Search Results (735)

The article presents a new AM (Additive Manufacturing) process development, necessary to repair parts made from Aluminum 6061 material, with T6 treatment. The laser Directed Energy Deposition (DED) and Extreme High-Speed Directed Energy Deposition (EHLA) capabilities are evaluated for repairing Al large components. To optimize the process parameters, single-track depositions were analyzed for both laser-powder DED (feed rate of 2 m/min) and EHLA (feed rate 20 m/min) for AlSi10Mg and Al6061 powders. The cross-sections of single tracks revealed the bonding characteristics and provided laser-powder DED, a suitable parameter selection for the repair. Three damage types were identified on the Al component to define the specification of the repair process and to highlight the capabilities of laser-powder DED and EHLA in repairing intricate surface scratches and dents. Our research is based on variation of the powder mass flow and beam power, studying the influence of these parameters on the weld bead geometry and bonding quality. The evaluation criteria include bonding defects, crack formation, porosity, and dilution zone depth. The bidirectional path planning strategy was applied with a fly-in and fly-out path for the hatching adjustment and acceleration distance. Samples were etched for a qualitative microstructure analysis, and the HV hardness was tested. The novelty of the paper is the new process parameters for laser-powder DED and EHLA deposition strategies to repair large Al components (6061 T6), using AlSi10Mg and Al6061 powder. Our experimental research tested the defect-free deposition and the compatibility of AlSi10Mg on the Al6061 substrate. The readers could replicate the method presented in this article to repair by laser-powder DED/EHLA large Al parts and avoid the replacement of Al components with new ones. Full article

Groundwater is one of the main water sources for consumption, domestic use, agriculture, and tourism in coastal communities. However, high total dissolved solids (TDS) levels in the water (700–2000 mg L⁻¹ TDS) and electrical conductivity (3000–5000 µS cm⁻¹) threaten the health and economic growth opportunities for residents. This research aims to evaluate the performance of a laboratory-scale electrodialysis system as a technology for desalinating brackish water. For this purpose, water samples were collected from real groundwater sources. Batch experiments were conducted with varying operational parameters, such as voltage (2–10 V), feed volume (100–1600 mL), recovery rate (50–80%), and cros-flow velocity (1.3–5.1 cm s⁻¹) to determine the electrodialysis system setup that meets the requirements for drinking water in terms of TDS and energy efficiency. A total specific energy consumption of 1.65 kWh m⁻³, including pumping energy, was achieved at a laboratory scale. The conditions were as follows: flow velocity of 5.14 cm s⁻¹, applied voltage of 6 V, feed volume of 1.6 L, and a water recovery of 66%. Furthermore, increasing the flow velocity and the applied voltage enhanced the desalination kinetics and salt removal. Additionally, the system presented opportunities for scalability. This research aims to evaluate a sustainable membrane-based treatment technology for meeting the growing demand for water resources in coastal communities, particularly in developing countries in South America. Full article

Understanding how habitat conditions drive morphological adaptations in animals is critical in ecology, yet amphibian studies remain limited. This study investigated intraspecific variation in ecomorphological traits of three montane stream-dwelling frogs (Quasipaa boulengeri, Amolops sinensis, and Odorrana margaratae) across elevation gradients in Tianping Mountain, China. Using morphological measurements and environmental variables collected from ten transects, we analyzed functional traits related to feeding and locomotion and assessed their associations with microhabitat variables. Significant trait differences between low- and high-elevation groups were detected only in Q. boulengeri, with high-elevation individuals exhibiting greater body mass and shorter hindlimbs. Redundancy analysis demonstrated that microhabitat variables, particularly air humidity, flow rate, and rock coverage, were linked to trait variations. For example, air humidity and flow rate significantly influenced Q. boulengeri’s body and limb proportions, while flow rate affected A. sinensis’s snout and limb morphology. In addition, sex and seasonal effects were also associated with trait variations. These results underscore amphibians’ phenotypic plasticity in response to the environment and highlight the role of microhabitat complexity in shaping traits. By linking habitat heterogeneity to eco-morphology, this study advocates for conservation strategies that preserve varied stream environments to support amphibian resilience amid environmental changes. Full article

Heuristic optimization is used to find sustainable cogeneration steam power plants with steam reheat and supercritical main steam parameters. Design solutions are analyzed for steam consumer (SC) pressures of 3.6 and 40 bar and a heat flow rate of 40% of the fuel heat flow rate. The objective functions consisted in simultaneous maximization of global and exergetic efficiencies, power-to-heat ratio in full cogeneration mode, and specific investment minimization. For 3.6 bar, the indicators improve with the increase in the ratio between reheating and main steam pressure. The increase in SC pressure worsens the performance indicators. For an SC steam pressure of 40 bar and 9 feed water preheaters, the ratio between reheating and main steam pressure should be over 0.186 for maximum exergetic efficiency and between 0.10 and 0.16 for maximizing both global efficiency and power-to-heat ratio in full cogeneration mode. The average global efficiency for an SC requiring steam at 3.6 bar is 4.4 percentage points higher than in the case with 40 bar, the average specific investment being 10% lower. The Pareto solutions found in this study are useful in the design of sustainable cogeneration supercritical power plants. Full article

This study presents the first combined techno-economic and environmental analysis of IPA dehydration using HybSi^® membranes across three configurations, offering a low-emission alternative to conventional azeotropic distillation. The processes are simulated in Aspen Plus, and include two hybrid separation processes (i.e., distillation–pervaporation and distillation–pervaporation–distillation) and one standalone pervaporation process. The pervaporation module uses data from experiments that were performed using HybSi^® AR membranes at 130 °C and two vacuum pressures (20 and 50 mbar). The separation processes were systematically compared using a comprehensive set of performance indicators covering technical, economic, and environmental aspects. A new cost-efficiency metric, COPCO, is introduced, alongside updated modeling under 2024 market conditions. The isopropanol recovery and water selectivity were >99.5% and >98.7%, respectively, in all pervaporation-based processes. It was found that the hybrid distillation–pervaporation process resulted in a 42% reduction in the levelized cost of the benchmark azeotropic distillation process, while standalone pervaporation resulted in a 38% reduction. The CO₂ footprint was also reduced significantly in all cases, up to 86% in the case of standalone pervaporation compared to azeotropic distillation. The COPCO analysis revealed that the distillation–pervaporation configuration offers the highest cost-efficiency among the evaluated systems. Sensitivity analysis revealed that feed flow rate, average water flux, membrane module price, membrane lifetime, and steam price significantly impact the levelized cost. Lower vacuum pressure and feed water near the azeotropic composition enhance economic performance. Full article

Direct air capture (DAC), as a complementary strategy to carbon capture and storage (CCS), offers a scalable and sustainable pathway to remove CO₂ directly from the ambient air. This study presents a detailed evaluation of the amine-functionalised metal-organic framework (MOF) sorbent, mmen-Mg₂(dobpdc), for DAC using a temperature–vacuum swing adsorption (TVSA) process. While this sorbent has demonstrated promising performance in point-source CO₂ capture, this is the first dynamic simulation-based study to rigorously assess its effectiveness for low-concentration atmospheric CO₂ removal. A transient one-dimensional TVSA model was developed in Aspen Adsorption and validated against experimental breakthrough data to ensure accuracy in capturing both the sharp and gradual adsorption kinetics. To enhance process efficiency and sustainability, this work provides a comprehensive parametric analysis of key operational factors, including air flow rate, temperature, adsorption/desorption durations, vacuum pressure, and heat exchanger temperature, on process performance, including CO₂ purity, recovery, productivity, and specific energy consumption. Under optimal conditions for this sorbent (vacuum pressure lower than 0.15 bar and feed temperature below 15 °C), the TVSA process achieved ~98% CO₂ purity, recovery over 70%, and specific energy consumption of about 3.5 MJ/KgCO₂. These findings demonstrate that mmen-Mg₂(dobpdc) can achieve performance comparable to benchmark DAC sorbents in terms of CO₂ purity and recovery, underscoring its potential for scalable DAC applications. This work advances the development of energy-efficient carbon removal technologies and highlights the value of step-shape isotherm adsorbents in supporting global carbon-neutrality goals. Full article

The integration of computational intelligence techniques into pharmaceutical wastewater treatment offers promising opportunities to improve process efficiency and minimize operational costs. This study compares the predictive capabilities of Response Surface Methodology (RSM) and Artificial Neural Network (ANN) models in forecasting the rejection efficiencies of caffeine and paracetamol using AFC 40 and AFC 80 nanofiltration (NF) membranes. Experiments were conducted under varying operating conditions, including transmembrane pressure, feed concentration, and flow rate. The predictive performance of both models was evaluated using statistical metrics such as the Coefficient of Determination (R²), Root Mean Square Error (RMSE), Marquardt’s Percentage Squared Error Deviation (MPSED), Hybrid fractional error function (HYBRID), and Average Absolute Deviation (AAD). Both models demonstrated strong predictive accuracy, with R² values of 0.9867 and 0.9832 for RSM and ANN, respectively, in AFC 40 membranes, and 0.9769 and 0.9922 in AFC 80 membranes. While both approaches closely matched the experimental results, the ANN model consistently yielded lower error values and higher R² values, indicating superior predictive performance. These findings support the application of ANNs as a robust modelling tool in optimizing NF membrane processes for pharmaceutical removal. Full article

This study developed a two-dimensional multiphysics-coupled model for co-electrolysis of CO₂ and H₂O in solid oxide electrolysis cells (SOECs) using COMSOL Multiphysics, systematically investigating the influence mechanisms of key operating parameters including temperature, voltage, feed ratio, and flow configuration on co-electrolysis performance. The results demonstrate that increasing temperature significantly enhances CO₂ electrolysis, with the current density increasing over 12-fold when temperature rises from 923 K to 1423 K. However, the H₂O electrolysis reaction slows beyond 1173 K due to kinetic limitations, leading to reduced H₂ selectivity. Higher voltages simultaneously accelerate all electrochemical reactions, with CO and H₂ production at 1.5 V increasing by 15-fold and 13-fold, respectively, compared to 0.8 V, while the water–gas shift reaction rate rises to 6.59 mol/m³·s. Feed ratio experiments show that increasing CO₂ concentration boosts CO yield by 5.7 times but suppresses H₂ generation. Notably, counter-current operation optimizes reactant concentration distribution, increasing H₂ and CO production by 2.49% and 2.3%, respectively, compared to co-current mode, providing critical guidance for reactor design. This multiscale simulation reveals the complex coupling mechanisms in SOEC co-electrolysis, offering theoretical foundations for developing efficient carbon-neutral technologies. Full article

Electrostatic separation is a promising technology for the recovery of valuable metals from electronic waste, particularly from printed circuit boards (PCBs). This study explores the application of electrostatic separation for the selective recovery of metallic and non-metallic fractions from crushed PCBs (PCBs). The process exploits the differences in electrical properties between conductive metals and non-conductive polymers and ceramics, facilitating their separation through applied electric fields. The raw materials were pre-treated via mechanical comminution using shredders and hammer mills to achieve an optimal particle size distribution (<3 mm), which enhances separation efficiency. Ferrous materials were removed prior to electrostatic separation to improve process selectivity. Key operational parameters, including particle size, charge accumulation, environmental conditions, and separation efficiency, were systematically analysed. The results demonstrate that electrostatic separation effectively recovers high-value metals such as copper and gold while minimizing material losses. Additionally, the process contributes to the sustainability of e-waste recycling by enabling the recovery of non-metallic fractions for potential secondary applications. This work underscores the significance of electrostatic separation as a viable technique for e-waste management and highlights optimization strategies for enhancing its performance in large-scale recycling operations. Full article

Background/Objectives: In the twin-screw wet granulation (TSWG) process, accurate measurement of residence time distribution (RTD) is critical, as it characterizes material transport kinetics and mixing behavior. It plays a critical role in evaluating the homogeneity and stability of the granulation process and optimizing process parameters. It is necessary to overcome the limitations arising from the complex and time-consuming procedures of conventional RTD determination methods. Methods: This study proposes a new RTD detection method based on image processing. It uses black dye as a tracer to obtain RTD curve data, and the effects of process parameters such as tracer dosage, screw speed, and feeding rate on the RTD were investigated. Results: The results show that the established method can accurately determine RTD and that the tracer dosage has no significant effect on the detection results. Further analysis revealed that the screw speed is negatively correlated with the mean residence time (MRT). As the speed increases, not only does the MRT shorten, but its distribution also decreases. Similarly, an increase in the feeding rate also leads to a decrease in the MRT and distribution, but it is worth noting that lower feeding rates are beneficial for achieving a state close to mixed flow, while excessively high feeding rates are not conducive to sufficient mixing of materials in the extruder. Conclusions: The RTD detection method provides a reliable parameter basis and theoretical guidance for the in-depth study of the TSWG process and the development of quality control strategies. Full article

This study systematically explored the performance of a vacuum membrane distillation (VMD) system equipped with polytetrafluoroethylene (PTFE) hollow fiber membranes for treating simulated, acidic, low-level radioactive liquid waste. By focusing on key operational parameters, including feed temperature, vacuum pressure, and flow velocity, an orthogonal experiment was designed to obtain the optimal parameters. Considering the potential application scenarios, the following two factors were also studied: the initial nuclide concentrations (0.5, 5, and 50 mg·L⁻¹) and tributyl phosphate (TBP) concentrations (0, 20, and 100 mg·L⁻¹) in the feed solution. The results indicated that the optimal operational parameters for VMD were as follows: a feed temperature of 70 °C, a vacuum pressure of 90 kPa, and a flow rate of 500 L·h⁻¹. Under these parameters, the VMD system demonstrated a maximum permeate flux of 0.9 L·m⁻²·h⁻¹, achieving a nuclide rejection rate exceeding 99.9%, as well as a nitric acid rejection rate of 99.4%. A significant negative correlation was observed between permeate flux and nuclide concentrations at levels above 50 mg·L⁻¹. The presence of TBP in the feed solution produced membrane fouling, leading to flux decline and a reduced separation efficiency, with severity increasing with TBP concentration. The VMD process simultaneously achieved nuclide rejection and nitric acid concentration in acidic radioactive wastewater, demonstrating strong potential for nuclear wastewater treatment. Full article

This study examines the effect of smooth and humped flow channels on the recovery of industrial magnetic seeds in a drum magnetic separator. The results demonstrate that under varying feeding slurry quantities and drum rotational speeds, the humped channel consistently achieves higher recovery rates compared with the smooth channel, with an improvement of up to 3%. Scanning electron microscopy and vibrating sample magnetometry analyses of the samples reveal the presence of a small amount of impurities (predominantly consisting of elements, such as Al, Si, and Ti) in the industrial magnetite magnetic particles. These impurities exhibit lower magnetization, leading to reduced capture efficiency in the conventional smooth-channel drum magnetic separator. Simulations of the magnetic field, flow field, and particle trajectory indicate that the magnetic field force at the bottom of the smooth channel is only 0.6 kg²/(m·s⁴·A²), i.e., approximately 18 times lower than that at the roller surface. The incorporation of a humped channel shifts the impure magnetic seeds from a region with low magnetic field force to a region with higher magnetic field force, significantly enhancing the capture efficiency of the impure magnetic seeds. Full article

The automatic feeding device is crucial in grassland livestock farming, enhancing feeding efficiency, ensuring regular and accurate feed delivery, minimizing waste, and reducing costs. The shape and size of pellet feed render it particularly suitable for the delivery mechanism of automated feeding troughs. The uniformity of pellet flow is a critical factor in the study of automatic feeding troughs, and optimizing the movement characteristics of the pellets contributes to enhanced operational efficiency of the equipment. However, existing research often lacks a systematic analysis of the pellet size characteristics (such as diameter and length) and flow behavior differences in pellet feed, which limits the practical application of feed troughs. This study optimized the angle of repose and structural parameters of the feeding trough using Matlab simulations and discrete element modeling. It explored how the stock bin slope and baffle opening height influence pellet feed flow characteristics. A programmable logic controller (PLC) and human–machine interface (HMI) were used for precise timing and quantitative feeding, validating the design’s practicality. The results indicated that the Matlab method could calibrate the Johnson–Kendall–Roberts (JKR) model’s surface energy. The optimal slope was found to be 63°, with optimal baffle heights of 28 mm for fine and medium pellets and 30 mm for coarse pellets. The experimental metrics showed relative errors of 3.5%, 2.8%, and 4.2% (for average feed rate) and 8.2%, 7.3%, and 1.2% (for flow time). The automatic feeding trough showed a feeding error of 0.3% with PLC-HMI. This study’s optimization of the automatic feeding trough offers a strong foundation and guidance for efficient, accurate pellet feed distribution. Full article

Permeate Gap Membrane Distillation (PGMD) is an emerging desalination technology that offers a promising alternative for freshwater production, particularly in energy-efficient and sustainable applications. This review provides a comprehensive analysis of PGMD, covering its fundamental principles, heat and mass transfer mechanisms, and key challenges such as temperature and concentration polarization. Various optimisation strategies, including Response Surface Morphology (RSM), Differential Evolution techniques, and Computational Fluid Dynamics (CFD) modelling, are explored to enhance PGMD performance. The study further discusses the latest advancements in system design, highlighting optimal configurations and the integration of PGMD with renewable energy sources. Factors influencing PGMD performance, such as operational parameters (flow rates, temperature, and feed concentration) and physical parameters (gap width, membrane properties, and cooling plate conductivity), are systematically analysed. Additionally, the techno-economic feasibility of PGMD for large-scale freshwater production is evaluated, with a focus on cost reduction strategies, energy efficiency, and hybrid system innovations. Finally, this review outlines the current limitations and future research directions for PGMD, emphasising novel system modifications, improved heat recovery techniques, and potential industrial applications. By consolidating recent advancements and identifying key challenges, this paper aims to guide future research and facilitate the broader adoption of PGMD in sustainable desalination and water purification processes. Full article

To address the low drilling efficiency of the composite rod drill in gas extraction boreholes, key drilling parameters are optimized using coal-seam hardness grading tests and response surface methodology. By conducting mechanical tests on coal samples from the Sangshuping, Zhangcun, and Wangzhuang coal mines, the coal seams are classified into three categories: soft (Pus coefficient 0.87), medium–hard (2.16), and hard (3.47). Multi-factor and multi-level field tests were then performed at different working faces, using Design Expert software to analyze the response surface of three factors: pump pressure, flow rate, and feed pressure. The response surface method was used to determine the influence of drilling factors on drilling time under different coal-seam hardness conditions and the optimal drilling parameters. The results indicate that the technology is not suitable for soft coal seams due to frequent bit jamming. The optimal parameters for medium–hard coal seams are a pump pressure of 4 MPa, a flow rate of 180 L/min, and a feed pressure of 6 MPa (time per 100 m: 62 min 33 s). For hard coal seams, the optimal parameters are a pump pressure of 6 MPa, a flow rate of 200 L/min, and a feed pressure of 8 MPa (time per 100 m: 55 min 27 s). This study provides a theoretical basis for efficient coal seam drilling. Full article