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Processes

Processes is an international, peer-reviewed, open access journal on processes/systems in chemistry, biology, material, energy, environment, food, pharmaceutical, manufacturing, automation control, catalysis, separation, particle and allied engineering fields published semimonthly online by MDPI.
The Brazilian Association of Chemical Engineering (ABEQ) is affiliated with Processes and its members receive discounts on the article processing charges. Please visit Society Collaborations for more details.

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This study addresses the dual challenges of low copper recovery and persistent arsenic pollution in the bioleaching of low-grade, high-arsenic copper ores containing enargite (Cu3AsS4). Through integrated electrochemical, chemical, and biological investigations, a selective and environmentally sustainable two-stage hybrid leaching process was developed. Electrochemical analysis identified a critical oxidation threshold of ~750 mV governing enargite dissolution. Chemical leaching and X-ray Photoelectron Spectroscopy (XPS) analysis revealed a temperature-dependent sulfur transformation pathway, enabling a staged thermal strategy: flotation below 40 °C to maximize hydrophobic elemental sulfur (S0) formation, and bioleaching at 40–55 °C to promote complete sulfur oxidation to sulfate. Optimization produced a two-stage process comprising 10-day chemical pre-leaching with FeSO4 (10.0 g/L Fe2+) followed by bioleaching, achieving 78.3% copper extraction while suppressing arsenic dissolution to approximately 10%. The use of FeSO4 instead of Fe2(SO4)3 reduces reagent costs by ~70%, saving an estimated CNY 47,250 daily at 1000 t/d scale. Leaching toxicity tests confirm residue As < 0.10 mg/L, meeting non-hazardous waste standards (GB5085.3-2007). This work provides the first integrated demonstration of electrochemical threshold control combined with temperature-dependent sulfur speciation for selective copper extraction from arsenic-bearing enargite ores, offering a scalable, reagent-economical, and environmentally sustainable metallurgical route.

13 March 2026

(a) Experimental workflow diagram showing the interconnection of the three modules (electrochemistry, chemical leaching, and bioleaching) and the material flow between them. (b) Schematic illustration of the electrochemical experimental setup.

Geothermal energy is a clean, renewable, and baseload-stable resource of strategic importance for carbon neutrality. Hot dry rock (HDR) reservoirs are characterized by high temperatures, great depths, and abundant reserves. However, their extremely low natural permeability requires artificial fracturing to establish effective heat exchange networks. Conventional hydraulic fracturing in enhanced geothermal systems (EGS) faces major challenges under HDR conditions, including excessive water consumption, strong water–rock interactions, and elevated induced seismicity risks, limiting its engineering applicability. Waterless or low-water fracturing technologies offer alternative stimulation pathways due to their distinctive physicochemical properties. Existing reviews have mainly addressed individual aspects, such as specific fracturing media or proppant transport, without systematically integrating recent advances in supercritical CO2 fracturing, foam fracturing, liquid nitrogen fracturing, and hybrid-fluid fracturing technologies, or comprehensively evaluating their engineering implications. This review systematically analyzed the fracturing mechanisms, heat exchange performance, environmental risks, and HDR-specific engineering challenges of these technologies. Results indicate that waterless/low-water fracturing technologies enhance heat extraction efficiency by generating complex fracture networks while mitigating seismic and reservoir damage risks. However, large-scale application requires further advances in the high-temperature stability of fracturing media, material durability, multiphase flow control, and field validation.

13 March 2026

Schematic diagram of EGS (modified from [38]).

Ozonation is widely applied for refractory wastewater treatment, but its practical engineering is often limited by poor ozone mass transfer and low ozone utilization. In this study, micro-nano bubbles (MNBs) technology was employed to improve ozone delivery, and the performance of an O3-MNBs system for treating coking reverse osmosis concentrate (ROC) was systematically compared with the conventional millimeter-sized ozone bubbles (O3-MBs) system. To further promote oxidation, hydrogen peroxide (H2O2) was introduced, forming an O3-MNBs/H2O2 system. Results showed that O3-MNBs (D50 = 36 μm) achieved a volumetric mass transfer coefficient 2.5 times higher than O3-MBs. Under optimized conditions (pH: 7–9, ozone dosage: 10 mg/(L·min), temperature: 20–30 °C), COD removal in the O3-MNBs system reached 34.9 ± 1.2%, nearly twice that of the O3-MBs system, while the O/C ratio decreased by approximately 50% (4.7 ± 0.2), indicating enhanced ozone utilization efficiency. The addition of H2O2 further increased COD removal to 52.1 ± 2.9% and reduced the O/C ratio to 2.9 ± 0.2, reflecting strong synergistic effects. Moreover, the integration of MNBs and H2O2 effectively reduced energy consumption per unit of pollutant removed. Overall, the O3-MNBs-based technology enhances organic pollutant degradation, ozone utilization and energy efficiency, offering a promising strategy for high-salinity refractory wastewater treatment.

13 March 2026

Schematic diagram and photographs of the experimental apparatus: (a) Schematic of the ozonation experimental setup; (b) Photograph of the actual apparatus; (c) Comparison of bubble morphologies during operation.

Thermochemical heat storage technology serves as an effective approach for efficient recovery and cross-seasonal storage of low-grade waste heat. However, traditional packed-bed heat exchange methods in industrial applications are prone to material contamination and performance degradation due to impurities in waste heat gases. To address this, this study proposes and constructs a thermochemical heat storage system based on moving-bed indirect heat exchange, using magnesium sulfate heptahydrate (MgSO4·7H2O) as the heat storage medium. The system investigates its desorption and heat storage characteristics within the moving bed. A small-scale moving-bed experimental platform was established, incorporating a vacuum-assisted system to promptly remove water vapor generated during desorption. The experimental system examines the effects of different operating parameters (e.g., inlet water temperature and flow rate) on particle temperature fields, desorption rates, and overall heat transfer performance. Results demonstrate that MgSO4·7H2O exhibits excellent heat storage stability and reaction controllability in the medium-low temperature range (60–95 °C). Increasing inlet water temperature and flow rate enhances desorption processes, but high temperatures also lead to increased temperature gradients, reducing waste heat recovery rates. Practical applications require optimizing the balance between heat transfer enhancement and desorption time. Compared to conventional heat storage particles, the moving-bed system using magnesium sulfate heptahydrate achieves approximately 30% higher overall heat transfer coefficient. Compared to traditional packed beds, the moving-bed heat exchange method demonstrates superior heat transfer uniformity and storage efficiency. This study validates the feasibility of the “moving-bed + thermochemical heat storage + vacuum desorption” technology under non-clean heat source conditions, providing experimental evidence and technical references for efficient industrial waste heat recovery and high-density storage.

13 March 2026

(a) Experimental apparatus diagram, (b) layout of temperature measurement points.

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Phytochemicals

Extraction, Optimization, Identification, Biological Activities, and Applications in the Food, Nutraceutical, and Pharmaceutical Industries
Editors: Ibrahim M. Abu-Reidah
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Processes - ISSN 2227-9717