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24 pages, 5737 KiB

Open AccessArticle

Systematic Cause Analysis of an Explosion Accident During the Packaging of Dangerous Goods

by Juwon Park, Keunwon Lee, Mimi Min, Chuntak Phark and Seungho Jung

Processes 2025, 13(3), 687; https://doi.org/10.3390/pr13030687 - 27 Feb 2025

Viewed by 560

Abstract

Chemical plants inherently handle and operate with a wide range of hazardous materials, making them more prone to accidents compared to other industrial sectors. Consequently, safety management in chemical plants tends to be systematically organized based on elements of process safety management (PSM) [...] Read more.

Chemical plants inherently handle and operate with a wide range of hazardous materials, making them more prone to accidents compared to other industrial sectors. Consequently, safety management in chemical plants tends to be systematically organized based on elements of process safety management (PSM) systems. In June 2023, South Korea’s Ministry of Employment and Labor released the Serious Injury and Fatality (SIF) report, which summarized 4432 major accident cases that occurred over six years (2016–2021), including 1834 cases in manufacturing and related industries and 2574 cases in construction. The report provided an overview of these accidents, their causes, and measures to prevent their recurrence, with a focus on fatalities and severe injuries associated with critical losses across different industries. This study examined 16 accident cases that occurred at PSM-regulated facilities, which are managed on the basis of a systematic safety framework established by regulatory requirements. Among these, particular attention was paid to an explosion accident in the organic catalyst packaging process at a facility with no prior accident history and exhibiting unique accident characteristics. A systemic root cause analysis was conducted using the barrier-based systemic cause analysis technique (BSCAT) and the system theoretic accident model and process (STAMP-CAST) methodologies. The systemic analysis highlighted the critical importance of clearly identifying materials or factors that may inadvertently mix during the process design or mass production phases and evaluating whether such interactions could lead to accidents during the hazard assessment stage. Beyond incorporating the risk mitigation measures identified in the process design and procedural development phases without omissions, it is essential to periodically conduct “worker-centered risk assessments”. These assessments help evaluate the potential for accidents resulting from human errors, such as workers’ non-compliance with established procedures, which is a key aspect of preventing chemical accidents. Although this study did not include an evaluation of the impacts of high pressures or high temperatures on workers near chemical accident sites—hence, no specific recommendations regarding safe working distances are made—the findings are expected to contribute to the development of preventive measures for chemical accidents in smaller-scale plants where workers directly manage and operate processes. Full article

(This article belongs to the Special Issue Technological Processes for Chemical and Related Industries)

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29 pages, 3980 KiB

Open AccessArticle

Integrating Process Safety and Process Security Risk Management: Practitioner Insights for a Resilience-Oriented Framework

by Muhammad Shah Ab Rahim, Genserik Reniers, Ming Yang and Parthiban Siwayanan

Processes 2025, 13(2), 392; https://doi.org/10.3390/pr13020392 - 1 Feb 2025

Viewed by 942

Abstract

Integrating process safety and process security risk management is increasingly essential for enhancing resilience in the chemical process industry. This study addresses how practitioners perceive the integration of these two domains, identifying key benefits, barriers, and strategies for effective implementation. A mixed-methods approach [...] Read more.

Integrating process safety and process security risk management is increasingly essential for enhancing resilience in the chemical process industry. This study addresses how practitioners perceive the integration of these two domains, identifying key benefits, barriers, and strategies for effective implementation. A mixed-methods approach was applied, combining quantitative survey data from 47 industry professionals with qualitative insights from open-ended responses. The findings highlight significant advantages of integration, such as optimized resource use, reduced operational redundancies, and improved risk management. However, barriers such as knowledge gaps, resource constraints, and communication silos were identified. Respondents emphasized the importance of adopting a resilience-oriented approach involving proactive risk management, continuous improvement, and adaptability in both safety and security practices. Critical enablers for integration include strong leadership, alignment of societal values, cross-disciplinary training, and integrated risk assessment methodologies. Emerging technologies and regulatory alignment were also identified as critical factors in facilitating integration. The study contributes to the theoretical understanding of integrated risk management by supporting resilience engineering and systems theory. It offers actionable strategies for overcoming barriers and leveraging enablers, laying the groundwork for developing a resilience-oriented framework for process safety and process security risk management. Full article

(This article belongs to the Special Issue Technological Processes for Chemical and Related Industries)

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22 pages, 26303 KiB

Open AccessArticle

Development of Digital Twins for Continuous Processes: Concept Description of Virtual Mass Balance Based on the Tennessee Eastman Process

by Jakub Fudyma, Łukasz Kura and Jacek Gębicki

Processes 2025, 13(2), 337; https://doi.org/10.3390/pr13020337 - 25 Jan 2025

Viewed by 608

Abstract

In this work, the authors describe a concept called Virtual Mass Balance and its applicability to oil and gas fields. This study relies on data modelling and data engineering to enrich operational data and achieve digitized Material Balance Tables for monitoring and benchmarking [...] Read more.

In this work, the authors describe a concept called Virtual Mass Balance and its applicability to oil and gas fields. This study relies on data modelling and data engineering to enrich operational data and achieve digitized Material Balance Tables for monitoring and benchmarking purposes. A data-driven set of stream properties allow for the calculation of newly proposed soft sensors, which are subsequently used for predictive functionalities. The implementation of this concept has proven popular in an industry set of tools, AVEVA PI. The concept could be classified as an Enriched Digital Twin. Incorporating the DEXPI Process model and deploying proposed soft sensors could, on the one hand, combine both asset and operational characteristics. On the other hand, its simplicity and moderate level of detail can be much easier to implement and would show flexible applicability at various corporate levels. The application of the Tennessee Eastman Process proves its flexibility. The presented soft sensors exhibit good monitoring capabilities and, furthermore, allow for the application of data-driven artificial intelligence methods without a reduction in model clarity for operational staff. Full article

(This article belongs to the Special Issue Technological Processes for Chemical and Related Industries)

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17 pages, 4254 KiB

Open AccessArticle

Optimizing Large-Scale Inorganic Processes: Model-Based Digital Design of RH-DS Apparatus

by Sławomir Szczeblewski, Maciej Wachowiak and Jacek Gębicki

Processes 2025, 13(1), 77; https://doi.org/10.3390/pr13010077 - 1 Jan 2025

Viewed by 1187

Abstract

The design of industrial installations using digital design techniques (digital twin), aligned with the concept of Industry 4.0, provides a tool to optimize maintenance costs, process gas emissions, energy consumption and to reduce the risks associated with production testing. Modern manufacturing plants conduct [...] Read more.

The design of industrial installations using digital design techniques (digital twin), aligned with the concept of Industry 4.0, provides a tool to optimize maintenance costs, process gas emissions, energy consumption and to reduce the risks associated with production testing. Modern manufacturing plants conduct chemical processes by combining production experience with model-based research. Analyzing processes using advanced digital techniques can replace traditional methods of technological process balancing. The methodology based on the digital twin already serves as a holistic system of process connections, supporting production, research and development, production planning, and quality control. This paper presents the digital design, optimization, and comparison of process data obtained through simulations for two different types of ammonia recovery units in soda ash production using the ammonia–soda process. Using specialized modeling software and relying on historical data, engineering assumptions, and new concepts, virtual models were created in which the material and thermal balances of the process were simulated. This research is divided into two stages. In the first stage, a model-based approach and model optimization techniques are presented, while in the second stage, the preparation of models of the distillation installation is presented, and the influence of various structural parameters of the equipment on the temperature profile and gas flow rate in the ammonia recovery section is discussed. The process of the research method, based on simulations in a virtual environment, allows for evaluating the implementation potential of the proposed concepts, optimizing process parameters, and redefining the approach to conducting chemical processes. A series of simulations conducted in studies on ammonia recovery indicated a potential increase in gaseous ammonia recovery by up to 14.09%, taking into account the type of distillation apparatus or the height of the packing section. Full article

(This article belongs to the Special Issue Technological Processes for Chemical and Related Industries)

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16 pages, 8772 KiB

Open AccessArticle

The Influence of Exogenous Particles on the Behavior of Non-Newtonian Mucus Fluid

by Agata Penconek, Urszula Michalczuk, Małgorzata Magnuska and Arkadiusz Moskal

Processes 2024, 12(12), 2765; https://doi.org/10.3390/pr12122765 - 5 Dec 2024

Viewed by 629

Abstract

Every day, approximately 7 m³ of air flows through the lungs of an adult, which comes into contact with 80 m² of the lung surface. This air contains both natural and anthropogenic particles, which can deposit on the surface of the [...] Read more.

Every day, approximately 7 m³ of air flows through the lungs of an adult, which comes into contact with 80 m² of the lung surface. This air contains both natural and anthropogenic particles, which can deposit on the surface of the mucus lining the respiratory tract. The presence of particles in the mucus leads to changes in its rheology and, consequently, in its functions. Therefore, this research aimed to determine how a non-Newtonian fluid suspension will behave during flow, illustrating the movement of mucus during coughing. The model mucus was an aqueous solution of carboxymethylcellulose (CMC). The tested particles suspended in a non-Newtonian fluid were Arizona Fine Dust, diesel exhaust particles, polyethylene microparticles, and pine pollen. It was noticed that as the fluid viscosity increases, the number of Kelvin–Helmholtz instabilities increases. The fluid’s expansion angle at the output of the measuring cell decreased, and the values of parameters characterizing the aerosol generated at the outlet decrease for selected particles present in the fluid. The research shows that the deposition of particles from polluted air in the respiratory tract, although they do not enter the bloodstream, may affect the human body. Deposited particles can change the behavior of mucus, which may translate into its functions. Full article

(This article belongs to the Special Issue Technological Processes for Chemical and Related Industries)

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14 pages, 4409 KiB

Open AccessArticle

Selective Processing of the Kaolinite Fraction of High-Silicon Bauxite

by Sergey Gladyshev, Symbat Dyussenova, Yerkezhan Abikak, Nazym Akhmadiyeva, Leila Imangaliyeva and Arina Bakhshyan

Processes 2024, 12(11), 2323; https://doi.org/10.3390/pr12112323 - 23 Oct 2024

Viewed by 834

Abstract

When processing low-quality gibbsite–kaolinite bauxites, technologies that involve different methods of mechanical and chemical enrichment with the separation of a difficult-to-utilize fine kaolinite fraction for disposal are used. Before production, problems related to waste storage and disposal arise. To solve the problem of [...] Read more.

When processing low-quality gibbsite–kaolinite bauxites, technologies that involve different methods of mechanical and chemical enrichment with the separation of a difficult-to-utilize fine kaolinite fraction for disposal are used. Before production, problems related to waste storage and disposal arise. To solve the problem of utilization, it is necessary to develop an effective technology for the selective processing of the kaolinite fraction. The efficiency of the technology will depend on the quality of pretreatment of raw materials prior to processing for Al₂O₃ extraction. Preliminary preparation of kaolinite fraction is associated with the maximum removal of excess silica during chemical enrichment by treatment with an alkaline solution. The presence of silica reduces the quality of final alumina products and requires a large consumption of reagents during the desiliconization of aluminate solutions. During the chemical enrichment of kaolinite fraction in alkaline solution, a serious problem of the co-dissolution of Al₂O₃ with silica arises. The solution to this problem can be the transformation of phase composition with the transformation of kaolin into a chemically resistant compound corundum, which will create conditions for the selective removal of silica. Kazakhstan’s alumina refinery, Pavlodar Aluminum Smelter, processes low-quality gibbsite–kaolinite bauxite from the Krasnogorsk deposit. To improve the quality of bauxite, preliminary gravity enrichment is carried out to separate the kaolinite fraction to a quantity greater than 50%. The purpose of this work was to study the possibility of the selective processing of the kaolinite fraction via various techniques, including preliminary thermal transformation, through sintering, chemical enrichment, autoclave leaching in a circulating aluminate solution, and low-temperature desiliconization, to obtain a solution for decomposition. As a result of this study, the possibility of obtaining a corundum phase after sintering at a temperature of 900–1000 °C was established, which made it possible to obtain 58.8% chemical enrichment through the extraction of SiO₂ into solution. Further use of the enriched kaolinite fraction in autoclave leaching in a circulating aluminate solution with low-temperature desiliconization made it possible to obtain an aluminate solution with a caustic modulus of 1.65–1.7, which is suitable for decomposition. Full article

(This article belongs to the Special Issue Technological Processes for Chemical and Related Industries)

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25 pages, 3591 KiB

Open AccessArticle

Predicting Petroleum SARA Composition from Density, Sulfur Content, Flash Point, and Simulated Distillation Data Using Regression and Artificial Neural Network Techniques

by Ivelina Shiskova, Dicho Stratiev, Sotir Sotirov, Evdokia Sotirova, Rosen Dinkov, Iliyan Kolev, Denis D. Stratiev, Svetoslav Nenov, Simeon Ribagin, Krassimir Atanassov, Dobromir Yordanov and Frans van den Berg

Processes 2024, 12(8), 1755; https://doi.org/10.3390/pr12081755 - 20 Aug 2024

Cited by 2 | Viewed by 1551

Abstract

The saturate, aromatic, resin, and asphaltene content in petroleum (SARA composition) provides valuable information about the chemical nature of oils, oil compatibility, colloidal stability, fouling potential, and other important aspects in petroleum chemistry and processing. For that reason, SARA composition data are important [...] Read more.

The saturate, aromatic, resin, and asphaltene content in petroleum (SARA composition) provides valuable information about the chemical nature of oils, oil compatibility, colloidal stability, fouling potential, and other important aspects in petroleum chemistry and processing. For that reason, SARA composition data are important for petroleum engineering research and practice. Unfortunately, the results of SARA composition measurements reported by diverse laboratories are frequently very dissimilar and the development of a method to assign SARA composition from oil bulk properties is a question that deserves attention. Petroleum fluids with great variability of SARA composition were employed in this study to model their SARA fraction contents from their density, flash point, sulfur content, and simulated distillation characteristics. Three data mining techniques: intercriteria analysis, regression, and artificial neural networks (ANNs) were applied. It was found that the ANN models predicted with higher accuracy the contents of resins and asphaltenes, whereas the non-linear regression model predicted most accurately the saturate fraction content but with an accuracy that was lower than that reported in the literature regarding uncertainty of measurement. The aromatic content was poorly predicted by all investigated techniques, although the prediction of aromatic content was within the uncertainty of measurement. The performed study suggests that as well as the investigated properties, additional characteristics need to be explored to account for complex petroleum chemistry in order to improve the accuracy of SARA composition prognosis. Full article

(This article belongs to the Special Issue Technological Processes for Chemical and Related Industries)

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16 pages, 1348 KiB

Open AccessArticle

Integration of Chemical Looping Combustion to a Gasified Stream with Low Hydrogen Content

by Guadalupe S. Fraga-Cruz, Mario A. Pérez-Méndez, Gladys Jiménez-García, Rafael Huirache-Acuña, Fabricio Nápoles-Rivera, Jaime Espino-Valencia and Rafael Maya-Yescas

Processes 2024, 12(5), 1033; https://doi.org/10.3390/pr12051033 - 19 May 2024

Cited by 1 | Viewed by 1262

Abstract

Global population growth requires the use of various natural resources to satisfy the basic needs of humanity. Fossil fuels are mainly used to produce electricity, transportation and the artificial air conditioning of habitats. Nevertheless, countries around the world are looking for alternative energy [...] Read more.

Global population growth requires the use of various natural resources to satisfy the basic needs of humanity. Fossil fuels are mainly used to produce electricity, transportation and the artificial air conditioning of habitats. Nevertheless, countries around the world are looking for alternative energy sources due to the decrease in the availability of these fuels and their high environmental impact. The mixture of hydrogen and carbon monoxide (H₂ + CO), commonly called syngas, is a high-value feedstock for various industrial applications. By varying the composition of syngas, especially the H₂/CO molar ratio, it can be used to produce methanol, fuels or synthetic natural gas. However, when this ratio is very low, the separation of this gas usually represents a great problem when making the energy balance, which is why it is proposed to adapt a combustion process in chemical cycles, taking advantage of the energy of this gas, reducing the energy impact of the process. During the present project, mass and energy balances were developed for combustion in chemical cycles, using ilmenite as a carrier, integrating heat exchangers to take advantage of the residual energy at the output of the process, to preheat the inlet current in the regenerator. Here, a comparative was made at different temperatures of the air stream and evaluating the mechanism of the ilmenite when a syngas stream is used as fuel. Full article

(This article belongs to the Special Issue Technological Processes for Chemical and Related Industries)

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16 pages, 6547 KiB

Open AccessArticle

Automatic Control of Nucleation and Crystal Growth Using Online Raman Analyzer

by Aofei Li, Boxue Chang, Zhen Li, Biao Chen, Kaidi Ji, Yangshun Chen, Shiqiang Ou, Fengming Zhang, Jiaoning Wei and Yinlan Ruan

Processes 2024, 12(4), 774; https://doi.org/10.3390/pr12040774 - 12 Apr 2024

Viewed by 1629

Abstract

The accurate determination of crystal formation during crystallization is crucial for obtaining crystal products with consistent quality and quantity. In this study, we aimed to identify the feasibility of using Raman spectroscopy to monitor the crystal growth stage in the crystallization process using [...] Read more.

The accurate determination of crystal formation during crystallization is crucial for obtaining crystal products with consistent quality and quantity. In this study, we aimed to identify the feasibility of using Raman spectroscopy to monitor the crystal growth stage in the crystallization process using cephalosporin intermediate 7-ACT as an example molecule. By observing the changes in the characteristic peak of the 7-ACT crystal (504 cm⁻¹) and the characteristic peak of the solvent acetonitrile (914 cm⁻¹), a correlation between the crystal growth stage and the change in the Raman intensity of the crystal solution was discovered. The determination of the optimal starting time for the crystal growth stage through a Raman analyzer significantly improves the consistency of crystal product quality. This led to a fivefold reduction in the variation in the weight and water content of the final 7-ACT crystal products compared to those obtained via manual control. In addition, our experiments also indicated that Raman monitoring could be more efficient at enabling the chemical synthesis reaction to be completed compared to manual control. Thus, our work demonstrates the potential of Raman spectroscopy in the real-time control of chemical synthesis reactions and crystallization processes. Full article

(This article belongs to the Special Issue Technological Processes for Chemical and Related Industries)

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21 pages, 4751 KiB

Open AccessArticle

On Using CFD and Experimental Data to Train an Artificial Neural Network to Reconstruct ECVT Images: Application for Fluidized Bed Reactors

by Carlos Montilla, Renaud Ansart, Anass Majji, Ranem Nadir, Emmanuel Cid, David Simoncini and Stephane Negny

Processes 2024, 12(2), 386; https://doi.org/10.3390/pr12020386 - 15 Feb 2024

Viewed by 1378

Abstract

Electrical capacitance volume tomography (ECVT) is an experimental technique capable of reconstructing 3D solid volume fraction distribution inside a sensing region. This technique has been used in fluidized beds as it allows for accessing data that are very difficult to obtain using other [...] Read more.

Electrical capacitance volume tomography (ECVT) is an experimental technique capable of reconstructing 3D solid volume fraction distribution inside a sensing region. This technique has been used in fluidized beds as it allows for accessing data that are very difficult to obtain using other experimental devices. Recently, artificial neural networks have been proposed as a new type of reconstruction algorithm for ECVT devices. One of the main drawbacks of neural networks is that they need a database containing previously reconstructed images to learn from. Previous works have used databases with very simple or limited configurations that might not be well adapted to the complex dynamics of fluidized bed configurations. In this work, we study two different approaches: a supervised learning approach that uses simulated data as a training database and a reinforcement learning approach that relies only on experimental data. Our results show that both techniques can perform as well as the classical algorithms. However, once the neural networks are trained, the reconstruction process is much faster than the classical algorithms. Full article

(This article belongs to the Special Issue Technological Processes for Chemical and Related Industries)

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16 pages, 1790 KiB

Open AccessFeature PaperEditor’s ChoiceArticle

The Pursuit of Energy Reduction in Generation of Stable Nanobubbles

by Karol Ulatowski, Andrzej Cecuga and Paweł Sobieszuk

Processes 2023, 11(9), 2739; https://doi.org/10.3390/pr11092739 - 14 Sep 2023

Cited by 1 | Viewed by 2377

Abstract

The repeatable and cost-efficient generation of nanobubbles is still a challenge. In most cases, the hydrodynamic generation of nanobubbles is used at larger scales. Therefore, every cost reduction possible in nanobubble generation is needed. In this work, we decided to check how the [...] Read more.

The repeatable and cost-efficient generation of nanobubbles is still a challenge. In most cases, the hydrodynamic generation of nanobubbles is used at larger scales. Therefore, every cost reduction possible in nanobubble generation is needed. In this work, we decided to check how the generation of nanobubbles changes when the surrounding liquid properties change. The generation of nanobubbles was carried out in a novel setup, designed by us. We investigated the minimum liquid velocity needed for nanobubble generation and propose correlations describing this based on the physicochemical properties of the liquid and gas phases. As carbon dioxide nanobubbles are commonly used for the treatment of ischemia and chronic wounds, the investigation of their stability enhancement is crucial for the wider public. We investigated the minimum rotation rate of the impeller needed for CO₂ nanobubble generation and the influence of a biomedical surfactant (Pluronic P-123) addition and concentration change on the size of nanobubbles and their stability over time. Nanobubbles were stable in the presence of surfactant additions and showed the impact of both changes in generation time and shear stress on their size. We hope that this study will be a step in the direction of the cost-efficient generation of stable carbon dioxide nanobubble dispersions. Full article

(This article belongs to the Special Issue Technological Processes for Chemical and Related Industries)

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13 pages, 7746 KiB

Open AccessArticle

Gangue Source Reduction Technology and Process Optimization Based on Underground Coal Gangue Photoelectric Separation

by Wei Zhou, Wanghao Xia, Liangliang Liu, Liansheng Li, Qiuyu Zeng, Shujie Wang and Jinbo Zhu

Processes 2023, 11(9), 2519; https://doi.org/10.3390/pr11092519 - 22 Aug 2023

Cited by 1 | Viewed by 1676

Abstract

The precise identification of damp, sticky coal gangue; efficient jet nozzle separation; and process layout in a narrow, restricted space are essential technologies for gangue source reduction based on underground gangue photoelectric separation, which is critical for the long-term growth of coal mines. [...] Read more.

The precise identification of damp, sticky coal gangue; efficient jet nozzle separation; and process layout in a narrow, restricted space are essential technologies for gangue source reduction based on underground gangue photoelectric separation, which is critical for the long-term growth of coal mines. In this paper, the X-ray absorption fine structure (XAFS) method was used to identify the X-ray absorption law of different atoms in coal-based minerals and explore the differences in the microscopic crystal properties of coal gangue; the numerical simulation calculation of four commonly used nozzles—namely, flat, convergent, flat–convergent, and streamline—was carried out using Fluent software for coal gangue jet separation to optimize the nozzle morphology and parameters. The technical characteristics of the underground layout of the photoelectric separation system for coal gangue were expounded, and the technological layout of the separation system was explored. The results showed that the absorption coefficients μ(E) of Al and Si atoms in minerals to X-rays are significantly different, and the XAFS method has the ability to identify coal, gangue, and other minerals. The streamlined nozzle has a long jet core area, slow decay of jet velocity, low gas consumption per unit time, and better performance than the other three types of nozzles. Based on the development and mining system of the Renjiazhuang Coal Mine, three kinds of photoelectric separation system layout schemes of coal gangue were designed, namely centralized layout, distributed layout, and mobile layout. The advantages and disadvantages of each scheme were compared, which enriched the technical means of gangue source reduction. Full article

(This article belongs to the Special Issue Technological Processes for Chemical and Related Industries)

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20 pages, 3121 KiB

Open AccessArticle

Estimating APC Model Parameters for Dynamic Intervals Determined Using Change-Point Detection in Continuous Processes in the Petrochemical Industry

by Yoseb Yu, Minyeob Lee, Chaekyu Lee, Yewon Cheon, Seungyun Baek, Youngmin Kim, Kyungmin Kim, Heechan Jung, Dohyeon Lim, Hyogeun Byun and Jongpil Jeong

Processes 2023, 11(8), 2229; https://doi.org/10.3390/pr11082229 - 25 Jul 2023

Viewed by 1523

Abstract

Several papers have proven that advanced process controller (APC) systems can save more energy in the process than proportional-integral-differential (PID) controller systems. Therefore, implementing an APC system is ultimately beneficial for saving energy in the plant. In a typical APC system deployment, the [...] Read more.

Several papers have proven that advanced process controller (APC) systems can save more energy in the process than proportional-integral-differential (PID) controller systems. Therefore, implementing an APC system is ultimately beneficial for saving energy in the plant. In a typical APC system deployment, the APC model parameters are calculated from dynamic data intervals obtained through the plant test. However, depending on the proficiency of the APC engineer, the results of the plant test and the APC model parameters are implemented differently. To minimize the influence of the APC engineer and calculate universal APC model parameters, a technique is needed to obtain dynamic data without a plant test. In this study, we utilize time-series data from a real petrochemical plant to determine dynamic intervals and estimate APC model parameters, which have not been investigated in previous studies. This involves extracting the data of the dynamic intervals with the smallest mean absolute error (MAE) by utilizing statistical techniques such as pruned exact linear time, linear kernel, and radial basis function kernel of change-point detection (CPD). After that, we fix the hyper parameters at the minimum MAE value and estimate the APC model parameters by training with the data from the dynamic intervals. The estimated APC model parameters are applied to the APC program to compare the APC model fitting rate and verify the accuracy of the APC model parameters in the dynamic intervals obtained through CPD. The final validation of the model fitting rates demonstrates that the identification of the dynamic intervals and the estimation of the APC model parameters through CPD show high accuracy. We show that it is possible to estimate APC model parameters from dynamic intervals determined by CPD without a plant test. Full article

(This article belongs to the Special Issue Technological Processes for Chemical and Related Industries)

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13 pages, 2091 KiB

Open AccessFeature PaperArticle

Synthesis and Physicochemical Characteristics of Chitosan-Based Polyurethane Flexible Foams

by Agnieszka Piotrowska-Kirschling, Adam Olszewski, Jakub Karczewski, Łukasz Piszczyk and Joanna Brzeska

Processes 2021, 9(8), 1394; https://doi.org/10.3390/pr9081394 - 12 Aug 2021

Cited by 4 | Viewed by 2540

Abstract

The use of shrimp waste to obtain chitosan (Ch) is an essential issue, considering a circular economy, waste management, and its application to environmentally friendly materials. In this study, northern prawn shells were utilized to obtain Ch, which could then be used for [...] Read more.

The use of shrimp waste to obtain chitosan (Ch) is an essential issue, considering a circular economy, waste management, and its application to environmentally friendly materials. In this study, northern prawn shells were utilized to obtain Ch, which could then be used for synthesizing chitosan-based polyurethane (PUR+Ch) foams with different Ch concentration. The chemical structure, morphology, hardness, thermal properties, viscoelastic properties, and sorption properties in relation to oil and water of these materials were determined. The results present that the addition of Ch into PUR influences the physicochemical characteristics and properties of the tested materials. PUR+Ch foams with 1–3 wt% Ch had more open cells and were softer than neat PUR. PUR+Ch1 had the best thermal properties. PUR+Ch2 foam with 2 wt% Ch as a whole was characterized as having the highest water sorption. The PUR+Ch1 foam with 1 wt% Ch had the best oil sorption. This paper shows that the modification of PUR by Ch is a very promising solution, and PUR+Ch foams can be applied in the water treatment of oil spills, which can be dangerous to the water environment. Full article

(This article belongs to the Special Issue Technological Processes for Chemical and Related Industries)

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Review

Jump to: Research

13 pages, 1260 KiB

Open AccessReview

Possibility of Using Alkali-Activated Phosphogypsum from the Production of Orthophosphoric Acid for the Building Materials—A Review

by Aleksandra Liczbińska and Jacek Gębicki

Processes 2025, 13(1), 97; https://doi.org/10.3390/pr13010097 - 3 Jan 2025

Viewed by 1267

Abstract

This paper focuses on the possibility of using phosphogypsum, which is a residue from the production of orthophosphoric acid as an additional source of calcium and the use of spent caustic as an alkaline activator for production of ceramic materials in construction industry. [...] Read more.

This paper focuses on the possibility of using phosphogypsum, which is a residue from the production of orthophosphoric acid as an additional source of calcium and the use of spent caustic as an alkaline activator for production of ceramic materials in construction industry. The use of the above-mentioned waste will allow to increase fraction of calcium, sodium and silicate needed for the geopolymerization process and improve properties of material. This review presents a description of the geopolymerization process and the influence of alkaline activator on the reactions occurring in ceramic materials. Collected information, which confirm the possibility of using post-production waste from chemical industry as components for the production of building materials. Full article

(This article belongs to the Special Issue Technological Processes for Chemical and Related Industries)

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19 pages, 1676 KiB

Open AccessReview

The Impact of Adsorption Property Modification by Crosslinkers on Graphene Oxide Membrane Separation Performance

by Martin Ayala-Claveria, Carlos Carlesi, Julieta Puig and Gianni Olguin

Processes 2024, 12(11), 2320; https://doi.org/10.3390/pr12112320 - 23 Oct 2024

Cited by 1 | Viewed by 1225

Abstract

The health risks associated with the presence of heavy metals in drinking water can be severe. To address this issue, membrane separation technology is one of the consolidated alternatives. Inorganic, porous membranes were found in applications where low energy consumption is highly desirable. [...] Read more.

The health risks associated with the presence of heavy metals in drinking water can be severe. To address this issue, membrane separation technology is one of the consolidated alternatives. Inorganic, porous membranes were found in applications where low energy consumption is highly desirable. The selectivity of these membranes is attained by functionalisation. Graphene oxide functionalised membrane technology is promising for removing heavy metal ions. This work summarises, discusses and presents the relationship between adsorption and overall membrane separation process performance for heavy metal ions removal from wastewater when a graphene oxide-functionalised membrane is used. The separation performance depends on the hydrophobic interactions of the membrane and the solute. The electrostatic interaction between the negatively charged membrane surface and positively charged metal ions facilitates the adsorption, leading to the rejection of these metal ions. The influences of the chemical nature of the modifiers of graphene oxide layers are highlighted. Full article

(This article belongs to the Special Issue Technological Processes for Chemical and Related Industries)

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