Special Issue "Redesign Processes in the Age of the Fourth Industrial Revolution"

A special issue of Processes (ISSN 2227-9717).

Deadline for manuscript submissions: closed (31 July 2021) | Viewed by 74677

Special Issue Editor

Prof. Dr. Giancarlo Cravotto
E-Mail Website
Guest Editor
Department of Drug Science and Technology, University of Turin, Via P. Giuria 9, 10125 Turin, Italy
Interests: green chemistry; process intensification; green extraction; enabling technologies (ultrasound, microwaves, hydrodynamic cavitation, ball milling, flow chemistry); sustainable chemical processes
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Special Issue Information

Dear Colleagues,

This Special Issue, which is supported by the journal's Editorial Board, aims to highlight new comprehensive transdisciplinary models for the design of innovative processes in a range of Science and Technology fields. This holistic approach is reshaping current research and production strategies, which are too often confined to traditional, linear thought patterns. The merging of academic and industrial experience with economic and environmental knowledge will help laboratories, industries, and businesses achieve sustainable growth. We are expecting papers with the power to disrupt and innovate, which exploit combinations of technologies to shape our future processes.

Prof. Dr. Giancarlo Cravotto
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Processes is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2000 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Published Papers (67 papers)

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Research

Article
Organic Amendment for the Recovery of Vineyard Soils: Effects of a Single Application on Soil Properties over Two Years
Processes 2022, 10(2), 317; https://doi.org/10.3390/pr10020317 - 07 Feb 2022
Viewed by 480
Abstract
Spent mushroom substrate (SMS) is the organic residue generated during mushroom cultivation, and it is being produced in ever-greater quantities around the world. Different applications for this residue have been proposed for its valorization, but its application as a soil amendment could be [...] Read more.
Spent mushroom substrate (SMS) is the organic residue generated during mushroom cultivation, and it is being produced in ever-greater quantities around the world. Different applications for this residue have been proposed for its valorization, but its application as a soil amendment could be one of the most sustainable. SMS improves soil quality by increasing its organic matter (OM), thereby enhancing the sustainability of agricultural systems. The objective of this work was to evaluate the effect of the application of two doses of SMS on the chemical, biochemical, and microbiological characteristics of two degraded vineyard soils in La Rioja (Spain) with different textures, as a new regenerative agricultural practice. The variations in organic carbon (OC), micro- and macronutrients, soil microbial biomass (BIO), respiration (RES), dehydrogenase activity (DHA), and the profile of phospholipid fatty acids (PLFAs) extracted from the soils were evaluated over two years. An initial increase in soil OC content was recorded in both soils, although the content that remained over time differed for each site. In general, SMS enhanced DHA, RES, and BIO in the soils, but the effect varied, possibly being conditioned by the availability of OC for soil microorganisms. In general, changes in the soils’ microbial structure after SMS application were not very significant over the two-year experimental period. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
High-Throughput Computational Screening of Ionic Liquids for Butadiene and Butene Separation
Processes 2022, 10(1), 165; https://doi.org/10.3390/pr10010165 - 15 Jan 2022
Viewed by 601
Abstract
The separation of 1,3-butadiene (1,3-C4H6) and 1-butene (n-C4H8) is quite challenging due to their close boiling points and similar molecular structures. Extractive distillation (ED) is widely regarded as a promising approach for such a separation [...] Read more.
The separation of 1,3-butadiene (1,3-C4H6) and 1-butene (n-C4H8) is quite challenging due to their close boiling points and similar molecular structures. Extractive distillation (ED) is widely regarded as a promising approach for such a separation task. For ED processes, the selection of suitable entrainer is of central importance. Traditional ED processes using organic solvents suffer from high energy consumption. To tackle this issue, the utilization of ionic liquids (ILs) can serve as a potential alternative. In this work, a high-throughput computational screening of ILs is performed to find proper entrainers, where 36,260 IL candidates comprising of 370 cations and 98 anions are involved. COSMO-RS is employed to calculate the infinite dilution extractive capacity and selectivity of the 36,260 ILs. In doing so, the ILs that satisfy the prespecified thermodynamic criteria and physical property constraints are identified. After the screening, the resulting IL candidates are sent for rigorous process simulation and design. 1,2,3,4,5-pentamethylimidazolium methylcarbonate is found to be the optimal IL solvent. Compared with the benchmark ED process where the organic solvent N-methyl-2-pyrrolidone is adopted, the energy consumption is reduced by 26%. As a result, this work offers a new IL-based ED process for efficient 1,3-C4H6 production. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Estimation of Shutdown Schedule to Remove Fouling Layers of Heat Exchangers Using Risk-Based Inspection (RBI)
Processes 2021, 9(12), 2177; https://doi.org/10.3390/pr9122177 - 02 Dec 2021
Cited by 2 | Viewed by 681
Abstract
Oil and Gas plants consist of a set of heat exchangers, which are used in recovering the waste heat from product streams to preheat the oil. The heat transfer coefficient of exchangers declines considerably during the operation period due to fouling. Fouling in [...] Read more.
Oil and Gas plants consist of a set of heat exchangers, which are used in recovering the waste heat from product streams to preheat the oil. The heat transfer coefficient of exchangers declines considerably during the operation period due to fouling. Fouling in heat exchangers is a complex phenomenon due to the acceleration of many layers of chemical substances across tubes of heat exchangers resulting from chemical reactions and surface roughness. In this paper, the fouling process was determined as a critical failure in the heat exchanger. Failure is an accelerated fouling layer across the heat exchanger tubes, which can be the reason for the clogging of tubes. Hence, a risk assessment was conducted using the Risk-Based Inspection (RBI) approach to estimate the probability of fouling in heat exchangers. The results showed that the RBI approach can be used successfully to predict the suitable time to shut down the plant and conduct the fouling cleaning process. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Novel Module-Based Design Algorithm for Intensified Membrane Reactor Systems
Processes 2021, 9(12), 2165; https://doi.org/10.3390/pr9122165 - 01 Dec 2021
Viewed by 513
Abstract
The growing interest in intensified process units that improve efficiency by combining several phenomena into one unit, has led to a loss in degrees of freedom when addressing the control scheme of these units. Previous work demonstrated that a novel module-based design approach [...] Read more.
The growing interest in intensified process units that improve efficiency by combining several phenomena into one unit, has led to a loss in degrees of freedom when addressing the control scheme of these units. Previous work demonstrated that a novel module-based design approach to membrane reactors could improve the operability index of membrane reactor systems. This approach sought to decouple the phenomena to regain some degrees of freedom for the control system. However, the computational time to determine such an optimal module design made this class of design problems intractable to solve in a reasonable amount of time. This work proposes a set of design heuristics for a new module-based design approach for membrane reactors. These heuristics are used in combination with a genetic algorithm formulation to produce a novel, two-staged algorithm for the design and control of membrane reactor systems. This algorithm is developed in Python and uses rigorous membrane reactor models built in AVEVA Process Simulation. The proposed algorithm solves the original non-polynomial (NP) complexity problem in polynomial time (P), while still being able to find the optimal designs discovered in previous work through exhaustive methods. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Optimized Organosolv Pretreatment of Biomass Residues Using 2-Methyltetrahydrofuran and n-Butanol
Processes 2021, 9(11), 2051; https://doi.org/10.3390/pr9112051 - 16 Nov 2021
Cited by 4 | Viewed by 579
Abstract
Wheat straw and eucalyptus residues were pretreated in a biphasic system, constituted of butanol (n-butanol) or 2-methyltetrahydrofuran (2M-THF) and aqueous oxalic acid solutions. The pretreatments were carried out in a 300 mL Parr reactor (Autoclave Buchi Limbo-li®) with a solid load [...] Read more.
Wheat straw and eucalyptus residues were pretreated in a biphasic system, constituted of butanol (n-butanol) or 2-methyltetrahydrofuran (2M-THF) and aqueous oxalic acid solutions. The pretreatments were carried out in a 300 mL Parr reactor (Autoclave Buchi Limbo-li®) with a solid load of 5 wt.%, the temperature in the range 140–180 °C, oxalic acid load from 0 to 10 wt.% and a duration of 30–90 min. The obtained slurry was then fractionated in three streams: the aqueous phase which contained solubilized hemicellulose, the organic phase which contained the solvated lignin, and the solid residue which contained cellulose. The solid was hydrolyzed using a commercial mix of enzymes to assess cellulose digestibility and glucose production. The pretreatment was optimized to maximize the purity of the cellulose and hemicellulose fractions and the glucose recovery as free sugar. The optimization was done by using an experimental design and response surface methodology. The mass flow details of the four optimized processes were obtained. In terms of biomass fractionation, butanol demonstrated significant advantages over 2M-THF in the same range of process conditions as shown by the recovery yield of free glucose which reached 98% of the theoretical value with butanol but was 67% with 2M-THF. Tests at low temperature and low enzyme loading highlighted the importance of the solvent choice over the operating conditions. 2M-THF showed interesting performances only in the delignification step, with 90% efficiency for the straw. Regarding the use of different feedstock, fractionation and recovery were generally higher for wheat straw than for eucalyptus wood residues. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Optimization of No-Wait Flowshop Scheduling Problem in Bakery Production with Modified PSO, NEH and SA
Processes 2021, 9(11), 2044; https://doi.org/10.3390/pr9112044 - 15 Nov 2021
Cited by 6 | Viewed by 1050
Abstract
In bakery production, to perform a processing task there might be multiple alternative machines that have the same functionalities. Finding an efficient production schedule is challenging due to the significant nondeterministic polynomial time (NP)-hardness of the problem when the number of products, processing [...] Read more.
In bakery production, to perform a processing task there might be multiple alternative machines that have the same functionalities. Finding an efficient production schedule is challenging due to the significant nondeterministic polynomial time (NP)-hardness of the problem when the number of products, processing tasks, and alternative machines are higher. In addition, many tasks are performed manually as small and medium-size bakeries are not fully automated. Therefore, along with machines, the integration of employees in production planning is essential. This paper presents a hybrid no-wait flowshop scheduling model (NWFSSM) comprising the constraints of common practice in bakeries. The schedule of an existing production line is simulated to examine the model and is optimized by performing particle swarm optimization (PSO), modified particle swarm optimization (MPSO), simulated annealing (SA), and Nawaz-Enscore-Ham (NEH) algorithms. The computational results reveal that the performance of PSO is significantly influenced by the weight distribution of exploration and exploitation in a run time. Due to the modification to the acceleration parameter, MPSO outperforms PSO, SA, and NEH in respect to effectively finding an optimized schedule. The best solution to the real case problem obtained by MPSO shows a reduction of the total idle time (TIDT) of the machines by 12% and makespan by 30%. The result of the optimized schedule indicates that for small- and medium-sized bakery industries, the application of the hybrid NWFSSM along with nature-inspired optimization algorithms can be a powerful tool to make the production system efficient. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Synthesis of New 1-Aryl-2-(3,5-dimethylpyrazol-1-yl)ethanone Oxime Ether Derivatives and Investigation of Their Cytotoxic Effects
Processes 2021, 9(11), 2019; https://doi.org/10.3390/pr9112019 - 11 Nov 2021
Cited by 2 | Viewed by 775
Abstract
In this study, 12 new 1-aryl-2-(3,5-dimethylpyrazol-1-yl)ethanone oxime ether derivatives were designed and synthesized to investigate their cytotoxic effects. The in vitro cytotoxic activities of the compounds were evaluated against cervix, colon, breast, glioma, neuroblastoma, and lung cancer cell lines, as well as a [...] Read more.
In this study, 12 new 1-aryl-2-(3,5-dimethylpyrazol-1-yl)ethanone oxime ether derivatives were designed and synthesized to investigate their cytotoxic effects. The in vitro cytotoxic activities of the compounds were evaluated against cervix, colon, breast, glioma, neuroblastoma, and lung cancer cell lines, as well as a healthy cell line using 3-(4,5-dimethylthiazol-2-yl)-2,5-diphenyltetrazo-lium bromide (MTT) assays with 5-fluorouracil (5-FU) as the reference compound. Compound 5f (IC50 = 5.13 µM) was found to be more effective than 5-FU (IC50 = 8.34 µM) in the C6 cancer cell line, and it had no cytotoxic effect on the L929 healthy cell line. Flow cytometry was used to investigate the mechanism of action of compound 5f on the cell cycle of the C6 cell line. The analysis showed that cell death was significantly due to apoptosis. These results indicate that compound 5f induces cell cycle arrest, and may be effective in treating glioma. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
A Case Study of Turbulent Free Jet Flows Issuing from Rectangular Slots on Process Performances and Quality of Hot-Air-Dried Apple
Processes 2021, 9(11), 1900; https://doi.org/10.3390/pr9111900 - 25 Oct 2021
Cited by 1 | Viewed by 567
Abstract
This study deals with the improvement in drying process performances and the quality of the final product for industrial equipment in the food industry. Designers need to optimize the design parameters of devices to create synergies between the greater energy efficiency of the [...] Read more.
This study deals with the improvement in drying process performances and the quality of the final product for industrial equipment in the food industry. Designers need to optimize the design parameters of devices to create synergies between the greater energy efficiency of the process and high-quality dried products. Air impingement drying was carried out on apple cylinders at 323 K and with air velocities ranging between 30 and 60 m s−1. The studied drying process presents a particular setup of jets as they are multiple rectangular slot jets issued from triangular nozzles. The effect of four design jet parameters (slot width, nozzle-to-surface height, nozzle-to-nozzle spacing, and airflow) on the drying process performances and the quality of the final product was analyzed and optimized using response surface methodology (RSM). A minimal influence of design jet parameters on the process performances was shown, while an important impact was observed on the quality of dried apple. The slot width and the nozzle-to-nozzle spacing had a significant effect on the textural and functional properties. Predictive models were established and good agreements were found between predictive and observed values. Sorption isotherms were properly modeled by the Guggenheim–Anderson–de Boer (GAB) model. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Novel Insights on the Sustainable Wet Mode Fractionation of Black Soldier Fly Larvae (Hermetia illucens) into Lipids, Proteins and Chitin
Processes 2021, 9(11), 1888; https://doi.org/10.3390/pr9111888 - 22 Oct 2021
Cited by 1 | Viewed by 1427
Abstract
The black soldier fly larvae (BSFL) is a sustainable ingredient for feed applications, biofuels, composite materials and other biobased products. Processing BSFL to obtain lipid and protein fractions with enhanced functional properties as a suitable replacement for conventional feed ingredients has gained considerable [...] Read more.
The black soldier fly larvae (BSFL) is a sustainable ingredient for feed applications, biofuels, composite materials and other biobased products. Processing BSFL to obtain lipid and protein fractions with enhanced functional properties as a suitable replacement for conventional feed ingredients has gained considerable momentum. In this regard, a novel and sustainable wet mode fractionation (WMF) scheme for BSFL was explored. Fresh BSFL were steam blanched and pulped to obtain BSFL juice and juice press cake. Subsequent treatment of BSFL juice employing homogenization or enzyme incubation and further centrifugation resulted in the obtention of four different BSFL fractions (Lipid—LF; Cream—CF; Aqueous—AF; and Solid—SF). Total energy consumption for a batch BSFL (500 g) WMF process was 0.321 kWh. Aqueous and solid fractions were the predominant constituents of BSFL juice. Lauric acid (44.52–49.49%) and linoleic acid (19.12–20.12%) were the primary fatty acids present in BSFL lipids. Lipid hydrolysis was observed in lipids belonging to the solid (free fatty acids > triacylglycerides) and cream fractions. Aqueous fraction proteins (ctrl) displayed superior emulsion stability and foam capacity than other treatments. Juice press cake retained 60% of the total chitin content and the rest, 40%, was found in the solid fraction (ctrl). The material distribution of principal constituents in different fractions of the WMF process and amino acid profile was elucidated. Overall, the versatile WMF process proposed in this study involves simple unit operations to obtain functional ingredients from BSFL, which can be further explored by researchers and industry stakeholders. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Pairing Experimental and Mathematical Modeling Studies on Fluidized Beds for Enhancement of Models Predictive Quality: A Current Status Overview
Processes 2021, 9(11), 1863; https://doi.org/10.3390/pr9111863 - 20 Oct 2021
Cited by 1 | Viewed by 551
Abstract
Modeling of gas-solid fluidized systems has been a prevailing challenge over the last few decades. With different approaches and implementing different sub-models to capture the essential multiphase and multiscale phenomena in these systems, major advances have been achieved, even though most models are [...] Read more.
Modeling of gas-solid fluidized systems has been a prevailing challenge over the last few decades. With different approaches and implementing different sub-models to capture the essential multiphase and multiscale phenomena in these systems, major advances have been achieved, even though most models are only subject to a practical validation of macroscopic parameters. The current description of fluidized beds through mathematical models relies on the inclusion of vast sub-models, leading to an unquantifiable degree of uncertainty on the models’ applicability for extrapolation studies. Furthermore, each closure and fitting parameter in the model represents a possible source of deviation, and their optimization, hence, becomes another major challenge. The recent advances in measurement techniques can enable us to troubleshoot and optimize the implemented models and sub-models based on local scale measurements. Local multiphase hydrodynamic information obtained by advanced measurement techniques can enable the validation of local predictions and optimization of the coupled sub-models, leading to the development of simplified and highly predictive models. Thus, pairing advanced experimental studies on these systems with insightful modeling approaches is required to advance the shortcoming and enhance the predictive quality of the models. In this work, an overview of the status of modeling and experimental measurement techniques for gas-solid fluidized beds is presented; then, an overview on pairing both experimental and modeling studies to improve the models’ local predictions for fluidized beds is presented. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Thermoeconomic Evaluation and Optimization of Using Different Environmentally Friendly Refrigerant Pairs for a Dual-Evaporator Cascade Refrigeration System
Processes 2021, 9(10), 1855; https://doi.org/10.3390/pr9101855 - 19 Oct 2021
Viewed by 569
Abstract
Applications of dual-evaporator refrigeration systems have recently gained much attention both in academia and industry due to their multiple benefits. In this study, a comprehensive thermodynamic and economic analysis is conducted to evaluate the potential of using several environmentally friendly refrigerant couples and [...] Read more.
Applications of dual-evaporator refrigeration systems have recently gained much attention both in academia and industry due to their multiple benefits. In this study, a comprehensive thermodynamic and economic analysis is conducted to evaluate the potential of using several environmentally friendly refrigerant couples and identifies the most suitable one yielding the best economic results. To achieve this goal, a detailed parametric study is conducted, and an optimization process is performed using a particle swarm optimization (PSO) approach to minimize the unit production cost of cooling (UPCC) of the cascade refrigeration system. The results showed that among all selected 18 refrigerant pairs and for all ranges of examined operating parameters, the R170-R161 pair and R1150-R1234yf pair are identified as the best and worst pairs, respectively, from both thermodynamic and economic viewpoints. The results also confirm that R170-R161 pair has an improvement over R717-R744, used as a typical refrigerant pair of cascade refrigeration cycles. For a base case analysis, the COP of R170-R161 and R1150-R1234yf pairs is determined as 1.727 and 1.552, respectively, while their UPCC is found to be $0.395/ton-hr and $0.419/ton-hr, respectively, showing the influence of proper selection of refrigerant pairs on the cascade cycle’s performance. Overall, this study offers a useful thermodynamic and economic insight regarding the selection of proper refrigerant pairs for a dual-evaporator cascade vapor compression refrigeration system. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Effect of Mn and Cu Substitution on the SrFeO3 Perovskite for Potential Thermochemical Energy Storage Applications
Processes 2021, 9(10), 1817; https://doi.org/10.3390/pr9101817 - 13 Oct 2021
Cited by 4 | Viewed by 587
Abstract
Perovskites are well-known oxides for thermochemical energy storage applications (TCES) since they show a great potential for spontaneous O2 release due to their non-stoichiometry. Transition-metal-based perovskites are particularly promising candidates for TCES owing to their different oxidation states. It is important to [...] Read more.
Perovskites are well-known oxides for thermochemical energy storage applications (TCES) since they show a great potential for spontaneous O2 release due to their non-stoichiometry. Transition-metal-based perovskites are particularly promising candidates for TCES owing to their different oxidation states. It is important to test the thermal behavior of the perovskites for TCES applications; however, the amount of sample that can be used in thermal analyses is limited. The use of redox cycles in fluidized bed tests can offer a more realistic approach, since a larger amount of sample can be used to test the cyclic behavior of the perovskites. In this study, the oxygen release/consumption behavior of Mn- or Cu-substituted SrFeO3 (SrFe0.5M0.5O3; M: Mn or Cu) under redox cycling was investigated via thermal analysis and fluidized bed tests. The reaction enthalpies of the perovskites were also calculated via differential scanning calorimetry (DSC). Cu substitution in SrFeO3 increased the performance significantly for both cyclic stability and oxygen release/uptake capacity. Mn substitution also increased the cyclic stability; however, the presence of Mn as a substitute for Fe did not improve the oxygen release/uptake performance of the perovskite. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Electrochemical Performance of Aluminum Doped Ni1−xAlxCo2O4 Hierarchical Nanostructure: Experimental and Theoretical Study
Processes 2021, 9(10), 1750; https://doi.org/10.3390/pr9101750 - 30 Sep 2021
Cited by 4 | Viewed by 764
Abstract
For electrochemical supercapacitors, nickel cobaltite (NiCo2O4) has emerged as a new energy storage material. The electrocapacitive performance of metal oxides is significantly influenced by their morphology and electrical characteristics. The synthesis route can modulate the morphological structure, while their [...] Read more.
For electrochemical supercapacitors, nickel cobaltite (NiCo2O4) has emerged as a new energy storage material. The electrocapacitive performance of metal oxides is significantly influenced by their morphology and electrical characteristics. The synthesis route can modulate the morphological structure, while their energy band gaps and defects can vary the electrical properties. In addition to modifying the energy band gap, doping can improve crystal stability and refine grain size, providing much-needed surface area for high specific capacitance. This study evaluates the electrochemical performance of aluminum-doped Ni1−xAlxCo2O4 (0 ≤ x ≤ 0.8) compounds. The Ni1−xAlxCo2O4 samples were synthesized through a hydrothermal method by varying the Al to Ni molar ratio. The physical, morphological, and electrochemical properties of Ni1−xAlxCo2O4 are observed to vary with Al3+ content. A morphological change from urchin-like spheres to nanoplate-like structures with a concomitant increase in the surface area, reaching up to 189 m2/g for x = 0.8, was observed with increasing Al3+ content in Ni1−xAlxCo2O4. The electrochemical performance of Ni1−xAlxCo2O4 as an electrode was assessed in a 3M KOH solution. The high specific capacitance of 512 F/g at a 2 mV/s scan rate, 268 F/g at a current density of 0.5 A/g, and energy density of 12.4 Wh/kg was observed for the x = 0.0 sample, which was reduced upon further Al3+ substitution. The as-synthesized Ni1−xAlxCo2O4 electrode exhibited a maximum energy density of 12.4 W h kg−1 with an outstanding high-power density of approximately 6316.6 W h kg−1 for x = 0.0 and an energy density of 8.7 W h kg−1 with an outstanding high-power density of approximately 6670.9 W h kg−1 for x = 0.6. The capacitance retention of 97% and 108.52% and the Coulombic efficiency of 100% and 99.24% were observed for x = 0.0 and x = 0.8, respectively. First-principles density functional theory (DFT) calculations show that the band-gap energy of Ni1−xAlxCo2O4 remained largely invariant with the Al3+ substitution for low Al3+ content. Although the capacitance performance is reduced upon Al3+ doping, overall, the Al3+ doped Ni1−xAlxCo2O4 displayed good energy, powder density, and retention performance. Thus, Al3+ could be a cost-effective alternative in replacing Ni with the performance trade off. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Intelligent and Data-Driven Fault Detection of Photovoltaic Plants
Processes 2021, 9(10), 1711; https://doi.org/10.3390/pr9101711 - 24 Sep 2021
Cited by 2 | Viewed by 806
Abstract
Most photovoltaic (PV) plants conduct operation and maintenance (O&M) by periodical inspection and cleaning. Such O&M is costly and inefficient. It fails to detect system faults in time, thus causing heavy loss. To ensure their operations are at an ideal state, this work [...] Read more.
Most photovoltaic (PV) plants conduct operation and maintenance (O&M) by periodical inspection and cleaning. Such O&M is costly and inefficient. It fails to detect system faults in time, thus causing heavy loss. To ensure their operations are at an ideal state, this work proposes an unsupervised method for intelligent performance evaluation and data-driven fault detection, which enables engineers to check PV panels in time and implement timely maintenance. It classifies monitoring data into three subsets: ideal period A, transition period S, and downturn period B. Based on A and B datasets, we build two non-continuous regression prediction models, which are based on a tree ensemble algorithm and then modified to fit the non-continuous characteristic of PV data. We compare real-time measured power with both upper and lower reference baselines derived from two predictive models. By calculating their threshold ranges, the proposed method achieves the instantaneous performance monitoring of PV power generation and provides failure identification and O&M suggestions to engineers. It has been assessed on a 6.95 MW PV plant. Its evaluation results indicate that it is able to accurately determine different functioning states and detect both direct and indirect faults in a PV system, thereby achieving intelligent data-driven maintenance. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
A Numerical Procedure for Multivariate Calibration Using Heteroscedastic Principal Components Regression
Processes 2021, 9(9), 1686; https://doi.org/10.3390/pr9091686 - 21 Sep 2021
Viewed by 986
Abstract
Many methods have been developed to allow for consideration of measurement errors during multivariate data analyses. The incorporation of the error structure into the analytical framework, usually described in terms of the covariance matrix of measurement errors, can provide better model estimation and [...] Read more.
Many methods have been developed to allow for consideration of measurement errors during multivariate data analyses. The incorporation of the error structure into the analytical framework, usually described in terms of the covariance matrix of measurement errors, can provide better model estimation and prediction. However, little effort has been made to evaluate the effects of heteroscedastic measurement uncertainties on multivariate analyses when the covariance matrix of measurement errors changes with the measurement conditions. For this reason, the present work describes a new numerical procedure for analyses of heteroscedastic systems (heteroscedastic principal component regression or H-PCR) that takes into consideration the variations of the covariance matrix of measurement fluctuations. In order to illustrate the proposed approach, near infrared (NIR) spectra of xylene and toluene mixtures were measured at different temperatures and stirring velocities and the obtained data were used to build calibration models with different multivariate techniques, including H-PCR. Modeling of available xylene–toluene NIR data revealed that H-PCR can be used successfully for calibration purposes and that the principal directions obtained with the proposed approach can be quite different from the ones calculated through standard PCR, when heteroscedasticity is disregarded explicitly. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
An Intelligent Process Fault Diagnosis System Based on Neural Networks and Andrews Plot
Processes 2021, 9(9), 1659; https://doi.org/10.3390/pr9091659 - 14 Sep 2021
Cited by 1 | Viewed by 804
Abstract
This paper proposes a neural network-based process fault diagnosis system with Andrews plot for information pre-processing to enhance the performance of online process fault diagnosis. By using features extracted from Andrews plot as the inputs to a neural network, as a classifier, the [...] Read more.
This paper proposes a neural network-based process fault diagnosis system with Andrews plot for information pre-processing to enhance the performance of online process fault diagnosis. By using features extracted from Andrews plot as the inputs to a neural network, as a classifier, the diagnosis speed and reliability are improved. A method for determining the important features in the Andrews function is proposed. The proposed fault diagnosis system is applied to a simulated continuous stirred tank reactor process and is compared with two conventional neural network-based fault diagnosis systems: scheme B where the monitored measurements are directly fed to a neural network after scaling and scheme C where the monitored measurements are converted to qualitative trend data before feeding to a neural network. Of all the considered faults, the proposed fault diagnosis system diagnosed the abrupt faults on average 5.45 s and 2.66 s earlier than schemes B and C, respectively and diagnosed the incipient faults on average 13.82 s and 5.09 s earlier than schemes B and C, respectively. The results reveal that Andrews plot method utilized in online process monitoring has a great potential in industrial process monitoring. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Synthesis of Ti Powder from the Reduction of TiCl4 with Metal Hydrides in the H2 Atmosphere: Thermodynamic and Techno-Economic Analyses
Processes 2021, 9(9), 1567; https://doi.org/10.3390/pr9091567 - 01 Sep 2021
Viewed by 741
Abstract
Titanium hydride (TiH2) is one of the basic materials for titanium (Ti) powder metallurgy. A novel method was proposed to produce TiH2 from the reduction of titanium tetrachloride (TiCl4) with magnesium hydride (MgH2) in the hydrogen [...] Read more.
Titanium hydride (TiH2) is one of the basic materials for titanium (Ti) powder metallurgy. A novel method was proposed to produce TiH2 from the reduction of titanium tetrachloride (TiCl4) with magnesium hydride (MgH2) in the hydrogen (H2) atmosphere. The primary approach of this process is to produce TiH2 at a low-temperature range through an efficient and energy-saving process for further titanium powder production. In this study, the thermodynamic assessment and technoeconomic analysis of the process were investigated. The results show that the formation of TiH2 is feasible at low temperatures, and the molar ratio between TiCl4 and metal hydride as a reductant material has a critical role in its formation. Moreover, it was found that the yield of TiH2 is slightly higher when CaH2 is used as a reductant agent. The calculated equilibrium composition diagrams show that when the molar ratio between TiCl4 and metal hydrides is greater than the stoichiometric amount, the TiCl3 phase also forms. With a further increase in this ratio to greater than 4, no TiH2 was formed, and TiCl3 was the dominant product. Furthermore, the technoeconomic study revealed that the highest return on investment was achieved for the production scale of 5 t/batch of Ti powder production, with a payback time of 2.54 years. The analysis shows that the application of metal hydrides for TiH2 production from TiCl4 is technically feasible and economically viable. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Numerical Characterization of Acoustic Cavitation Bubbles with Respect to the Bubble Size Distribution at Equilibrium
Processes 2021, 9(9), 1546; https://doi.org/10.3390/pr9091546 - 30 Aug 2021
Cited by 1 | Viewed by 693
Abstract
In addition to bubble number density, bubble size distribution is an important population parameter governing the activity of acoustic cavitation bubbles. In the present paper, an iterative numerical method for equilibrium size distribution is proposed and combined to a model for bubble counting, [...] Read more.
In addition to bubble number density, bubble size distribution is an important population parameter governing the activity of acoustic cavitation bubbles. In the present paper, an iterative numerical method for equilibrium size distribution is proposed and combined to a model for bubble counting, in order to approach the number density within a population of acoustic cavitation bubbles of inhomogeneous sizing, hence the sonochemical activity of the inhomogeneous population based on discretization into homogenous groups. The composition of the inhomogeneous population is analyzed based on cavitation dynamics and shape stability at 300 kHz and 0.761 W/cm2 within the ambient radii interval ranging from 1 to 5 µm. Unstable oscillation is observed starting from a radius of 2.5 µm. Results are presented in terms of number probability, number density, and volume probability within the population of acoustic cavitation bubbles. The most probable group having an equilibrium radius of 3 µm demonstrated a probability in terms of number density of 27%. In terms of contribution to the void, the sub-population of 4 µm plays a major role with a fraction of 24%. Comparisons are also performed with the homogenous population case both in terms of number density of bubbles and sonochemical production of HO,HO2, and H under an oxygen atmosphere. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Liquid Hot Water Pretreatment of Lignocellulosic Biomass at Lab and Pilot Scale
Processes 2021, 9(9), 1518; https://doi.org/10.3390/pr9091518 - 27 Aug 2021
Cited by 6 | Viewed by 978
Abstract
Liquid hot water pretreatment is considered to be a promising method for increasing biomass digestibility due to the moderate operational conditions without chemical additions. A necessary step towards the scalability of this pretreatment process is performing pilot plant trials. Upscaling was evaluated with [...] Read more.
Liquid hot water pretreatment is considered to be a promising method for increasing biomass digestibility due to the moderate operational conditions without chemical additions. A necessary step towards the scalability of this pretreatment process is performing pilot plant trials. Upscaling was evaluated with a scaling factor of 500, by using 50 mL in the laboratory and 25 L in a pilot plant batch reactor. Pretreatment times were varied from 30 to 240 min, and temperatures used were 180–188 °C, while applying similar heating profiles at both scales. The initial mass fraction of poplar wood chips ranged from 10% to 16%. Liquid hot water pretreatment at laboratory and pilot scale led to analogous results. The acetic acid analysis of the liquid and solid fractions obtained after pretreatment indicated that complete deacetylation of poplar biomass can be achieved. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Model Discrimination for Hydrogen Peroxide Consumption towards γ-Alumina in Homogeneous Liquid and Heterogeneous Liquid-Liquid Systems
Processes 2021, 9(8), 1476; https://doi.org/10.3390/pr9081476 - 23 Aug 2021
Viewed by 726
Abstract
The use of hydrogen peroxide as an oxidizing agent becomes increasingly important in chemistry. The example of vegetable oil epoxidation is an excellent illustration of the potential of such an agent. This reaction is traditionally performed by Prileschajew oxidation, i.e., by the in [...] Read more.
The use of hydrogen peroxide as an oxidizing agent becomes increasingly important in chemistry. The example of vegetable oil epoxidation is an excellent illustration of the potential of such an agent. This reaction is traditionally performed by Prileschajew oxidation, i.e., by the in situ production of percarboxylic acids. Drawbacks of this approach are side reactions of ring-opening and thermal runaway reactions due to percarboxylic acid instability. One way to overcome this issue is the direct epoxidation by hydrogen peroxide by using γ-alumina. However, the reaction mechanism is not elucidated: does hydrogen peroxide decompose with alumina or oxidize the hydroxyl groups at the surface? The kinetics of hydrogen peroxide consumption with alumina in homogeneous liquid and heterogeneous liquid-liquid systems was investigated to reply to this question. Bayesian inference was used to determine the most probable models. The results obtained led us to conclude that the oxidation mechanism is the most credible for the heterogeneous liquid-liquid system. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Ultrasound-Assisted Cold Pasteurization in Liquid or SC-CO2
Processes 2021, 9(8), 1457; https://doi.org/10.3390/pr9081457 - 21 Aug 2021
Viewed by 624
Abstract
Various types of chemical and physical protocols are used, thermal treatment in particular, to increase the quality of bulk food products (for example, dates or some sort of nuts) and extend shelf life, and combinations of methods are frequently used to achieve the [...] Read more.
Various types of chemical and physical protocols are used, thermal treatment in particular, to increase the quality of bulk food products (for example, dates or some sort of nuts) and extend shelf life, and combinations of methods are frequently used to achieve the best results. However, the use of these processing methods is not always the best option to preserve the initial taste and appearance of food products. For instance, a product may lose its initial natural appearance and acquire different flavors due to chemical transformations that occur at certain temperatures or when the products are treated with chemicals. Non-thermal treatment methods are called “cold” pasteurization. This is a set of advanced techniques that are based on physical and chemical effects that do not result in the structural food-product transformations caused by heating. We have developed and tested a new technique for efficient food-product processing and cold pasteurization in an ultrasonic field under pressure in an atmosphere of supercritical or subcritical carbon dioxide. A laboratory-scale unit that was designed and built for this purpose has experimentally proven the feasibility of this process and demonstrated high efficiency in suppressing pathogenic flora. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Optimization of Hydrolysis-Acidogenesis Phase of Swine Manure for Biogas Production Using Two-Stage Anaerobic Fermentation
Processes 2021, 9(8), 1324; https://doi.org/10.3390/pr9081324 - 29 Jul 2021
Cited by 45 | Viewed by 1682
Abstract
The traditional pig manure wastewater treatment in Taiwan has been low in methane production efficiency due to unstable influent concentration, wastewater volume, and quality. Two-stage anaerobic systems, in contrast, have the advantage of buffering the organic loading rate in the first stage (hydrolysis-acidogenesis [...] Read more.
The traditional pig manure wastewater treatment in Taiwan has been low in methane production efficiency due to unstable influent concentration, wastewater volume, and quality. Two-stage anaerobic systems, in contrast, have the advantage of buffering the organic loading rate in the first stage (hydrolysis-acidogenesis phase), allowing a more constant feeding rate to the second stage (methanogenesis phase). Response surface methodology was applied to optimize the operational period (0.5–2.0 d) and initial operational pH (4–10) for hydrolysis and acidogenesis of the swine manure (total solid 5.3%) at 35 °C in batch operation mode. A methanogenesis verification experiment with the optimal condition of operational period 1.5 d and pH 6.5 using batch operation resulted in peak volatile acid production 7 g COD/L, methane production rate (MPR) 0.3 L-CH4/L-d, and methane yield (MY) 92 mL-CH4/g-CODre (chemical oxygen demand removed). Moreover, a two-stage system including a hydrolysis-acidogenesis reactor with the optimal operating condition and a methanogenesis reactor provided an average MPR 163 mL/L-d and MY 38 mL/g volatile solids, which values are 60% higher than those of a single-stage system; both systems have similar dominant methane-producing species of Firmicutes and Bacteroidetes with each having around 30%–40%. The advantages of a two-stage anaerobic fermentation system in treating swine manure for biogas production are obvious. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
A Novel Manganese-Rich Pokeweed Biochar for Highly Efficient Adsorption of Heavy Metals from Wastewater: Performance, Mechanisms, and Potential Risk Analysis
Processes 2021, 9(7), 1209; https://doi.org/10.3390/pr9071209 - 14 Jul 2021
Cited by 3 | Viewed by 721
Abstract
A novel manganese-rich pokeweed biochar was prepared at different temperatures from manganese-rich pokeweed plants collected at manganese tailings, resulting in materials identified as BC300, BC400, and BC500. The synthetized biochar materials were investigated as regards their potential for removing Cu2+, Pb [...] Read more.
A novel manganese-rich pokeweed biochar was prepared at different temperatures from manganese-rich pokeweed plants collected at manganese tailings, resulting in materials identified as BC300, BC400, and BC500. The synthetized biochar materials were investigated as regards their potential for removing Cu2+, Pb2+, and Cd2+, specifically in terms of adsorption performances, adsorption kinetics, adsorption isotherms, and potential environmental pollution risk. The results showed that the sorption process fitted well to the pseudo-second-order kinetic and Langmuir models, and the maximum adsorption capacities of BC500 were 246, 326, and 310 mg·g−1 for Cu2+, Pb2+, and Cd2+ respectively. The physicochemical characteristics of the biochars, and the adsorption mechanisms, were revealed by using scanning electron microscopy-energy spectrometer, elemental analysis, Brunauer–Emmett–Teller techniques, X-ray diffraction, X-ray photoelectron spectroscopy, and Fourier transform infrared spectroscopy. The sorption mechanism of these three heavy metal ions onto biochars included ion exchange, electrostatic adsorption, chemical adsorption, and precipitation. Besides, the potential pollution risk of manganese-rich pokeweed biochars was significantly reduced after pyrolysis. Therefore, it is feasible to transform manganese-rich pokeweed biomass into manganese-rich pokeweed biochar with potential for heavy metals removal, showing high adsorption capacity, recyclability, and low environmental pollution. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Integrated Process Re-Design with Operation in the Digital Era: Illustration through an Industrial Case Study
Processes 2021, 9(7), 1203; https://doi.org/10.3390/pr9071203 - 12 Jul 2021
Cited by 2 | Viewed by 636
Abstract
This work discusses what should be the desirable path and correct tools for the optimal re-design and operation of processes in the Industry 4.0 framework, as illustrated in a challenging case study corresponding to a complex network of evaporation plants in a viscose-fiber [...] Read more.
This work discusses what should be the desirable path and correct tools for the optimal re-design and operation of processes in the Industry 4.0 framework, as illustrated in a challenging case study corresponding to a complex network of evaporation plants in a viscose-fiber factory. The goal is to integrate optimal design, to improve the existing cooling systems, together with the optimal operation of the whole network, balancing the initial investment with the potentially achievable savings. A rigorous mathematical model for such optimization purpose has been built. The model explicitly considers different structural alternatives as a superstructure for the incorporation of new equipment into the network. The uncertainty associated to future operating conditions is also considered by using a two-stage stochastic formulation. Furthermore, the model is also the base from which a deterministic real-time optimization (RTO) builds upon to support the daily management of the future network operation. The RTO tool suggests the allocation of different products to evaporation plants, the distribution of the cooling water and the suitable number of heat pumps to switch on for optimal economic operation. Design and operation problems are formulated and solved via mixed-integer non-linear programming and the results have been tested with historical plant data. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Chemical Composition and Low-Temperature Fluidity Properties of Jet Fuels
Processes 2021, 9(7), 1184; https://doi.org/10.3390/pr9071184 - 07 Jul 2021
Viewed by 866
Abstract
The physicochemical properties of petroleum-derived jet fuels mainly depend on their chemical composition, which can vary from sample to sample as a result of the diversity of the crude diet processed by the refinery. Jet fuels are exposed to very low temperatures both [...] Read more.
The physicochemical properties of petroleum-derived jet fuels mainly depend on their chemical composition, which can vary from sample to sample as a result of the diversity of the crude diet processed by the refinery. Jet fuels are exposed to very low temperatures both at altitude and on the ground in places subject to extreme climates and must be able to maintain their fluidity at these low temperatures otherwise the flow of fuel to turbine engines will be reduced or even stopped. In this work, an experimental evaluation of the effect of chemical composition on low-temperature fluidity properties of jet fuels (freezing point, crystallization onset temperature and viscosity at −20 °C) was carried out. Initially, a methodology based on gas chromatography coupled to mass spectrometry (GC–MS) was adapted to determine the composition of 70 samples of Jet A1 and Jet A fuels. This methodology allowed quantifying the content, in weight percentage, of five main families of hydrocarbons: paraffinic, naphthenic, aromatic, naphthalene derivatives, and tetralin- and indane-derived compounds. Fuel components were also grouped into 11 classes depending on structural characteristics and the number of carbon atoms in the compound. The latter compositional approach allowed obtaining more precise model regressions for predicting the composition–property dependence and identifying individual components or hydrocarbon classes contributing to increased or decreased property values. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Implementation of the Digital Sales Channel in the Coatings Industry
Processes 2021, 9(7), 1168; https://doi.org/10.3390/pr9071168 - 05 Jul 2021
Viewed by 964
Abstract
The development process in the coatings industry can be shortened by digital transformation, and its costs can be reduced using a technical enabler. However, formulators need up-to-date and comprehensive data on existing and potential ingredients to develop the formulation. We were curious about [...] Read more.
The development process in the coatings industry can be shortened by digital transformation, and its costs can be reduced using a technical enabler. However, formulators need up-to-date and comprehensive data on existing and potential ingredients to develop the formulation. We were curious about how to supply formulators with data. The idea was that suppliers of ingredients provide data using the “common enabling technology”. We hypothesize that direct data entry compensates suppliers because they can shorten the sales process and increase sales. We used a survey to select key sales channels in the industry. Detailed process models were designed using structured interviews. We analyzed models using structural and operational indicators. Finally, we formed a new digital sales process and verified it. The results show that the digitally formatted sales process can be shortened by up to 32%. Simultaneously, more potential customers can be accessed using the common technology. Existing sales channels would not be closed down. Nevertheless, the digital sales channel is expected to prove its worth over time and gradually increase its share. The suppliers of ingredients can thus avoid a radical process transformation and the immediate integration of additional information technology into the company information system in such an evolutionary way. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
g-C3N4 Sensitized by an Indoline Dye for Photocatalytic H2 Evolution
Processes 2021, 9(6), 1055; https://doi.org/10.3390/pr9061055 - 17 Jun 2021
Cited by 1 | Viewed by 779
Abstract
Protonated g-C3N4 (pCN) formed by treating bulk g-C3N4 with an aqueous HCl solution was modified with D149 dye, i.e., 5-[[4[4-(2,2-diphenylethenyl) phenyl]-1,2,3,3a,4,8b-hexahydrocyclopent[b]indol-7-yl] methylene]-2-(3-ethyl-4-oxo-2-thioxo-5-thiazolidinylidene)-4-oxo-thiazolidin-2-ylidenerhodanine, for photocatalytic water splitting (using Pt as a co-catalyst). The D149/pCN-Pt composite showed a much [...] Read more.
Protonated g-C3N4 (pCN) formed by treating bulk g-C3N4 with an aqueous HCl solution was modified with D149 dye, i.e., 5-[[4[4-(2,2-diphenylethenyl) phenyl]-1,2,3,3a,4,8b-hexahydrocyclopent[b]indol-7-yl] methylene]-2-(3-ethyl-4-oxo-2-thioxo-5-thiazolidinylidene)-4-oxo-thiazolidin-2-ylidenerhodanine, for photocatalytic water splitting (using Pt as a co-catalyst). The D149/pCN-Pt composite showed a much higher rate (2138.2 µmol·h−1·g−1) of H2 production than pCN-Pt (657.0 µmol·h−1·g−1). Through relevant characterization, the significantly high activity of D149/pCN-Pt was linked to improved absorption of visible light, accelerated electron transfer, and more efficient separation of charge carriers. The presence of both D149 and Pt was found to be important for these factors. A mechanism was proposed. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Real-Time Industrial Process Fault Diagnosis Based on Time Delayed Mutual Information Analysis
Processes 2021, 9(6), 1027; https://doi.org/10.3390/pr9061027 - 11 Jun 2021
Cited by 4 | Viewed by 990
Abstract
Causal relations among variables may change significantly due to different control strategies and fault types. Off line-based knowledge is not adequate for fault diagnosis, and existing causal models obtained from data driven methods are mostly based on historical data only. However, variable correlation [...] Read more.
Causal relations among variables may change significantly due to different control strategies and fault types. Off line-based knowledge is not adequate for fault diagnosis, and existing causal models obtained from data driven methods are mostly based on historical data only. However, variable correlation would not remain identical, and could be very different under certain industrial operation conditions. To deal with this problem, a fault diagnosis framework is proposed based on information solely extracted from process data. By this method, mutual information (MI) between each pair of variables is first calculated to obtain thresholds using historical data, as variable correlation under normal conditions is mostly contributed by random noises, which is often neglected in existing causal analysis models. Once a process deviation is detected, each pair of variables with mutual information beyond these thresholds are further investigated by time delayed mutual information (TDMI) analysis using current data, so as to determine the causal logic between them, which is represented as fault propagation paths, can be tracked all the way back to the root cause. The proposed method is first applied to a simulated process and the Tennessee Eastman process. The results show that the difference in variable correlation under diverse operation or control response conditions can be captured in real time, and fault propagation path can be objectively identified, together with the root cause. Then, the method has been successfully applied to a whole year data in an industrial process, which proves the feasibility of industrial application. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Effect of Steam Quality on Extra-Heavy Crude Oil Upgrading and Oil Recovery Assisted with PdO and NiO-Functionalized Al2O3 Nanoparticles
Processes 2021, 9(6), 1009; https://doi.org/10.3390/pr9061009 - 07 Jun 2021
Cited by 8 | Viewed by 1051
Abstract
This work focuses on evaluating the effect of the steam quality on the upgrading and recovering extra-heavy crude oil in the presence and absence of two nanofluids. The nanofluids AlNi1 and AlNi1Pd1 consist of 500 mg·L−1 of alumina doped with 1.0% in [...] Read more.
This work focuses on evaluating the effect of the steam quality on the upgrading and recovering extra-heavy crude oil in the presence and absence of two nanofluids. The nanofluids AlNi1 and AlNi1Pd1 consist of 500 mg·L−1 of alumina doped with 1.0% in mass fraction of Ni (AlNi1) and alumina doped with 1.0% in mass fraction of Ni and Pd (AlNi1Pd1), respectively, and 1000 mg·L−1 of tween 80 surfactant. Displacement tests are done in different stages, including (i) basic characterization, (ii) waterflooding, (iii) steam injection at 0.5 quality, (iv) steam injection at 1.0 quality, (v) batch injection of nanofluids, and (vi) steam injection after nanofluid injection at 0.5 and 1.0 qualities. The steam injection is realized at 210 °C, the reservoir temperature is fixed at 80 °C, and pore and overburden pressure at 1.03 MPa (150 psi) and 5.51 MPa (800 psi), respectively. After the steam injection at 0.5 and 1.0 quality, oil recovery is increased 3.0% and 7.0%, respectively, regarding the waterflooding stage, and no significant upgrade in crude oil is observed. Then, during the steam injection with nanoparticles, the AlNi1 and AlNi1Pd1 increase the oil recovery by 20.0% and 13.0% at 0.5 steam quality. Meanwhile, when steam is injected at 1.0 quality for both nanoparticles evaluated, no incremental oil is produced. The crude oil is highly upgraded for the AlNi1Pd1 system, reducing oil viscosity 99%, increasing the American Petroleum Institute (API)° from 6.9° to 13.3°, and reducing asphaltene content 50% at 0.5 quality. It is expected that this work will eventually help understand the appropriate conditions in which nanoparticles should be injected in a steam injection process to improve its efficiency in terms of oil recovery and crude oil quality. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Accuracy Improvement of the 14C Method Applied in Biomass and Coal Co-Firing Power Stations
Processes 2021, 9(6), 994; https://doi.org/10.3390/pr9060994 - 04 Jun 2021
Cited by 1 | Viewed by 700
Abstract
The 14C method is an approach used to determine the proportion of carbon derived from biomass and fossil fuel in the co-fired flue gas. Its accuracy is mainly limited by the deviations between the applied biomass fuels’ 14C activity reference value [...] Read more.
The 14C method is an approach used to determine the proportion of carbon derived from biomass and fossil fuel in the co-fired flue gas. Its accuracy is mainly limited by the deviations between the applied biomass fuels’ 14C activity reference value and virtual value. To enrich the theoretical basis of the 14C method when applied to a Chinese biomass and coal co-firing power station, this study performed field sampling experiments and established a new evaluation method based on domestic literature. Unlike previous studies, this study revealed that the 14C activity of biomass far away from fossil carbon sources was 0.7–1.3 pMC lower than the local atmosphere. The 14C activity laws between tree rings and barks, specifically between eucalyptus bark and poplar bark were different, due to different growth models and different bark regeneration cycles, respectively. According to the test results and renewal conclusions, this study proposed a reasonable idea for constructing the prediction equation of referential biomass fuels’ 14C activity. Following this equation, the biomass fuels’ 14C activities of biomass direct-fired power stations at different Chinese cities were obtained. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Pressure Drops and Energy Consumption Model of Low-Scale Closed Circuit Cooling Towers
Processes 2021, 9(6), 974; https://doi.org/10.3390/pr9060974 - 31 May 2021
Cited by 1 | Viewed by 880
Abstract
Heat transfer models of closed-circuit cooling towers are available in the literature. Using these models, traditional parametric studies show how the inlet conditions of the streams influence the cooling capacity. This type of analysis could yield to suboptimal operation of the cooling tower [...] Read more.
Heat transfer models of closed-circuit cooling towers are available in the literature. Using these models, traditional parametric studies show how the inlet conditions of the streams influence the cooling capacity. This type of analysis could yield to suboptimal operation of the cooling tower since optimal heat and mass transfer processes do not necessarily imply an energy efficient cooling device. The optimal design of closed-circuit cooling towers should include any evaluation of pressure loses associated with the three streams involved. Air-water biphasic pressure drop across tube bundles in such devices was not sufficiently investigated in literature. The proposed literature correlations depend on geometry parameters, and these parameters are not known. In this work, an experimental device has been designed and constructed to study pressure drops, and an energy consumption model has been developed. The pressure drop was successfully calculated modifying a general correlation proposed for two phase flow across tube bundles. The energy model results show that the optimum was obtained where the intube water Reynolds number is near the transition region, and at air velocities near 1 m/s. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Insights into Equilibrium and Adsorption Rate of Phenol on Activated Carbon Pellets Derived from Cigarette Butts
Processes 2021, 9(6), 934; https://doi.org/10.3390/pr9060934 - 26 May 2021
Cited by 6 | Viewed by 842
Abstract
In the present work, the preparation of activated carbon pellets from cigarette butts by thermal treatment was evaluated. The morphological, textural, topological, and surface chemical properties were studied by SEM-EDX, N2 adsorption, Raman, and FTIR spectroscopy. For adsorption assays, activated carbon was [...] Read more.
In the present work, the preparation of activated carbon pellets from cigarette butts by thermal treatment was evaluated. The morphological, textural, topological, and surface chemical properties were studied by SEM-EDX, N2 adsorption, Raman, and FTIR spectroscopy. For adsorption assays, activated carbon was tested for the adsorption of phenol as a model molecule at different solution pH, temperature, and type of water. In addition, leaching tests before and after carbonization were conducted to evaluate the lixiviation of ions present in the solid. The results revealed a microporous material, composed of cylindrical fibers (thickness of 13 µm) with a microporous area of 713 m2/g and narrow and uniform slit-shaped pores (0.4–0.8 nm). The surface chemistry analysis evidenced the presence of oxygenated groups (carboxylic, esters, and phenolics). Activated carbon leaching tests indicated that the concentrations of the leached ions did not exceed the maximum permissible limit for drinking water. Phenol adsorption revealed an exothermic process with a maximum adsorption capacity of 272 mg/g at 10 °C. Finally, it was confirmed that phenol diffusion was drastically affected by hindered phenomena due to the similarity in the molecular size of phenol and the average size of micropores, and as a result an effective diffusion coefficient between 6.10 × 10−0 and 5.50 × 10−12 cm2/s and a maximum tortuosity value of 3.3 were obtained. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Solubility Temperature Dependence of Bio-Based Levulinic Acid, Furfural, and Hydroxymethylfurfural in Water, Nonpolar, Polar Aprotic and Protic Solvents
Processes 2021, 9(6), 924; https://doi.org/10.3390/pr9060924 - 24 May 2021
Cited by 5 | Viewed by 984
Abstract
Bio-based levulinic acid (LA), furfural (FF), and hydroxymethylfurfural (HMF) represent key chemical intermediates when biorefining biomass resources, i.e., either cellulose, glucose, hexoses, etc. (HMF/LA), or hemicellulose, xylose, and pentose (FF). Despite their importance, their online in situ detection by process analytical technologies (PATs), [...] Read more.
Bio-based levulinic acid (LA), furfural (FF), and hydroxymethylfurfural (HMF) represent key chemical intermediates when biorefining biomass resources, i.e., either cellulose, glucose, hexoses, etc. (HMF/LA), or hemicellulose, xylose, and pentose (FF). Despite their importance, their online in situ detection by process analytical technologies (PATs), solubility, and its temperature dependence are seldom available. Herein, we report their solubility and temperature dependence by examining n-hexane, cyclohexane, benzene, toluene, 1,4-dioxane, diethyl ether, dichloromethane, tetrahydrofuran, ethyl acetate, acetone, dimethylformamide, acetonitrile, dimethyl sulfoxide, formic acid, n-butanol, n-propanol, ethanol, methanol, and water. These solvents were selected as they are the most common nonpolar, polar aprotic, and polar protic solvents. Fourier-transform infrared (FTIR) spectroscopy was applied as a fast, accurate, and sensitive method to the examined solutions or mixtures. The latter also enables operando monitoring of the investigated compounds in pressurized reactors. Selected temperatures investigated were chosen, as they are within typical operating ranges. The calculated thermodynamic data are vital for designing biorefinery process intensification, e.g., reaction yield optimization by selective compound extraction. In addition to extracting, upstream or downstream unit operations that can benefit from the results include dissolution, crystallization, and precipitation. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Optimization of Methanol Synthesis under Forced Periodic Operation
Processes 2021, 9(5), 872; https://doi.org/10.3390/pr9050872 - 15 May 2021
Cited by 3 | Viewed by 1126
Abstract
Traditionally, methanol is produced in large amounts from synthesis gas with heterogeneous Cu/ZnO/Al2O3 catalysts under steady state conditions. In this paper, the potential of alternative forced periodic operation modes is studied using numerical optimization. The focus is a well-mixed isothermal [...] Read more.
Traditionally, methanol is produced in large amounts from synthesis gas with heterogeneous Cu/ZnO/Al2O3 catalysts under steady state conditions. In this paper, the potential of alternative forced periodic operation modes is studied using numerical optimization. The focus is a well-mixed isothermal reactor with two periodic inputs, namely, CO concentration in the feed and total feed flow rate. Exploiting a detailed kinetic model which also describes the dynamics of the catalyst, a sequential NLP optimization approach is applied to compare optimal steady state solutions with optimal periodic regimes. Periodic solutions are calculated using dynamic optimization with a periodicity constraint. The NLP optimization is embedded in a multi-objective optimization framework to optimize the process with respect to two objective functions and generate the corresponding Pareto fronts. The first objective is the methanol outlet flow rate. The second objective is the methanol yield based on the total carbon in the feed. Additional constraints arising from the complex methanol reaction and the practical limitations are introduced step by step. The results show that significant improvements for both objective functions are possible through periodic forcing of the two inputs considered here. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Heat Transfer and Hydrodynamics in Stirred Tanks with Liquid-Solid Flow Studied by CFD–DEM Method
Processes 2021, 9(5), 849; https://doi.org/10.3390/pr9050849 - 12 May 2021
Cited by 5 | Viewed by 1083
Abstract
The heat transfer and hydrodynamics of particle flows in stirred tanks are investigated numerically in this paper by using a coupled CFD–DEM method combined with a standard k-e turbulence model. Particle–fluid and particle–particle interactions, and heat transfer processes are considered in this model. [...] Read more.
The heat transfer and hydrodynamics of particle flows in stirred tanks are investigated numerically in this paper by using a coupled CFD–DEM method combined with a standard k-e turbulence model. Particle–fluid and particle–particle interactions, and heat transfer processes are considered in this model. The numerical method is validated by comparing the calculated results of our model to experimental results of the thermal convection of gas-particle flows in a fluidized bed published in the literature. This coupling model of computational fluid dynamics and discrete element (CFD–DEM) method, which could calculate the particle behaviors and individual particle temperature clearly, has been applied for the first time to the study of liquid-solid flows in stirred tanks with convective heat transfers. This paper reports the effect of particles on the temperature field in stirred tanks. The effects on the multiphase flow convective heat transfer of stirred tanks without and with baffles as well as various heights from the bottom are investigated. Temperature range of the multiphase flow is from 340 K to 350 K. The height of the blade is varied from about one-sixth to one-third of the overall height of the stirred tank. The numerical results show that decreasing the blade height and equipping baffles could enhance the heat transfer of the stirred tank. The calculated temperature field that takes into account the effects of particles are more instructive for the actual processes involving solid phases. This paper provides an effective method and is helpful for readers who have interests in the multiphase flows involving heat transfers in complex systems. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Tuning Metal–Support Interactions on Ni/Al2O3 Catalysts to Improve Catalytic Activity and Stability for Dry Reforming of Methane
Processes 2021, 9(4), 706; https://doi.org/10.3390/pr9040706 - 16 Apr 2021
Cited by 18 | Viewed by 1325
Abstract
Ni-based catalysts supported on alumina derived from the pseudo-boehmite prepared by the impregnation method were employed for catalytic dry reforming of methane reaction at the temperature of 550–750 °C. The effect of calcination temperature on physicochemical properties such as the Ni dispersion, reduction [...] Read more.
Ni-based catalysts supported on alumina derived from the pseudo-boehmite prepared by the impregnation method were employed for catalytic dry reforming of methane reaction at the temperature of 550–750 °C. The effect of calcination temperature on physicochemical properties such as the Ni dispersion, reduction degree, nickel crystallite sizes, and metal–support interaction of the catalysts was investigated. The characterization results show that increasing the catalyst calcination temperature leads to the formation of nickel-alumina spinel, which enhances the metal–support interaction and increases the reduction temperature. The nickel nanoparticle size decreases and the effective dispersion increases with the increasing calcination temperature from 450 °C to 750 °C due to the formation of nickel aluminate. The catalyst calcined at 750 °C exhibits the highest CH4 and CO2 conversion owing to the small Ni0 active sites and high Ni dispersion. In a 200 h stability test in dry reforming of methane at 700 °C, the Ni/Al2O3-750 catalyst exhibits excellent catalytic stability and anti-coking ability. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Estimating Breakup Frequencies in Industrial Emulsification Devices: The Challenge of Inferring Local Frequencies from Global Methods
Processes 2021, 9(4), 645; https://doi.org/10.3390/pr9040645 - 07 Apr 2021
Cited by 3 | Viewed by 627
Abstract
Experimental methods to study the breakup frequency in industrial devices are increasingly important. Since industrial production-scale devices are often inaccessible to single-drop experiments, breakup frequencies for these devices can only be studied with “global methods”; i.e., breakup frequency estimated from analyzing emulsification-experiment data. [...] Read more.
Experimental methods to study the breakup frequency in industrial devices are increasingly important. Since industrial production-scale devices are often inaccessible to single-drop experiments, breakup frequencies for these devices can only be studied with “global methods”; i.e., breakup frequency estimated from analyzing emulsification-experiment data. However, how much can be said about the local breakup frequencies (e.g., needed in modelling) from these global estimates? This question is discussed based on insights from a numerical validation procedure where set local frequencies are compared to global estimates. It is concluded that the global methods provide a valid estimate of local frequencies as long as the dissipation rate of turbulent kinetic energy is fairly homogenous throughout the device (although a residence-time-correction, suggested in this contribution, is needed as long as the flow is not uniform in the device). For the more realistic case of an inhomogeneous breakup frequency, the global estimate underestimates the local frequency (at the volume-averaged dissipation rate of turbulent kinetic energy). However, the relative error between local frequencies and global estimates is approximately constant when comparing between conditions. This suggest that the global methods are still valuable for studying how local breakup frequencies scale across operating conditions, geometries and fluid properties. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Evaluation of the Engineering Properties of Powdered Activated Carbon Amendments in Porous Asphalt Pavement
Processes 2021, 9(4), 582; https://doi.org/10.3390/pr9040582 - 26 Mar 2021
Cited by 2 | Viewed by 798
Abstract
Porous asphalt pavement (PAP) with a high drainage capacity was modified with powdered activated carbon (PAC) addition to produce permeable reactive pavement (PRP), which may exhibit the potential to reduce environmental non-point source (NPS) pollution. The experimental design mixtures used to produce and [...] Read more.
Porous asphalt pavement (PAP) with a high drainage capacity was modified with powdered activated carbon (PAC) addition to produce permeable reactive pavement (PRP), which may exhibit the potential to reduce environmental non-point source (NPS) pollution. The experimental design mixtures used to produce and test the PRP incorporated with PAC (named PRP-PACs) were conducted as follows: first, the PACs were initially tested to determine their feasibility as an additive in PAP; second, different amounts of PAC were added during the preparation of PAP to produce PRP-PAC, and the unregulated and regulated physical characteristics for the mechanical performance of PRP-PACs were examined to ensure that they meet the regulatory specifications. Third, the aqueous contaminants, namely benzene, toluene, ethyl-benzene, and xylene (BTEX), column adsorption tests were preliminarily conducted to demonstrate their adsorption capacities compared to traditional PAP. The compositions of 0.8% and 1.5% PAC (by wt.) (PRP-PAC08 and PRP-PAC15) met all the regulated specifications. As compared to PAP, PRP-PAC08 exhibited higher BTEX adsorption capacities than PAP, which were 47%, 49%, 29% and 2%. PRP-PAC08 showed both superior physical properties and adsorption performance than PAP and may be recommended as an engineering application that reduces the potential for NPS contamination of air, soil, groundwater, and surface water. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
CO2-Tolerant Oxygen Permeation Membranes Containing Transition Metals as Sintering Aids with High Oxygen Permeability
Processes 2021, 9(3), 528; https://doi.org/10.3390/pr9030528 - 15 Mar 2021
Cited by 2 | Viewed by 776
Abstract
Chemical doping of ceramic oxides may provide a possible route for realizing high-efficient oxygen transport membranes. Herein, we present a study of the previously unreported dual-phase mixed-conducting oxygen-permeable membranes with the compositions of 60 wt.% Ce0.85Pr0.1M0.05O2-δ [...] Read more.
Chemical doping of ceramic oxides may provide a possible route for realizing high-efficient oxygen transport membranes. Herein, we present a study of the previously unreported dual-phase mixed-conducting oxygen-permeable membranes with the compositions of 60 wt.% Ce0.85Pr0.1M0.05O2-δ-40 wt.%Pr0.6Sr0.4Fe0.8Al0.2O3-δ (M = Fe, Co, Ni, Cu) (CPM-PSFA) adding sintering aids, which is expected to not only improve the electronic conductivity of fluorite phase, but also reduce the sintering temperature and improve the sintering properties of the membranes. X-ray powder diffraction (XRD) results indicate that the CPM-PSFA contain only the fluorite and perovskite two phases, implying that they are successfully prepared with a modified Pechini method. Backscattered scanning electron microscopy (BSEM) results further confirm that two phases are evenly distributed, and the membranes are very dense after sintering at 1275 °C for 5 h, which is much lower than that (1450 °C, 5 h) of the composite 60 wt.%Ce0.9Pr0.1O2-δ-40 wt.%Pr0.6Sr0.4Fe0.8Al0.2O3-δ (CP-PSFA) without sintering aids. The results of oxygen permeability test demonstrate that the oxygen permeation flux through the CPCu-PSFA and CPCo-PSFA is higher than that of undoped CP-PSFA and can maintain stable oxygen permeability for a long time under pure CO2 operation condition. Our results imply that these composite membranes with high oxygen permeability and stability provide potential candidates for the application in oxygen separation, solid oxide fuel cell (SOFC), and oxy-fuel combustion based on carbon dioxide capture. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Process Performance Verification Using Viability Theory
Processes 2021, 9(3), 482; https://doi.org/10.3390/pr9030482 - 08 Mar 2021
Viewed by 617
Abstract
The development of efficient methods for process performance verification has drawn a lot of attention in the research community. Viability theory is a mathematical tool to identify the trajectories of a dynamical system which remains in a constraint set. In this paper, viability [...] Read more.
The development of efficient methods for process performance verification has drawn a lot of attention in the research community. Viability theory is a mathematical tool to identify the trajectories of a dynamical system which remains in a constraint set. In this paper, viability theory is investigated for this purpose in the case of nonlinear processes that can be represented in Linear Parameter Varying (LPV) form. In particular, verification algorithms based on the use of invariance and viability kernels and capture basin are proposed. The difficulty with the application of this theory is the computation of these sets. A Lagrangian method has been used to approximate these sets. Because of simplicity and efficient computations, zonotopes are adopted for set representation. Two new sets called Safe Work Area (SWA) and Required Performance (RP) are defined and an algorithm is proposed to use these concepts for the verification purpose. Finally, two application examples based on well-known case studies, a two-tank system and PH neutralization plant, are provided to show the effectiveness of the proposed method. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Vapor Phase Modification for Selective Enrichment of Grafted Styrene/Acrylonitrile onto Carbon Nanotubes Via ATRP
Processes 2021, 9(3), 459; https://doi.org/10.3390/pr9030459 - 03 Mar 2021
Cited by 2 | Viewed by 966
Abstract
Nitric acid vapor phase oxidation of multi-walled carbon nanotubes (MWCNTs) was proposed as a promising technique to fabricate poly styrene-co-acrylonitrile (SAN)-grafted-CNTs via atom transfer radical polymerization (ATRP). The in-situ ATRP grafting approach was successfully employed to graft polystyrene (PS), SAN and polyacrylonitrile (PAN), [...] Read more.
Nitric acid vapor phase oxidation of multi-walled carbon nanotubes (MWCNTs) was proposed as a promising technique to fabricate poly styrene-co-acrylonitrile (SAN)-grafted-CNTs via atom transfer radical polymerization (ATRP). The in-situ ATRP grafting approach was successfully employed to graft polystyrene (PS), SAN and polyacrylonitrile (PAN), onto the convex surfaces of pristine MWCNTs (PCNT) and acid-functionalized MWCNTs (FCNT). Fourier transform infrared spectroscopy (FTIR), proton nuclear magnetic resonance (1H-NMR), and thermogravimetric analysis (TGA) confirmed the effectiveness of the modification via the ATRP grafting approach. The molar composition of acrylonitrile in the synthesized copolymer on the surface of CNTs for an FCNTs was calculated to be about 80% and 67.5% by 1H-NMR and TGA respectively, whereas the value is lower for PCNTs. Morphological studies showed that SAN-grafted FCNTs exhibit rougher surface morphology compared to the SAN-grafted PCNTs. Moreover, the higher diameter of the FCNTs indicated the higher polymer content, which was coated onto CNTs functionalized by vapor-phase oxidation. Therefore, the vapor phase oxidation strategy employed in this study could be utilized as a general method to prepare CNTs which can serve as an ATRP macroinitiator for the fabrication of various polymer grafted CNTs. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Dynamic and Statistical Operability of an Experimental Batch Process
Processes 2021, 9(3), 441; https://doi.org/10.3390/pr9030441 - 28 Feb 2021
Viewed by 1080
Abstract
The operability approach has been traditionally applied to measure the ability of a continuous process to achieve desired specifications, given physical or design restrictions and considering expected disturbances at steady state. This paper introduces a novel dynamic operability analysis for batch processes based [...] Read more.
The operability approach has been traditionally applied to measure the ability of a continuous process to achieve desired specifications, given physical or design restrictions and considering expected disturbances at steady state. This paper introduces a novel dynamic operability analysis for batch processes based on classical operability concepts. In this analysis, all sets and statistical region delimitations are quantified using mathematical operations involving polytopes at every time step. A statistical operability analysis centered on multivariate correlations is employed for the first time to evaluate desired output sets during transition that serve as references to be followed to achieve the final process specifications. A dynamic design space for a batch process is, thus, generated through this analysis process and can be used in practice to guide process operation. A probabilistic expected disturbance set is also introduced, whereby the disturbances are described by pseudorandom variables and disturbance scenarios other than worst-case scenarios are considered, as is done in traditional operability methods. A case study corresponding to a pilot batch unit is used to illustrate the developed methods and to build a process digital twin to generate large datasets by running an automated digital experimentation strategy. As the primary data source of the analysis is built in a time-series database, the developed framework can be fully integrated into a plant information management system (PIMS) and an Industry 4.0 infrastructure. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Coupling Microbial Electrolysis Cell and Activated Carbon Biofilter for Source-Separated Greywater Treatment
Processes 2021, 9(2), 281; https://doi.org/10.3390/pr9020281 - 02 Feb 2021
Cited by 1 | Viewed by 914
Abstract
Reclamation and reuse of wastewater are increasingly viewed as a pragmatic tool for water conservation. Greywater, which includes water from baths, washing machines, dishwashers, and kitchen sinks, is a dilute wastewater stream, making it an attractive stream for extraction of non-potable water. However, [...] Read more.
Reclamation and reuse of wastewater are increasingly viewed as a pragmatic tool for water conservation. Greywater, which includes water from baths, washing machines, dishwashers, and kitchen sinks, is a dilute wastewater stream, making it an attractive stream for extraction of non-potable water. However, most previous studies primarily focused on passively aerated biological and physicochemical treatment processes for greywater treatment. Here, we investigated an integrated process of a microbial electrochemical cell (MEC) followed by granular activated carbon (GAC) biofilter for greywater treatment. The integrated system could achieve 99.3% removal of total chemical oxygen demand (TCOD) and 98.7% removal of the anionic surfactants (linear alkylbenzene sulphonates) from synthetic greywater at a total hydraulic residence time (HRT) of 25 h (1 day for MEC and 1 h for GAC biofilter). For one-day HRT, the maximum peak volumetric current density from MEC was 0.65 A/m3, which was comparable to that achieved at four-day HRT (0.66 A/m3). The adsorption by GAC was identified as a key mechanism for the removal of organics and surfactants. In addition, recirculation of liquid within the GAC biofilter was identified as a critical factor in achieving high-rate treatment. Although results indicated that GAC biofilter could be a standalone process for greywater, MEC can provide an opportunity for potential energy recovery from greywater. However, further studies should focus on developing high-rate MECs with higher energy recovery potential for practical operation. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Extra-Heavy Crude Oil Viscosity Reduction Using and Reusing Magnetic Copper Ferrite Nanospheres
Processes 2021, 9(1), 175; https://doi.org/10.3390/pr9010175 - 19 Jan 2021
Cited by 7 | Viewed by 1856
Abstract
The main objective of this study is the synthesis, use, and reuse of magnetic copper ferrite nanospheres (CFNS) for extra-heavy oil viscosity reduction. The CFNS were synthesized using a solvothermal method resulting in mean particle size of 150 nm. Interactions of CFNS with [...] Read more.
The main objective of this study is the synthesis, use, and reuse of magnetic copper ferrite nanospheres (CFNS) for extra-heavy oil viscosity reduction. The CFNS were synthesized using a solvothermal method resulting in mean particle size of 150 nm. Interactions of CFNS with the crude oil were evaluated through asphaltene adsorption isotherms, as well as static and dynamic rheology measurements for two cycles at 25 °C. Adsorption and desorption experiments corroborated that most of the asphaltenes adsorbed can be removed for nanoparticle reuse. During the rheology tests, nanoparticles were evaluated in the first cycle at different concentrations from 300 to 1500 mg/L, leading to the highest degree of viscosity reduction of 18% at 500 mg/L. SiO2 nanoparticles were evaluated for comparison issues, obtaining similar results regarding the viscosity reduction. After measurements, the CFNS were removed with a magnet, washed with toluene, and further dried for the second cycle of viscosity reduction. Rheology tests were performed for a second time at a fixed concentration of 500 mg/L, and slight differences were observed regarding the first cycle. Finally, changes in the extra-heavy oil microstructure upon CFNS addition were observed according to the significant decrease in elastic and viscous moduli. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Impacts of Low-Carbon Targets and Hydrogen Production Alternatives on Energy Supply System Transition: An Infrastructure-Based Optimization Approach and a Case Study of China
Processes 2021, 9(1), 160; https://doi.org/10.3390/pr9010160 - 15 Jan 2021
Cited by 5 | Viewed by 1129
Abstract
Low-carbon transition pathways oriented from different transition targets would result in a huge variation of energy system deployment and transition costs. Hydrogen is widely considered as an imperative energy carrier to reach carbon neutral targets. However, hydrogen production, either from non-fossil power or [...] Read more.
Low-carbon transition pathways oriented from different transition targets would result in a huge variation of energy system deployment and transition costs. Hydrogen is widely considered as an imperative energy carrier to reach carbon neutral targets. However, hydrogen production, either from non-fossil power or fossil fuels with carbon capture, is closely linked with an energy supply system and has great impacts on its structure. Identifying an economically affordable transition pathway is attractive, and energy infrastructure is critical due to massive investment and long life-span. In this paper, a multi-regional, multi-period, and infrastructure-based model is proposed to quantify energy supply system transition costs with different low-carbon targets and hydrogen production alternatives, and China is taken as a case study. Results show that, fulfilling 2-degree and 1.5-degree temperature increase targets would result in 84% and 151% increases in system transition costs, 114% and 246% increases in infrastructure investment, and 211% and 339% increases in stranded investment, compared to fulfilling stated policy targets. Producing hydrogen from coal would be economical when carbon capture and sequestration cost is lower than 437 yuan per tonne, and reduce infrastructure investment and stranded coal investment by 16% and 35% respectively, than producing hydrogen from renewable power. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Nano-Intermediate of Magnetite Nanoparticles Supported on Activated Carbon from Spent Coffee Grounds for Treatment of Wastewater from Oil Industry and Energy Production
Processes 2021, 9(1), 63; https://doi.org/10.3390/pr9010063 - 30 Dec 2020
Cited by 11 | Viewed by 1998
Abstract
This work focused on evaluating the adsorptive removal of crude oil using a nano-intermediate based on magnetite nanoparticles supported on activated carbon synthesized from spent coffee grounds and the subsequent catalytic oil decomposition to recover by-products and regenerate the support material. The magnetite [...] Read more.
This work focused on evaluating the adsorptive removal of crude oil using a nano-intermediate based on magnetite nanoparticles supported on activated carbon synthesized from spent coffee grounds and the subsequent catalytic oil decomposition to recover by-products and regenerate the support material. The magnetite nanoparticles were synthesized by the co-precipitation method and were used as active phases on prepared activated carbon. The amount of crude oil adsorbed was determined by adsorption isotherms. In addition, dynamic tests were performed on a packed bed to evaluate the efficiency of the removal process. Thermogravimetric analysis and mass spectrometry were used to evaluate the catalytic powder and the quantification of by-products. Contrasting the results with commercial carbon, the one synthesized from the coffee residue showed a greater affinity for the oil. Likewise, the adsorption capacity increased by doping activated carbon with magnetite nanoparticles, obtaining an efficiency greater than 10%. The crude oil decomposition was carried out successfully by thermal cracking, obtaining a 100% removal. The gas produced after decomposition contains light hydrocarbons such as C2H4 and CH4 and shows a decrease in polluting species such as CO and CO2, leading to greater environmental sustainability of the process. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
The Supervision of Dough Fermentation Using Image Analysis Complemented by a Continuous Discrete Extended Kalman Filter
Processes 2020, 8(12), 1669; https://doi.org/10.3390/pr8121669 - 17 Dec 2020
Cited by 3 | Viewed by 791
Abstract
Dough fermentation is an important step during the preparation of fermented baking goods. For the supervision of dough fermentation, a continuous-discrete extended Kalman filter was applied, which uses an image analysis system as the measurement. By estimation a fixed number of gas bubbles [...] Read more.
Dough fermentation is an important step during the preparation of fermented baking goods. For the supervision of dough fermentation, a continuous-discrete extended Kalman filter was applied, which uses an image analysis system as the measurement. By estimation a fixed number of gas bubbles inside the dough, the radius of an average bubble was determined. A mathematical dough model was used by the extended Kalman filter to estimate the radius of the average bubble, the CO2 concentration of the non-gas dough phase and the number of CO2 molecules in the average bubble. During a fermentation of 50 min, the extended Kalman filter estimated that the average radius increased from 50 µm to 127 µm, the CO2 concentration in the non-gas dough increased to 23 mol/m³, and the CO2 amount in the bubble increased from 0.1 × 10−10 to 4 × 10−10 mol. Also, the specific CO2 production rate was estimated to be in the range from 1.5 × 10−3 to more than 4 × 10−3 mol·m³/kg/s. The advantages of an extended Kalman filter for the supervision of the dough fermentation process are discussed. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Communication
Trimeric SARS-CoV-2 Spike Proteins Produced from CHO Cells in Bioreactors Are High-Quality Antigens
Processes 2020, 8(12), 1539; https://doi.org/10.3390/pr8121539 - 25 Nov 2020
Cited by 12 | Viewed by 4576
Abstract
The spike protein of the pandemic human corona virus is essential for its entry into human cells. In fact, most neutralizing antibodies against Severe Acute Respiratory Syndrome Corona Virus 2 (SARS-CoV-2) are directed against the Virus-surface exposed spike protein, making it the antigen [...] Read more.
The spike protein of the pandemic human corona virus is essential for its entry into human cells. In fact, most neutralizing antibodies against Severe Acute Respiratory Syndrome Corona Virus 2 (SARS-CoV-2) are directed against the Virus-surface exposed spike protein, making it the antigen of choice for use in vaccines and diagnostic tests. In the current pandemic context, global demand for spike proteins has rapidly increased and could exceed hundreds of grams to kilograms annually. Coronavirus spikes are large heavily glycosylated homo-trimeric complexes, with inherent instability. The poor manufacturability now threatens the availability of these proteins for vaccines and diagnostic tests. Here, we outline scalable, Good Manufacturing Practice (GMP) compliant, and chemically defined processes for the production of two cell-secreted stabilized forms of the trimeric spike proteins (Wuhan and D614G variant). The processes are chemically defined and based on clonal suspension-CHO cell populations and on protein purification via a two-step scalable downstream process. The trimeric conformation was confirmed using electron microscopy and HPLC analysis. Binding to susceptible cells was shown using a virus-inhibition assay. The diagnostic sensitivity and specificity for detection of serum SARS-CoV-2-specific-immunoglobulin molecules was found to exceed that of spike fragments (Spike subunit-1, S1 and Receptor Binding Domain, RBD). The process described here will enable production of sufficient high-quality trimeric spike protein to meet the global demand for SARS-CoV-2 diagnostic tests and potentially vaccines. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Digital Twinning Process for Stirred Tank Reactors/Separation Unit Operations through Tandem Experimental/Computational Fluid Dynamics (CFD) Simulations
Processes 2020, 8(11), 1511; https://doi.org/10.3390/pr8111511 - 21 Nov 2020
Cited by 4 | Viewed by 1732
Abstract
Computational fluid dynamics simulations (CFD) were used to evaluate mixing in baffled and unbaffled vessels. The Reynolds-averaged Navier−Stokes kε model was implemented in OpenFOAM for obtaining the fluid flow field. The 95% homogenization times were determined by tracer tests. Experimental tests [...] Read more.
Computational fluid dynamics simulations (CFD) were used to evaluate mixing in baffled and unbaffled vessels. The Reynolds-averaged Navier−Stokes kε model was implemented in OpenFOAM for obtaining the fluid flow field. The 95% homogenization times were determined by tracer tests. Experimental tests were conducted by injecting sodium chloride into the vessel and measuring the conductivity with two conductivity probes, while the simulations replicated the experimental conditions with the calculation of the transport of species. It was found that the geometry of the system had a great effect on the mixing time, since the irregular flow distribution, which can be obtained with baffles, can lead to local stagnation zones, which will increase the time needed to achieve the homogenization of the solute. It was also found that measuring local, pointwise concentrations can lead to a high underestimation of the global mixing time required for the homogenization of the entire vessel. Dissolution of sucrose was also studied experimentally and by mathematical modeling. The dissolution of sucrose was found to be kinetically limited and a very good agreement was found between the experiments and the modeling approach. The extent of the applicability of CFD simulations was evaluated for enabling rapid process design via simulations. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Influence of Acoustic Oscillations on Continuous-Flow Water Disinfection
Processes 2020, 8(10), 1259; https://doi.org/10.3390/pr8101259 - 07 Oct 2020
Cited by 1 | Viewed by 745
Abstract
Water disinfection and potential sterilization in continuous flow was achieved in a hybrid reactor with a broadband hydrodynamic emitter combined with ultrasonic vibrations at different frequencies and with excess pressure. Such a combination showed synergistic effects by increasing the acoustic power in the [...] Read more.
Water disinfection and potential sterilization in continuous flow was achieved in a hybrid reactor with a broadband hydrodynamic emitter combined with ultrasonic vibrations at different frequencies and with excess pressure. Such a combination showed synergistic effects by increasing the acoustic power in the reactor vortex flow. The present combined physical treatment, compared with sonication alone, could increase microorganism inactivation by 15–20%. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Computational Optimization of Porous Structures for Electrochemical Processes
Processes 2020, 8(10), 1205; https://doi.org/10.3390/pr8101205 - 23 Sep 2020
Cited by 6 | Viewed by 1402
Abstract
Porous structures are naturally involved in electrochemical processes. The specific architectures of the available porous materials, as well as their physical properties, crucially affect their applications, e.g., their use in fuel cells, batteries, or electrolysers. A key point is the correlation of transport [...] Read more.
Porous structures are naturally involved in electrochemical processes. The specific architectures of the available porous materials, as well as their physical properties, crucially affect their applications, e.g., their use in fuel cells, batteries, or electrolysers. A key point is the correlation of transport properties (mass, heat, and charges) in the spatially—and in certain cases also temporally—distributed pore structure. In this paper, we use mathematical modeling to investigate the impact of the pore structure on the distribution of wetting and non-wetting phases in porous transport layers used in water electrolysis. We present and discuss the potential of pore network models and an upscaling strategy for the simulation of the saturation of the pore space with liquid and gas, as well as the computation of the relative permeabilities and oxygen dissolution and diffusion. It is studied how a change of structure, i.e., the spatial grading of the pore size distribution and porosity, change the transport properties. Several situations are investigated, including a vertical gradient ranging from small to large pore sizes and vice versa, as well as a dual-porosity network. The simulation results indicate that the specific porous structure has a significant impact on the spatial distribution of species and their respective relative permeabilities. In more detail, it is found that the continuous increase of pore sizes from the catalyst layer side towards the water inlet interface yields the best transport properties among the investigated pore networks. This outcome could be useful for the development of grading strategies, specifically for material optimization for improved transport kinetics in water electrolyser applications and for electrochemical processes in general. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
MILP Formulation for Solving and Initializing MINLP Problems Applied to Retrofit and Synthesis of Hydrogen Networks
Processes 2020, 8(9), 1102; https://doi.org/10.3390/pr8091102 - 04 Sep 2020
Cited by 4 | Viewed by 1103
Abstract
The demand for hydrogen in refineries is growing due to its importance as a sulfur capture element. Therefore, hydrogen management is critical for fulfilling demands as efficiently as possible. Through mathematical modeling, hydrogen network management can be better performed. Cost-efficient Mixed-Integer Linear Programming [...] Read more.
The demand for hydrogen in refineries is growing due to its importance as a sulfur capture element. Therefore, hydrogen management is critical for fulfilling demands as efficiently as possible. Through mathematical modeling, hydrogen network management can be better performed. Cost-efficient Mixed-Integer Linear Programming (MILP) and Mixed-Integer Nonlinear Programming (MINLP) optimization models for (re)designing were proposed and implemented in GAMS with two case studies. Linear programming has the limitation of no stream mixing allowed; therefore, to overcome this limitation, an algorithm-based procedure called the Virtual Compressor Approach was proposed. Based on the MILP optimal solution obtained, the streams and compressors were merged. As a result, the number of compressors was reduced, along with the inherent investment costs. An operational cost reduction of more than 28% (example 1) and 26% (example 2) was obtained with a linear model. The optimal MILP solution after rearranging compressors was then provided as a good starting point to the MINLP. The operating costs were decreased by more than 31% (example 1) and 32% (example 2). Most of the cost reduction was obtained only with the usage of the MILP model. Besides, a higher level of cost reduction was only obtained when the linear model was used as the starting point. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Communication
Highly-Efficient Caffeine Recovery from Green Coffee Beans under Ultrasound-Assisted SC–CO2 Extraction
Processes 2020, 8(9), 1062; https://doi.org/10.3390/pr8091062 - 01 Sep 2020
Cited by 4 | Viewed by 1715
Abstract
Natural caffeine from decaffeination processes is widely used by pharmaceutical, cosmetic and soft-drink industries. Supercritical CO2 extraction (SFE–CO2) is extensively exploited industrially, and one of its most representative applications is the decaffeination process, which is a greener alternative to the [...] Read more.
Natural caffeine from decaffeination processes is widely used by pharmaceutical, cosmetic and soft-drink industries. Supercritical CO2 extraction (SFE–CO2) is extensively exploited industrially, and one of its most representative applications is the decaffeination process, which is a greener alternative to the use of organic solvents. Despite its advantages, extraction kinetics are rather slow near the CO2 critical point, meaning that improvements are highly sought after. The effect exerted by a combination of SFE–CO2 and ultrasound (US–SFE–CO2) has been investigated in this preliminary study, with the aim of improving mass transfer and selectivity in the extraction of caffeine from green coffee beans. This hybrid technology can considerably enhance the extraction efficiency and cut down process time. Further studies are in progress to demonstrate the complete decaffeination of green coffee beans of different types and origins. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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Article
Residue Char Derived from Microwave-Assisted Pyrolysis of Sludge as Adsorbent for the Removal of Methylene Blue from Aqueous Solutions
Processes 2020, 8(8), 979; https://doi.org/10.3390/pr8080979 - 13 Aug 2020
Cited by 1 | Viewed by 1044
Abstract
Residue char is the main by-product of the microwave-assisted pyrolysis of activated sludge and it has a high content of fixed carbon and porous structure, but little is known about its character as an absorbent. In this study, residue char of activated sludge [...] Read more.
Residue char is the main by-product of the microwave-assisted pyrolysis of activated sludge and it has a high content of fixed carbon and porous structure, but little is known about its character as an absorbent. In this study, residue char of activated sludge with microwave-assisted pyrolysis was used as an adsorbent to absorb methylene blue. The effects of pyrolysis temperature, pyrolysis holding time, contact time, and adsorption temperature on the adsorption ability of residue char were investigated. Kinetics, isotherm, and thermodynamic models were also included to study the adsorption behavior. The results showed that the optimal pyrolysis condition was 15 min and 603 °C, and the adsorption capacity reached up to 80.01 mg/g. The kinetics analyses indicated the adsorption behavior followed the pseudo-second-order kinetics model and the adsorption process was mainly due to chemical interaction. The adsorption isotherm was described by Freundlich model and thus, its process was multimolecular layer adsorption. Furthermore, the thermodynamics parameters (ΔG0, ΔH0, and ΔS0) at different temperatures indicated that the nature of the adsorption process was endothermic and spontaneous. Full article
(This article belongs to the Special Issue Redesign Processes in the Age of the Fourth Industrial Revolution)
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