiesel production step are reaction time (2–6) h, methanol to oil ratio (9–15), catalyst loading (1–5) %, and reaction temperature (50–70) °C. The impact of reaction parameters on reaction responses was assessed using the response surface methodology technique. A formula that represents the reaction response as a function of all the independent factors has been created. The optimization of the process is done in two steps: the first one is for the CaCO₃ process while the second one is biodiesel production optimization. The first optimization was done to get the CaCO₃ with minimum particle size and yield. The second optimization was done to get the maximum amount of biodiesel using minimum energy and low reaction conditions. Process optimization resulted in another economic benefit for this research. The resulted biodiesel yield equals 95.8% biodiesel yield at 2 h reaction time, 15:1 molar ratio of methanol to oil, 56 °C reaction temperature, and 1% catalyst loading. Full article

Emerging pollutants are present in wastewaters treated by conventional processes. Due to water cycle interactions, these contaminants have been reported in groundwater, surface water, and drinking waters. Since conventional processes cannot guarantee their removal or biotransformation, it is necessary to study processes that comply with complete elimination. The current literature review was conducted to describe and provide an overview of the available information about the most significant groups of emerging pollutants that could potentially be found in the wastewater and the environment. In addition, it describes the main entry and distribution pathways of emerging contaminants into the environment through the water and wastewater cycle, as well as some of the potential effects they may cause to flora, fauna, and humans. Relevant information on the SARS-CoV-2 virus and its potential spread through wastewater is included. Furthermore, it also outlines some of the Advanced Oxidation Processes (AOPs) used for the total or partial emerging pollutants removal, emphasizing the reaction mechanisms and process parameters that need to be considered. As well, some biological processes that, although slow, are effective for the biotransformation of some emerging contaminants and can be used in combination with advanced oxidation processes. Full article