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Keywords = OPEX (operating expense)

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23 pages, 1948 KB  
Article
Identification of Energy Storage in Distribution Channels
by Joanna Alicja Dyczkowska, Aleksandra Panek and Norbert Chamier-Gliszczynski
Energies 2025, 18(18), 4981; https://doi.org/10.3390/en18184981 - 19 Sep 2025
Viewed by 1020
Abstract
Energy storage facilities serve as flexible resources that comprehensively support grid operations; they are also essential, especially when the thermal power plants that previously served as regulators run out. Electricity is becoming the dominant carrier through which the bulk of consumers’ energy needs [...] Read more.
Energy storage facilities serve as flexible resources that comprehensively support grid operations; they are also essential, especially when the thermal power plants that previously served as regulators run out. Electricity is becoming the dominant carrier through which the bulk of consumers’ energy needs are met. The efficiency of long-distance transmission and the ease of conversion to other forms of energy in Poland are attributed to the national grid. Thanks to the development of new technologies and distribution channels, energy is changing its supply network system. The purpose of this article is to discuss the economic viability of energy storage systems and their strategic role in the energy transition. The research methods used are data analysis, and the dependence on capital expenditures (CAPEX) and operating costs (OPEX) of energy storage in distribution channels. Energy storage facilities operated by grid companies account for 90% of the installed capacity, but there is a noticeable increase in the number of prosumer installations, with an energy storage of up to 50 KWh at microinstallations. Full article
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23 pages, 2594 KB  
Article
A Study on the Optimal Configuration of Offshore Substation Transformers
by Byeonghyeon An, Jeongsik Oh and Taesik Park
Energies 2025, 18(12), 3076; https://doi.org/10.3390/en18123076 - 11 Jun 2025
Cited by 1 | Viewed by 2538
Abstract
The growing scale of offshore wind farms and increasing transmission distances has driven the demand for optimized offshore substation (OSS) configurations. This study proposes a comprehensive techno-economic framework to minimize the total lifecycle cost (LCC) of an OSS by determining the optimal number [...] Read more.
The growing scale of offshore wind farms and increasing transmission distances has driven the demand for optimized offshore substation (OSS) configurations. This study proposes a comprehensive techno-economic framework to minimize the total lifecycle cost (LCC) of an OSS by determining the optimal number of OSSs and transformers considering wind farm capacity and transmission distance. The methodology incorporates three cost models: capital expenditure (CAPEX), operational expenditure (OPEX), and expected energy not supplied (EENS). CAPEX considers transformer costs, topside structural mass effects, and nonlinear installation costs. OPEX accounts for substation maintenance and vessel operating expenses, and EENS is calculated using transformer failure probability models and redundancy configurations. The optimization is performed through scenario-based simulations and a net present value (NPV)-based comparative analysis to determine the cost-effective configurations. The quantitative analysis demonstrates that for small- to medium-scale wind farms (500–1000 MW), configurations using 1–2 substations and 3–4 transformers achieve minimal LCC regardless of the transmission distance. In contrast, large-scale wind farms (≥1500 MW) require additional substations to mitigate transmission losses and disruption risks, particularly over long distances. These results demonstrate that OSS design should holistically balance initial investment costs, operational reliability, and supply security, providing practical insights for cost-effective planning of next-generation offshore wind projects. Full article
(This article belongs to the Section A3: Wind, Wave and Tidal Energy)
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16 pages, 2606 KB  
Article
Techno-Economic and CO2 Net Assessment of Dimethyl Carbonate Production from Biomass-Derived Methanol
by Renan Fagundes Custodio, Osvaldo Valarini Junior, Admilson Lopes Vieira, Thiago Leandro de Souza, Felipi Luiz de Assunção Bezerra and Lucas Bonfim-Rocha
Processes 2025, 13(2), 573; https://doi.org/10.3390/pr13020573 - 18 Feb 2025
Cited by 2 | Viewed by 3405
Abstract
The increasing concern over greenhouse gas emissions, particularly CO2, has emphasized the urgency for practical solutions to mitigate the environmental impacts of climate change. This study assessed the technical, economic, and environmental feasibility of producing dimethyl carbonate (DMC) through an integrated [...] Read more.
The increasing concern over greenhouse gas emissions, particularly CO2, has emphasized the urgency for practical solutions to mitigate the environmental impacts of climate change. This study assessed the technical, economic, and environmental feasibility of producing dimethyl carbonate (DMC) through an integrated route using methanol derived from biomass gasification in sugarcane-based industries. Unlike previous studies that analyzed isolated aspects of DMC production, this research was conducted through process modeling and simulation in Aspen Plus® V12.1, evaluating key performance indicators such as conversion rates, product purity, capital and operating expenses, and CO2 emissions. A DMC conversion rate of 78.06% and a purity level of 96.80% were achieved. However, the integration of methanol production increased both CAPEX and OPEX, leading to a net present value (NPV) of R$ 36.7 million over 10 years, lower than alternative routes using commercially available methanol. Additionally, the process resulted in a net CO2 emission of 3.41 kg CO2 per kg of DMC, exceeding conventional methods. These findings suggest that under the evaluated conditions, process integration did not offer economic advantages, despite many environmental advantages over commercially available methanol. Full article
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20 pages, 1628 KB  
Review
Energy Efficiency for 5G and Beyond 5G: Potential, Limitations, and Future Directions
by Adrian Ichimescu, Nirvana Popescu, Eduard C. Popovici and Antonela Toma
Sensors 2024, 24(22), 7402; https://doi.org/10.3390/s24227402 - 20 Nov 2024
Cited by 21 | Viewed by 9809
Abstract
Energy efficiency constitutes a pivotal performance indicator for 5G New Radio (NR) networks and beyond, and achieving optimal efficiency necessitates the meticulous consideration of trade-offs against other performance parameters, including latency, throughput, connection densities, and reliability. Energy efficiency assumes it is of paramount [...] Read more.
Energy efficiency constitutes a pivotal performance indicator for 5G New Radio (NR) networks and beyond, and achieving optimal efficiency necessitates the meticulous consideration of trade-offs against other performance parameters, including latency, throughput, connection densities, and reliability. Energy efficiency assumes it is of paramount importance for both User Equipment (UE) to achieve battery prologue and base stations to achieve savings in power and operation cost. This paper presents an exhaustive review of power-saving research conducted for 5G and beyond 5G networks in recent years, elucidating the advantages, disadvantages, and key characteristics of each technique. Reinforcement learning, heuristic algorithms, genetic algorithms, Markov Decision Processes, and the hybridization of various standard algorithms inherent to 5G and 5G NR represent a subset of the available solutions that shall undergo scrutiny. In the final chapters, this work identifies key limitations, namely, computational expense, deployment complexity, and scalability constraints, and proposes a future research direction by theoretically exploring online learning, the clustering of the network base station, and hard HO to lower the consumption of networks like 2G or 4G. In lowering carbon emissions and lowering OPEX, these three additional features could help mobile network operators achieve their targets. Full article
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32 pages, 4014 KB  
Article
Techno-Economic Feasibility Analysis of Post-Combustion Carbon Capture in an NGCC Power Plant in Uzbekistan
by Azizbek Kamolov, Zafar Turakulov, Patrik Furda, Miroslav Variny, Adham Norkobilov and Marcos Fallanza
Clean Technol. 2024, 6(4), 1357-1388; https://doi.org/10.3390/cleantechnol6040065 - 10 Oct 2024
Cited by 17 | Viewed by 6753
Abstract
As natural gas-fired combined cycle (NGCC) power plants continue to constitute a crucial part of the global energy landscape, their carbon dioxide (CO2) emissions pose a significant challenge to climate goals. This paper evaluates the feasibility of implementing post-combustion carbon capture, [...] Read more.
As natural gas-fired combined cycle (NGCC) power plants continue to constitute a crucial part of the global energy landscape, their carbon dioxide (CO2) emissions pose a significant challenge to climate goals. This paper evaluates the feasibility of implementing post-combustion carbon capture, storage, and utilization (CCSU) technologies in NGCC power plants for end-of-pipe decarbonization in Uzbekistan. This study simulates and models a 450 MW NGCC power plant block, a first-generation, technically proven solvent—MEA-based CO2 absorption plant—and CO2 compression and pipeline transportation to nearby oil reservoirs to evaluate the technical, economic, and environmental aspects of CCSU integration. Parametric sensitivity analysis is employed to minimize energy consumption in the regeneration process. The economic analysis evaluates the levelized cost of electricity (LCOE) on the basis of capital expenses (CAPEX) and operational expenses (OPEX). The results indicate that CCSU integration can significantly reduce CO2 emissions by more than 1.05 million tonnes annually at a 90% capture rate, although it impacts plant efficiency, which decreases from 55.8% to 46.8% because of the significant amount of low-pressure steam extraction for solvent regeneration at 3.97 GJ/tonne CO2 and multi-stage CO2 compression for pipeline transportation and subsequent storage. Moreover, the CO2 capture, compression, and transportation costs are almost 61 USD per tonne, with an equivalent LCOE increase of approximately 45% from the base case. This paper concludes that while CCSU integration offers a promising path for the decarbonization of NGCC plants in Uzbekistan in the near- and mid-term, its implementation requires massive investments due to the large scale of these plants. Full article
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14 pages, 2870 KB  
Article
Hydrogen Fuel Cell as an Electric Generator: A Case Study for a General Cargo Ship
by Omer Berkehan Inal, Burak Zincir, Caglar Dere and Jean-Frédéric Charpentier
J. Mar. Sci. Eng. 2024, 12(3), 432; https://doi.org/10.3390/jmse12030432 - 28 Feb 2024
Cited by 20 | Viewed by 7088
Abstract
In this study, real voyage data and ship specifications of a general cargo ship are employed, and it is assumed that diesel generators are replaced with hydrogen proton exchange membrane fuel cells. The effect of the replacement on CO2, NOX [...] Read more.
In this study, real voyage data and ship specifications of a general cargo ship are employed, and it is assumed that diesel generators are replaced with hydrogen proton exchange membrane fuel cells. The effect of the replacement on CO2, NOX, SOX, and PM emissions and the CII value is calculated. Emission calculations show that there is a significant reduction in emissions when hydrogen fuel cells are used instead of diesel generators on the case ship. By using hydrogen fuel cells, there is a 37.4% reduction in CO2 emissions, 32.5% in NOX emissions, 37.3% in SOX emissions, and 37.4% in PM emissions. If hydrogen fuel cells are not used instead of diesel generators, the ship will receive an A rating between 2023 and 2026, a B rating in 2027, a C rating in 2028–2029, and an E rating in 2030. On the other hand, if hydrogen fuel cells are used, the ship will always remain at an A rating between 2023 and 2030. The capital expenditure (CAPEX) and operational expenditure (OPEX) of the fuel cell system are USD 1,305,720 and USD 2,470,320, respectively, for a 15-year lifetime, and the hydrogen fuel expenses are competitive at USD 260,981, while marine diesel oil (MDO) fuel expenses are USD 206,435. Full article
(This article belongs to the Special Issue New Advances on Energy and Propulsion Systems for Ship)
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25 pages, 9823 KB  
Article
An Energy-Efficient Multi-Level Sleep Strategy for Periodic Uplink Transmission in Industrial Private 5G Networks
by Taehwa Kim, Seungjin Lee, Hyungwoo Choi, Hong-Shik Park and Junkyun Choi
Sensors 2023, 23(22), 9070; https://doi.org/10.3390/s23229070 - 9 Nov 2023
Cited by 5 | Viewed by 3099
Abstract
This paper proposes an energy-efficient multi-level sleep mode control for periodic transmission (MSC-PUT) in private fifth-generation (5G) networks. In general, private 5G networks meet IIoT requirements but face rising energy consumption due to dense base station (BS) deployment, particularly impacting operating expenses (OPEX). [...] Read more.
This paper proposes an energy-efficient multi-level sleep mode control for periodic transmission (MSC-PUT) in private fifth-generation (5G) networks. In general, private 5G networks meet IIoT requirements but face rising energy consumption due to dense base station (BS) deployment, particularly impacting operating expenses (OPEX). An approach of BS sleep mode has been studied to reduce energy consumption, but there has been insufficient consideration for the periodic uplink transmission of industrial Internet of Things (IIoT) devices. Additionally, 5G New Reno’s synchronization signal interval limits the effectiveness of the deepest sleep mode in reducing BS energy consumption. By addressing this issue, the aim of this paper is to propose an energy-efficient multi-level sleep mode control for periodic uplink transmission to improve the energy efficiency of BSs. In advance, we develop an energy-efficient model that considers the trade-off between throughput impairment caused by increased latency and energy saving by sleep mode operation for IIoT’s periodic uplink transmission. Then, we propose an approach based on proximal policy optimization (PPO) to determine the deep sleep mode of BSs, considering throughput impairment and energy efficiency. Our simulation results verify the proposed MSC-PUT algorithm’s effectiveness in terms of throughput, energy saving, and energy efficiency. Specifically, we verify that our proposed MSC-PUT enhances energy efficiency by nearly 27.5% when compared to conventional multi-level sleep operation and consumes less energy at 75.21% of the energy consumed by the conventional method while incurring a throughput impairment of nearly 4.2%. Numerical results show that the proposed algorithm can significantly reduce the energy consumption of BSs accounting for periodic uplink transmission of IIoT devices. Full article
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24 pages, 3453 KB  
Article
Alternatives for the Valorization of Avocado Waste Generated in the Different Links of the Value Chain Based on a Life-Cycle Analysis Approach
by Maria Camila Garcia-Vallejo, Tatiana Agudelo Patiño, Jhonny Alejandro Poveda-Giraldo, Sara Piedrahita-Rodríguez and Carlos Ariel Cardona Alzate
Agronomy 2023, 13(9), 2229; https://doi.org/10.3390/agronomy13092229 - 25 Aug 2023
Cited by 22 | Viewed by 5925
Abstract
This work evaluates the sustainability of small-scale biorefineries as a potential enterprise alternative to be introduced in rural areas based on experimental and simulation data. Four scenarios were evaluated: the first scenario involves the production of guacamole, the second involves the production of [...] Read more.
This work evaluates the sustainability of small-scale biorefineries as a potential enterprise alternative to be introduced in rural areas based on experimental and simulation data. Four scenarios were evaluated: the first scenario involves the production of guacamole, the second involves the production of animal feed, and the third and fourth scenarios involve the extraction of bioactive compounds and the production of avocado oil or animal feed, respectively. In addition, all scenarios produce biogas and fertilizer. Each of the scenarios were evaluated considering the technical, economic, environmental, and social aspects. As a main result, the first scenario showed the lowest operating and investment costs, as well as the lowest economic profitability (profit margin 35%). On the other hand, the third and fourth scenarios present the highest investment and operating expenses (OpEx USD 6.2 million per year and CapEx USD 1.0 million), but their profit margins are in the 60–70% range. Furthermore, a life-cycle assessment (LCA) was carried out and allows inferring that the transformer link presents the highest environmental impact of the entire value chain and that the carbon footprint for all scenarios ranges between 1.01–2.41 kg CO2 eq per kg avocado. Similarly, the social impact methodology shows that the proposed scenarios do not present any social risk. Thus, the biorefinery for animal feed, bioactive compounds, biogas, and fertilizer was selected as the best option to be implemented in Caldas. Full article
(This article belongs to the Special Issue Pretreatment and Bioconversion of Crop Residues II)
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18 pages, 1272 KB  
Article
A Techno-Economic Study for Off-Grid Green Hydrogen Production Plants: The Case of Chile
by Marcelo León, Javier Silva, Rodrigo Ortíz-Soto and Samuel Carrasco
Energies 2023, 16(14), 5327; https://doi.org/10.3390/en16145327 - 12 Jul 2023
Cited by 32 | Viewed by 7297
Abstract
In this study, we present a pre-feasibility analysis that examines the viability of implementing autonomous green hydrogen production plants in two strategic regions of Chile. With abundant renewable energy resources and growing interest in decarbonization in Chile, this study aims to provide a [...] Read more.
In this study, we present a pre-feasibility analysis that examines the viability of implementing autonomous green hydrogen production plants in two strategic regions of Chile. With abundant renewable energy resources and growing interest in decarbonization in Chile, this study aims to provide a comprehensive financial analysis from the perspective of project initiators. The assessment includes determining the optimal sizing of an alkaline electrolyzer stack, seawater desalination system, and solar and wind renewable energy farms and the focus is on conducting a comprehensive financial analysis from the perspective of project initiators to assess project profitability using key economic indicators such as net present value (NPV). The analyses involve determining appropriate sizing of an alkaline electrolyzer stack, a seawater desalination system, and solar and wind renewable energy farms. Assuming a base case production of 1 kiloton per year of hydrogen, the capital expenditures (CAPEX) and operating expenses (OPEX) are determined. Then, the manufacturing and production costs per kilogram of green hydrogen are calculated, resulting in values of USD 3.53 kg−1 (utilizing wind energy) and USD 5.29 kg−1 (utilizing photovoltaic solar energy). Cash flows are established by adjusting the sale price of hydrogen to achieve a minimum expected return on investment of 4% per year, yielding minimum prices of USD 7.84 kg−1 (with wind energy) and USD 11.10 kg−1 (with photovoltaic solar energy). Additionally, a sensitivity analysis is conducted to assess the impact of variations in investment and operational costs. This research provides valuable insights into the financial feasibility of green hydrogen production in Chile, contributing to understanding renewable energy-based hydrogen projects and their potential economic benefits. These results can provide a reference for future investment decisions and the global development of green hydrogen production plants. Full article
(This article belongs to the Section C: Energy Economics and Policy)
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17 pages, 1094 KB  
Article
Costs of Gasification Technologies for Energy and Fuel Production: Overview, Analysis, and Numerical Estimation
by Gonçalo Lourinho, Octávio Alves, Bruno Garcia, Bruna Rijo, Paulo Brito and Catarina Nobre
Recycling 2023, 8(3), 49; https://doi.org/10.3390/recycling8030049 - 19 May 2023
Cited by 55 | Viewed by 31085
Abstract
During recent years, gasification technology has gained a high potential and attractiveness to convert biomass and other solid wastes into a valuable syngas for energy production or synthesis of new biofuels. The implementation of real gasification facilities implies a good insight of all [...] Read more.
During recent years, gasification technology has gained a high potential and attractiveness to convert biomass and other solid wastes into a valuable syngas for energy production or synthesis of new biofuels. The implementation of real gasification facilities implies a good insight of all expenses that are involved, namely investments required in equipment during the project and construction phases (capital expenditures, CapEx) and costs linked to the operation of the plant, or periodic maintenance interventions (operational expenditures, OpEx) or costs related to operations required for an efficient and sustainable performance of a gasification plant (e.g., feedstock pre-treatment and management of by-products). Knowledge of these economic parameters and their corresponding trends over time may help decision-makers to make adequate choices regarding the eligible technologies and to perform comparisons with other conventional scenarios. The present work aims to provide an overview on CapEx associated with gasification technologies devoted to convert biomass or solid waste sources, with a view of reducing the carbon footprint during energy generation or production of new energy carriers. In addition, an analysis of technology cost trends over time using regression methods is also presented, as well as an evaluation of specific capital investments according to the amount of output products generated for different gasification facilities. The novelty of this work is focused on an analysis of CapEx of existing gasification technologies to obtain distinct products (energy and fuels), and to determine mathematical correlations relating technology costs with time and product output. For these purposes, a survey of data and categorization of gasification plants based on the final products was made, and mathematical regression methods were used to obtain the correlations, with a statistical analysis (coefficient of determination) for validation. Specific investments on liquid biofuel production plants exhibited the highest decreasing trend over time, while electricity production became the least attractive solution. Linear correlations of specific investment versus time fitted better for electricity production plants (R2 = 0.67), while those relating the product output were better for liquid biofuel plants through exponential regressions (R2 = 0.65). Full article
(This article belongs to the Special Issue Recycling and Recovery of Biomass Materials II)
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24 pages, 1173 KB  
Article
RealPrice: Blockchain-Powered Real-Time Pricing for Software-Defined Enabled Edge Network
by Yustus Eko Oktian, Thi-Thu-Huong Le, Uk Jo and Howon Kim
Sensors 2022, 22(24), 9639; https://doi.org/10.3390/s22249639 - 8 Dec 2022
Cited by 4 | Viewed by 2327
Abstract
With the limited Internet bandwidth in a given area, unlimited data plans can create congestion because there is no retribution for transmitting many packets. The real-time pricing mechanism can inform users of their Internet consumption to limit congestion during peak hours. However, implementing [...] Read more.
With the limited Internet bandwidth in a given area, unlimited data plans can create congestion because there is no retribution for transmitting many packets. The real-time pricing mechanism can inform users of their Internet consumption to limit congestion during peak hours. However, implementing real-time pricing is opex-heavy from the network provider side and requires high-integrity operations to gain consumer trust. This paper aims to leverage the software-defined network to solve the opex issues and blockchain technology to solve trust issues. First, the network congestion level in a given area is analyzed. Then, the price is adjusted accordingly. Devices that send a lot of traffic during congestion will be charged more expensive bills than if transmitting traffic during an off-peak period. To prevent over-charging, the consumers can pre-configure a customized Internet profile stating how many data bytes they are willing to send during congestion. The software-defined controller also authenticates consumers and checks whether they have enough token deposits in the blockchain as Internet usage fees. We implement our work using Ethereum and POX controllers. The experiment results show that the proposed real-time pricing can be performed seamlessly, and the network provider can reap up to 72.91% more profits than existing approaches, such as usage-based pricing or time-dependent pricing. The fairness and trustability of real-time pricing is also guaranteed through the proof-of-usage mechanism and the transparency of the blockchain. Full article
(This article belongs to the Special Issue Lifetime Extension Framework for Wireless Sensor Networks)
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31 pages, 5580 KB  
Article
A Novel Deep Learning Model for Sea State Classification Using Visual-Range Sea Images
by Muhammad Umair, Manzoor Ahmed Hashmani, Syed Sajjad Hussain Rizvi, Hasmi Taib, Mohd Nasir Abdullah and Mehak Maqbool Memon
Symmetry 2022, 14(7), 1487; https://doi.org/10.3390/sym14071487 - 20 Jul 2022
Cited by 13 | Viewed by 5524
Abstract
Wind-waves exhibit variations both in shape and steepness, and their asymmetrical nature is a well-known feature. One of the important characteristics of the sea surface is the front-back asymmetry of wind-wave crests. The wind-wave conditions on the surface of the sea constitute a [...] Read more.
Wind-waves exhibit variations both in shape and steepness, and their asymmetrical nature is a well-known feature. One of the important characteristics of the sea surface is the front-back asymmetry of wind-wave crests. The wind-wave conditions on the surface of the sea constitute a sea state, which is listed as an essential climate variable by the Global Climate Observing System and is considered a critical factor for structural safety and optimal operations of offshore oil and gas platforms. Methods such as statistical representations of sensor-based wave parameters observations and numerical modeling are used to classify sea states. However, for offshore structures such as oil and gas platforms, these methods induce high capital expenditures (CAPEX) and operating expenses (OPEX), along with extensive computational power and time requirements. To address this issue, in this paper, we propose a novel, low-cost deep learning-based sea state classification model using visual-range sea images. Firstly, a novel visual-range sea state image dataset was designed and developed for this purpose. The dataset consists of 100,800 images covering four sea states. The dataset was then benchmarked on state-of-the-art deep learning image classification models. The highest classification accuracy of 81.8% was yielded by NASNet-Mobile. Secondly, a novel sea state classification model was proposed. The model took design inspiration from GoogLeNet, which was identified as the optimal reference model for sea state classification. Systematic changes in GoogLeNet’s inception block were proposed, which resulted in an 8.5% overall classification accuracy improvement in comparison with NASNet-Mobile and a 7% improvement from the reference model (i.e., GoogLeNet). Additionally, the proposed model took 26% less training time, and its per-image classification time remains competitive. Full article
(This article belongs to the Special Issue Machine Learning and Data Analysis)
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20 pages, 26236 KB  
Article
Fast and Flexible mRNA Vaccine Manufacturing as a Solution to Pandemic Situations by Adopting Chemical Engineering Good Practice—Continuous Autonomous Operation in Stainless Steel Equipment Concepts
by Axel Schmidt, Heribert Helgers, Florian Lukas Vetter, Alex Juckers and Jochen Strube
Processes 2021, 9(11), 1874; https://doi.org/10.3390/pr9111874 - 21 Oct 2021
Cited by 26 | Viewed by 10607
Abstract
SARS-COVID-19 vaccine supply for the total worldwide population has a bottleneck in manufacturing capacity. Assessment of existing messenger ribonucleic acid (mRNA) vaccine processing shows a need for digital twins enabled by process analytical technology approaches in order to improve process transfer for manufacturing [...] Read more.
SARS-COVID-19 vaccine supply for the total worldwide population has a bottleneck in manufacturing capacity. Assessment of existing messenger ribonucleic acid (mRNA) vaccine processing shows a need for digital twins enabled by process analytical technology approaches in order to improve process transfer for manufacturing capacity multiplication, a reduction in out-of-specification batch failures, qualified personal training for faster validation and efficient operation, optimal utilization of scarce buffers and chemicals and speed-up of product release by continuous manufacturing. In this work, three manufacturing concepts for mRNA-based vaccines are evaluated: Batch, full-continuous and semi-continuous. Technical transfer from batch single-use to semi-continuous stainless-steel, i.e., plasmid deoxyribonucleic acid (pDNA) in batch and mRNA in continuous operation mode, is recommended, in order to gain: faster plant commissioning and start-up times of about 8–12 months and a rise in dose number by a factor of about 30 per year, with almost identical efforts in capital expenditures (CAPEX) and personnel resources, which are the dominant bottlenecks at the moment, at about 25% lower operating expenses (OPEX). Consumables are also reduceable by a factor of 6 as outcome of this study. Further optimization potential is seen at consequent digital twin and PAT (Process Analytical Technology) concept integration as key-enabling technologies towards autonomous operation including real-time release-testing. Full article
(This article belongs to the Special Issue Towards Autonomous Operation of Biologics and Botanicals)
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13 pages, 4243 KB  
Article
Bipolar Membrane Electrodialysis for Sulfate Recycling in the Metallurgical Industries
by Kuldeep, Wouter Dirk Badenhorst, Pertti Kauranen, Heikki Pajari, Ronja Ruismäki, Petri Mannela and Lasse Murtomäki
Membranes 2021, 11(9), 718; https://doi.org/10.3390/membranes11090718 - 18 Sep 2021
Cited by 42 | Viewed by 12158
Abstract
Demand for nickel and cobalt sulfate is expected to increase due to the rapidly growing Li-battery industry needed for the electrification of automobiles. This has led to an increase in the production of sodium sulfate as a waste effluent that needs to be [...] Read more.
Demand for nickel and cobalt sulfate is expected to increase due to the rapidly growing Li-battery industry needed for the electrification of automobiles. This has led to an increase in the production of sodium sulfate as a waste effluent that needs to be processed to meet discharge guidelines. Using bipolar membrane electrodialysis (BPED), acids and bases can be effectively produced from corresponding salts found in these waste effluents. However, the efficiency and environmental sustainability of the overall BPED process depends upon several factors, including the properties of the ion exchange membranes employed, effluent type, and temperature which affects the viscosity and conductivity of feed effluent, and the overpotentials. This work focuses on the recycling of Na2SO4 rich waste effluent, through a feed and bleed BPED process. A high ion-exchange capacity and ionic conductivity with excellent stability up to 41 °C is observed during the proposed BPED process, with this temperature increase also leading to improved current efficiency. Five and ten repeating units were tested to determine the effect on BPED stack performance, as well as the effect of temperature and current density on the stack voltage and current efficiency. Furthermore, the concentration and maximum purity (>96.5%) of the products were determined. Using the experimental data, both the capital expense (CAPEX) and operating expense (OPEX) for a theoretical plant capacity of 100 m3 h−1 of Na2SO4 at 110 g L−1 was calculated, yielding CAPEX values of 20 M EUR, and OPEX at 14.2 M EUR/year with a payback time of 11 years, however, the payback time is sensitive to chemical and electricity prices. Full article
(This article belongs to the Special Issue Selected Papers from the MELPRO 2020)
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20 pages, 5202 KB  
Article
Creating Values from Biomass Pyrolysis in Sweden: Co-Production of H2, Biocarbon and Bio-Oil
by Ilman Nuran Zaini, Nanta Sophonrat, Kurt Sjöblom and Weihong Yang
Processes 2021, 9(3), 415; https://doi.org/10.3390/pr9030415 - 25 Feb 2021
Cited by 27 | Viewed by 6637
Abstract
Hydrogen and biocarbon are important materials for the future fossil-free metallurgical industries in Sweden; thus, it is interesting to investigate the process that can simultaneously produce both. Process simulations of biomass pyrolysis coupled with steam reforming and water-gas-shift to produce H2, [...] Read more.
Hydrogen and biocarbon are important materials for the future fossil-free metallurgical industries in Sweden; thus, it is interesting to investigate the process that can simultaneously produce both. Process simulations of biomass pyrolysis coupled with steam reforming and water-gas-shift to produce H2, biocarbon, and bio-oil are investigated in this work. The process simulation is performed based on a biomass pyrolysis plant currently operating in Sweden. Two co-production schemes are proposed: (1) production of biocarbon and H2, and (2) production of biocarbon, H2, and bio-oil. Sensitivity analysis is also performed to investigate the performance of the production schemes under different operating parameters. The results indicated that there are no notable differences in terms of the thermal efficiency for both cases. Varying the bio-oil condenser temperature only slightly changes the system’s thermal efficiency by less than 2%. On the other hand, an increase in biomass moisture content from 7 to 14 wt.% can decrease the system’s efficiency from 79.0% to 72.6%. Operating expenses are evaluated to elucidate the economics of 3 different cases: (1) no bio-oil production, (2) bio-oil production with the condenser at 50 °C, and (3) bio-oil production with the condenser at 130 °C. Based on operation expenses (OPEX) and revenue alone, it is found that producing more bio-oil helps improving the economics of the process. However, capital costs and the cost for post-processing of bio-oil should also be considered in the future. The estimated minimum selling price for biocarbon based on OPEX alone is approx. 10 SEK, which is within the range of the current commercial price of charcoal and coke. Full article
(This article belongs to the Special Issue Process Design of Biomass Thermochemical Conversion)
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