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16 pages, 1196 KiB  
Article
Integrated Additive Manufacturing of TGV Interconnects and High-Frequency Circuits via Bipolar-Controlled EHD Jetting
by Dongqiao Bai, Jin Huang, Hongxiao Gong, Jianjun Wang, Yunna Pu, Jiaying Zhang, Peng Sun, Zihan Zhu, Pan Li, Huagui Wang, Pengbing Zhao and Chaoyu Liang
Micromachines 2025, 16(8), 907; https://doi.org/10.3390/mi16080907 (registering DOI) - 2 Aug 2025
Abstract
Electrohydrodynamic (EHD) printing offers mask-free, high-resolution deposition across a broad range of ink viscosities, yet combining void-free filling of high-aspect-ratio through-glass vias (TGVs) with ultrafine drop-on-demand (DOD) line printing on the same platform requires balancing conflicting requirements: for example, high field strengths to [...] Read more.
Electrohydrodynamic (EHD) printing offers mask-free, high-resolution deposition across a broad range of ink viscosities, yet combining void-free filling of high-aspect-ratio through-glass vias (TGVs) with ultrafine drop-on-demand (DOD) line printing on the same platform requires balancing conflicting requirements: for example, high field strengths to drive ink into deep and narrow vias; sufficiently high ink viscosity to prevent gravity-induced leakage; and stable meniscus dynamics to avoid satellite droplets and charge accumulation on the glass surface. By coupling electrostatic field analysis with transient level-set simulations, we establish a dimensionless regime map that delineates stable cone-jetting regime; these predictions are validated by high-speed imaging and surface profilometry. Operating within this window, the platform achieves complete, void-free filling of 200 µm × 1.52 mm TGVs and continuous 10 µm-wide traces in a single print pass. Demonstrating its capabilities, we fabricate transparent Ku-band substrate-integrated waveguide antennas on borosilicate glass: the printed vias and arc feed elements exhibit a reflection coefficient minimum of –18 dB at 14.2 GHz, a –10 dB bandwidth of 12.8–16.2 GHz, and an 8 dBi peak gain with 37° beam tilt, closely matching full-wave predictions. This physics-driven, all-in-one EHD approach provides a scalable route to high-performance, glass-integrated RF devices and transparent electronics. Full article
28 pages, 15264 KiB  
Article
Effect of Auxiliary Air-Suction Seed-Filling Structure on Seed Discharge Performance of Peanut High-Speed Seed-Metering Machine
by Peng Guo, Bin Sun, Shuqi Shang, Jialin Hou, Dongwei Wang, Zhuang Zhao, Ahmed Elshafie, Xiaoshuai Zheng and Farid Eltoum
Agriculture 2025, 15(15), 1678; https://doi.org/10.3390/agriculture15151678 (registering DOI) - 2 Aug 2025
Abstract
Aiming to resolve the problem of the poor peanut seed-filling effect under high-speed operation when developing high-speed peanut sowing with precision, a peanut precision seed-metering machine with an auxiliary air-suction seed-filling device was designed. Focusing on the force analysis of peanuts in the [...] Read more.
Aiming to resolve the problem of the poor peanut seed-filling effect under high-speed operation when developing high-speed peanut sowing with precision, a peanut precision seed-metering machine with an auxiliary air-suction seed-filling device was designed. Focusing on the force analysis of peanuts in the seed chamber, the peanut seed disturbance principle in the seed-metering machine for the blowing structure of an auxiliary air-suction seed-filling device was clarified. The seed-filling process was analyzed via DEM-CFD coupled simulation, and three factors affecting the seed-filling effect were identified, namely the seed-filling chamber ‘V’ angle γ, the bottom blow-air-hole cross-sectional area S, and the bottom blow-air-hole airflow velocity vq, and the ranges of values of the three factors were determined. The Box–Behnken test was conducted using the seed-filling index and leakage index as the indexes. The results show that the seed-filling chamber ‘V’ angle γ is 56.59°, the bottom blowhole cross-sectional area S is 1088.4 mm2, and the blowhole air velocity vq is 12.11 m·s−1. At this point, the peanut seed suction qualification index and leakage index are optimal, the seed suction qualification index is 96.33%, and the seed leakage index is 2.59%. At the same time, the field test shows that a sowing operation speed of 8–12 km·h−1, a qualified index > 93%, and a leakage index < 4.5% are required to meet the agronomic requirements of peanut precision sowing. Full article
(This article belongs to the Section Agricultural Technology)
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15 pages, 3579 KiB  
Article
Dual-Control-Gate Reconfigurable Ion-Sensitive Field-Effect Transistor with Nickel-Silicide Contacts for Adaptive and High-Sensitivity Chemical Sensing Beyond the Nernst Limit
by Seung-Jin Lee, Seung-Hyun Lee, Seung-Hwa Choi and Won-Ju Cho
Chemosensors 2025, 13(8), 281; https://doi.org/10.3390/chemosensors13080281 (registering DOI) - 2 Aug 2025
Abstract
In this study, we propose a bidirectional chemical sensor platform based on a reconfigurable ion-sensitive field-effect transistor (R-ISFET) architecture. The device incorporates Ni-silicide Schottky barrier source/drain (S/D) contacts, enabling ambipolar conduction and bidirectional turn-on behavior for both p-type and n-type configurations. Channel polarity [...] Read more.
In this study, we propose a bidirectional chemical sensor platform based on a reconfigurable ion-sensitive field-effect transistor (R-ISFET) architecture. The device incorporates Ni-silicide Schottky barrier source/drain (S/D) contacts, enabling ambipolar conduction and bidirectional turn-on behavior for both p-type and n-type configurations. Channel polarity is dynamically controlled via the program gate (PG), while the control gate (CG) suppresses leakage current, enhancing operational stability and energy efficiency. A dual-control-gate (DCG) structure enhances capacitive coupling, enabling sensitivity beyond the Nernst limit without external amplification. The extended-gate (EG) architecture physically separates the transistor and sensing regions, improving durability and long-term reliability. Electrical characteristics were evaluated through transfer and output curves, and carrier transport mechanisms were analyzed using band diagrams. Sensor performance—including sensitivity, hysteresis, and drift—was assessed under various pH conditions and external noise up to 5 Vpp (i.e., peak-to-peak voltage). The n-type configuration exhibited high mobility and fast response, while the p-type configuration demonstrated excellent noise immunity and low drift. Both modes showed consistent sensitivity trends, confirming the feasibility of complementary sensing. These results indicate that the proposed R-ISFET sensor enables selective mode switching for high sensitivity and robust operation, offering strong potential for next-generation biosensing and chemical detection. Full article
(This article belongs to the Section Electrochemical Devices and Sensors)
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21 pages, 2240 KiB  
Review
A Review of Fluorescent pH Probes: Ratiometric Strategies, Extreme pH Sensing, and Multifunctional Utility
by Weiqiao Xu, Zhenting Ma, Qixin Tian, Yuanqing Chen, Qiumei Jiang and Liang Fan
Chemosensors 2025, 13(8), 280; https://doi.org/10.3390/chemosensors13080280 (registering DOI) - 2 Aug 2025
Abstract
pH is a critical parameter requiring precise monitoring across scientific, industrial, and biological domains. Fluorescent pH probes offer a powerful alternative to traditional methods (e.g., electrodes, indicators), overcoming limitations in miniaturization, long-term stability, and electromagnetic interference. By utilizing photophysical mechanisms—including intramolecular charge transfer [...] Read more.
pH is a critical parameter requiring precise monitoring across scientific, industrial, and biological domains. Fluorescent pH probes offer a powerful alternative to traditional methods (e.g., electrodes, indicators), overcoming limitations in miniaturization, long-term stability, and electromagnetic interference. By utilizing photophysical mechanisms—including intramolecular charge transfer (ICT), photoinduced electron transfer (PET), and fluorescence resonance energy transfer (FRET)—these probes enable high-sensitivity, reusable, and biocompatible sensing. This review systematically details recent advances, categorizing probes by operational pH range: strongly acidic (0–3), weakly acidic (3–7), strongly alkaline (>12), weakly alkaline (7–11), near-neutral (6–8), and wide-dynamic range. Innovations such as ratiometric detection, organelle-specific targeting (lysosomes, mitochondria), smartphone colorimetry, and dual-analyte response (e.g., pH + Al3+/CN) are highlighted. Applications span real-time cellular imaging (HeLa cells, zebrafish, mice), food quality assessment, environmental monitoring, and industrial diagnostics (e.g., concrete pH). Persistent challenges include extreme-pH sensing (notably alkalinity), photobleaching, dye leakage, and environmental resilience. Future research should prioritize broadening functional pH ranges, enhancing probe stability, and developing wide-range sensing strategies to advance deployment in commercial and industrial online monitoring platforms. Full article
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16 pages, 2734 KiB  
Article
A 13-Bit 100 kS/s Two-Step Single-Slope ADC for a 64 × 64 Infrared Image Sensor
by Qiaoying Gan, Wenli Liao, Weiyi Zheng, Enxu Yu, Zhifeng Chen and Chengying Chen
Eng 2025, 6(8), 180; https://doi.org/10.3390/eng6080180 (registering DOI) - 1 Aug 2025
Abstract
An Analog-to-Digital Converter (ADC) is an indispensable part of image sensor systems. This paper presents a silicon-based 13-bit 100 kS/s two-step single-slope analog-to-digital converter (TS-SS ADC) for infrared image sensors with a frame rate of 100 Hz. For the charge leakage and offset [...] Read more.
An Analog-to-Digital Converter (ADC) is an indispensable part of image sensor systems. This paper presents a silicon-based 13-bit 100 kS/s two-step single-slope analog-to-digital converter (TS-SS ADC) for infrared image sensors with a frame rate of 100 Hz. For the charge leakage and offset voltage issues inherent in conventional TS-SS ADC, a four-terminal comparator was employed to resolve the fine ramp voltage offset caused by charge redistribution in storage and parasitic capacitors. In addition, a current-steering digital-to-analog converter (DAC) was adopted to calibrate the voltage reference of the dynamic comparator and mitigate differential nonlinearity (DNL)/integral nonlinearity (INL). To eliminate quantization dead zones, a 1-bit redundancy was incorporated into the fine quantization circuit. Finally, the quantization scheme consisted of 7-bit coarse quantization followed by 7-bit fine quantization. The ADC was implemented using an SMIC 55 nm processSemiconductor Manufacturing International Corporation, Shanghai, China. The post-simulation results show that when the power supply is 3.3 V, the ADC achieves a quantization range of 1.3 V–3 V. Operating at a 100 kS/s sampling rate, the proposed ADC exhibits an effective number of bits (ENOBs) of 11.86, a spurious-free dynamic range (SFDR) of 97.45 dB, and a signal-to-noise-and-distortion ratio (SNDR) of 73.13 dB. The power consumption of the ADC was 22.18 mW. Full article
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15 pages, 4578 KiB  
Article
Improving Balance Between Oxygen Permeability and Stability of Ba0.5Sr0.5Co0.8Fe0.2O3−δ Through High-Entropy Design
by Yongfan Zhu, Meng Wu, Guangru Zhang, Zhengkun Liu and Gongping Liu
Membranes 2025, 15(8), 232; https://doi.org/10.3390/membranes15080232 - 1 Aug 2025
Abstract
Currently, the trade-off between oxygen permeation flux and structural stability in conventional perovskite oxides restricts the practical application of oxygen permeable membranes. In this study, a high-entropy design was applied to the B-site of BSCF matrix materials, resulting in the successful synthesis of [...] Read more.
Currently, the trade-off between oxygen permeation flux and structural stability in conventional perovskite oxides restricts the practical application of oxygen permeable membranes. In this study, a high-entropy design was applied to the B-site of BSCF matrix materials, resulting in the successful synthesis of a high-entropy perovskite, Ba0.5Sr0.5Co0.71Fe0.2Ta0.03Ni0.03Zr0.03O3−δ. The crystal structure, microstructure, and elemental composition of the material were systematically characterized and analyzed. Theoretical analysis and experimental characterization confirm that the material exhibits a stable single-phase high-entropy perovskite oxide structure. Under He as the sweep gas, the membrane achieved an oxygen permeation flux of 1.28 mL·cm−2·min−1 and operated stably for over 100 h (1 mm thick, 900 °C). In a 20% CO2/He atmosphere, the flux remained above 0.92 mL·cm−2·min−1 for over 100 h, demonstrating good CO2 tolerance. Notably, when the sweep gas is returned to the pure He atmosphere, the oxygen permeation flux fully recovers to 1.28 mL·cm−2·min−1, with no evidence of leakage. These findings indicate that the proposed B-site doping strategy can break the trade-off between oxygen permeability and structural stability in conventional perovskite membranes. This advancement supports the industrialization of oxygen permeable membranes and offers valuable theoretical guidance for the design of high-performance perovskite materials. Full article
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13 pages, 13107 KiB  
Article
Ceramic Isolated High-Torque Permanent Magnet Coupling for Deep-Sea Applications
by Liying Sun, Xiaohui Gao and Yongguang Liu
J. Mar. Sci. Eng. 2025, 13(8), 1474; https://doi.org/10.3390/jmse13081474 - 31 Jul 2025
Viewed by 34
Abstract
Permanent magnetic couplings provide critical advantages for deep-sea systems through static-sealed, contactless power transmission. However, conventional metallic isolation sleeves incur significant eddy current losses, limiting efficiency and high-speed operation. Limited torque capacities fail to meet the operational demands of harsh marine environments. This [...] Read more.
Permanent magnetic couplings provide critical advantages for deep-sea systems through static-sealed, contactless power transmission. However, conventional metallic isolation sleeves incur significant eddy current losses, limiting efficiency and high-speed operation. Limited torque capacities fail to meet the operational demands of harsh marine environments. This study presents a novel permanent magnet coupling featuring a ceramic isolation sleeve engineered for deep-sea cryogenic ammonia submersible pumps. The ceramic sleeve eliminates eddy current losses and provides exceptional corrosion resistance in acidic/alkaline environments. To withstand 3.5 MPa hydrostatic pressure, a 6-mm-thick sleeve necessitates a 10 mm operational air gap, challenging magnetic circuit efficiency. To address this limitation, an improved 3D magnetic equivalent circuit (MEC) model was developed that explicitly accounts for flux leakage and axial end-effects, enabling the accurate characterization of large air gap fields. Leveraging this model, a Taguchi method-based optimization framework was implemented by balancing key parameters to maximize the torque density. This co-design strategy achieved a 21% increase in torque density, enabling higher torque transfer per unit volume. Experimental validation demonstrated a maximum torque of 920 Nm, with stable performance under simulated deep-sea conditions. This design establishes a new paradigm for high-power leak-free transmission in corrosive, high-pressure marine environments, advancing applications from deep-sea propulsion to offshore energy systems. Full article
(This article belongs to the Section Ocean Engineering)
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19 pages, 1072 KiB  
Article
Efficient and Reliable Identification of Probabilistic Cloning Attacks in Large-Scale RFID Systems
by Chu Chu, Rui Wang, Nanbing Deng and Gang Li
Micromachines 2025, 16(8), 894; https://doi.org/10.3390/mi16080894 (registering DOI) - 31 Jul 2025
Viewed by 49
Abstract
Radio Frequency Identification (RFID) technology is widely applied in various scenarios, including logistics tracking, supply chain management, and target monitoring. In these contexts, the malicious cloning of legitimate tag information can lead to sensitive data leakage and disrupt the normal acquisition of tag [...] Read more.
Radio Frequency Identification (RFID) technology is widely applied in various scenarios, including logistics tracking, supply chain management, and target monitoring. In these contexts, the malicious cloning of legitimate tag information can lead to sensitive data leakage and disrupt the normal acquisition of tag information by readers, thereby threatening personal privacy and corporate security and incurring significant economic losses. Although some efforts have been made to detect cloning attacks, the presence of missing tags in RFID systems can obscure cloned ones, resulting in a significant reduction in identification efficiency and accuracy. To address these problems, we propose the block-based cloned tag identification (BCTI) protocol for identifying cloning attacks in the presence of missing tags. First, we introduce a block indicator to sort all tags systematically and design a block mechanism that enables tags to respond repeatedly within a block with minimal time overhead. Then, we design a superposition strategy to further reduce the number of verification times, thereby decreasing the execution overhead. Through an in-depth analysis of potential tag response patterns, we develop a precise method to identify cloning attacks and mitigate interference from missing tags in probabilistic cloning attack scenarios. Moreover, we perform parameter optimization of the BCTI protocol and validate its performance across diverse operational scenarios. Extensive simulation results demonstrate that the BCTI protocol meets the required identification reliability threshold and achieves an average improvement of 24.01% in identification efficiency compared to state-of-the-art solutions. Full article
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39 pages, 14288 KiB  
Article
Design and Performance Study of a Magnetic Flux Leakage Pig for Subsea Pipeline Defect Detection
by Fei Qu, Shengtao Chen, Meiyu Zhang, Kang Zhang and Yongjun Gong
J. Mar. Sci. Eng. 2025, 13(8), 1462; https://doi.org/10.3390/jmse13081462 - 30 Jul 2025
Viewed by 191
Abstract
Subsea pipelines, operating in high-pressure and high-salinity conditions, face ongoing risks of leakage. Pipeline leaks can pollute the marine environment and, in severe cases, cause safety incidents, endangering human lives and property. Regular integrity inspections of subsea pipelines are critical to prevent corrosion-related [...] Read more.
Subsea pipelines, operating in high-pressure and high-salinity conditions, face ongoing risks of leakage. Pipeline leaks can pollute the marine environment and, in severe cases, cause safety incidents, endangering human lives and property. Regular integrity inspections of subsea pipelines are critical to prevent corrosion-related leaks. This study develops a magnetic flux leakage (MFL)-based pig for detecting corrosion in subsea pipelines. Using a three-dimensional finite element model, this study analyzes the effects of defect geometry, lift-off distance, and operating speed on MFL signals. It proposes a defect estimation method based on axial peak-to-valley values and radial peak spacing, with inversion accuracy validated against simulation results. This study establishes a theoretical and practical framework for subsea pipeline integrity management, providing an effective solution for corrosion monitoring. Full article
(This article belongs to the Special Issue Theoretical Research and Design of Subsea Pipelines)
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32 pages, 5581 KiB  
Article
Composite Noise Reduction Method for Internal Leakage Acoustic Emission Signal of Safety Valve Based on IWTD-IVMD Algorithm
by Shuxun Li, Xiaoqi Meng, Jianjun Hou, Kang Yuan and Xiaoya Wen
Sensors 2025, 25(15), 4684; https://doi.org/10.3390/s25154684 - 29 Jul 2025
Viewed by 214
Abstract
As the core device for protecting the safety of the pressure-bearing system, the spring full-open safety valve is prone to various forms of valve seat sealing surface damage after long-term opening and closing impact, corrosion, and medium erosion, which may lead to internal [...] Read more.
As the core device for protecting the safety of the pressure-bearing system, the spring full-open safety valve is prone to various forms of valve seat sealing surface damage after long-term opening and closing impact, corrosion, and medium erosion, which may lead to internal leakage. In view of the problems that the high-frequency acoustic emission signal of the internal leakage of the safety valve has, namely, a large number of energy-overlapping areas in the frequency domain, the overall signal presents broadband characteristics, large noise content, and no obvious time–frequency characteristics. A composite denoising method, IWTD, improved wavelet threshold function with dual adjustable factors, and the improved VMD algorithm is proposed. In view of the problem that the optimal values of the dual adjustment factors a and b of the function are difficult to determine manually, an improved dung beetle optimization algorithm is proposed, with the maximum Pearson coefficient as the optimization target; the optimization is performed within the value range of the dual adjustable factors a and b, so as to obtain the optimal value. In view of the problem that the key parameters K and α in VMD decomposition are difficult to determine manually, the maximum Pearson coefficient is taken as the optimization target, and the improved dung beetle algorithm is used to optimize within the value range of K and α, so as to obtain the IVMD algorithm. Based on the IVMD algorithm, the characteristic decomposition of the internal leakage acoustic emission signal occurs after the denoising of the IWTD function is performed to further improve the denoising effect. The results show that the Pearson coefficients of all types of internal leakage acoustic emission signals after IWTD-IVMD composite noise reduction are greater than 0.9, which is much higher than traditional noise reduction methods such as soft and hard threshold functions. Therefore, the IWTD-IVMD composite noise reduction method can extract more main features out of the measured spring full-open safety valve internal leakage acoustic emission signals, and has a good noise reduction effect. Feature recognition after noise reduction can provide a good evaluation for the safe operation of the safety valve. Full article
(This article belongs to the Section Physical Sensors)
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37 pages, 5345 KiB  
Article
Synthesis of Sources of Common Randomness Based on Keystream Generators with Shared Secret Keys
by Dejan Cizelj, Milan Milosavljević, Jelica Radomirović, Nikola Latinović, Tomislav Unkašević and Miljan Vučetić
Mathematics 2025, 13(15), 2443; https://doi.org/10.3390/math13152443 - 29 Jul 2025
Viewed by 122
Abstract
Secure autonomous secret key distillation (SKD) systems traditionally depend on external common randomness (CR) sources, which often suffer from instability and limited reliability over long-term operation. In this work, we propose a novel SKD architecture that synthesizes CR by combining a keystream of [...] Read more.
Secure autonomous secret key distillation (SKD) systems traditionally depend on external common randomness (CR) sources, which often suffer from instability and limited reliability over long-term operation. In this work, we propose a novel SKD architecture that synthesizes CR by combining a keystream of a shared-key keystream generator KSG(KG) with locally generated binary Bernoulli noise. This construction emulates the statistical properties of the classical Maurer satellite scenario while enabling deterministic control over key parameters such as bit error rate, entropy, and leakage rate (LR). We derive a closed-form lower bound on the equivocation of the shared-secret key  KG from the viewpoint of an adversary with access to public reconciliation data. This allows us to define an admissible operational region in which the system guarantees long-term secrecy through periodic key refreshes, without relying on advantage distillation. We integrate the Winnow protocol as the information reconciliation mechanism, optimized for short block lengths (N=8), and analyze its performance in terms of efficiency, LR, and final key disagreement rate (KDR). The proposed system operates in two modes: ideal secrecy, achieving secret key rates up to 22% under stringent constraints (KDR < 10−5, LR < 10−10), and perfect secrecy mode, which approximately halves the key rate. Notably, these security guarantees are achieved autonomously, without reliance on advantage distillation or external CR sources. Theoretical findings are further supported by experimental verification demonstrating the practical viability of the proposed system under realistic conditions. This study introduces, for the first time, an autonomous CR-based SKD system with provable security performance independent of communication channels or external randomness, thus enhancing the practical viability of secure key distribution schemes. Full article
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38 pages, 6652 KiB  
Review
Remote Sensing Perspective on Monitoring and Predicting Underground Energy Sources Storage Environmental Impacts: Literature Review
by Aleksandra Kaczmarek and Jan Blachowski
Remote Sens. 2025, 17(15), 2628; https://doi.org/10.3390/rs17152628 - 29 Jul 2025
Viewed by 249
Abstract
Geological storage is an integral element of the green energy transition. Geological formations, such as aquifers, depleted reservoirs, and hard rock caverns, are used mainly for the storage of hydrocarbons, carbon dioxide and increasingly hydrogen. However, potential adverse effects such as ground movements, [...] Read more.
Geological storage is an integral element of the green energy transition. Geological formations, such as aquifers, depleted reservoirs, and hard rock caverns, are used mainly for the storage of hydrocarbons, carbon dioxide and increasingly hydrogen. However, potential adverse effects such as ground movements, leakage, seismic activity, and environmental pollution are observed. Existing research focuses on monitoring subsurface elements of the storage, while on the surface it is limited to ground movement observations. The review was carried out based on 191 research contributions related to geological storage. It emphasizes the importance of monitoring underground gas storage (UGS) sites and their surroundings to ensure sustainable and safe operation. It details surface monitoring methods, distinguishing geodetic surveys and remote sensing techniques. Remote sensing, including active methods such as InSAR and LiDAR, and passive methods of multispectral and hyperspectral imaging, provide valuable spatiotemporal information on UGS sites on a large scale. The review covers modelling and prediction methods used to analyze the environmental impacts of UGS, with data-driven models employing geostatistical tools and machine learning algorithms. The limited number of contributions treating geological storage sites holistically opens perspectives for the development of complex approaches capable of monitoring and modelling its environmental impacts. Full article
(This article belongs to the Special Issue Advancements in Environmental Remote Sensing and GIS)
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28 pages, 2976 KiB  
Review
Catalytic Combustion Hydrogen Sensors for Vehicles: Hydrogen-Sensitive Performance Optimization Strategies and Key Technical Challenges
by Biyi Huang, Yi Wang, Chao Wang, Lijian Wang and Shubin Yan
Processes 2025, 13(8), 2384; https://doi.org/10.3390/pr13082384 - 27 Jul 2025
Viewed by 333
Abstract
As an efficient and low-carbon renewable energy source, hydrogen plays a strategic role in the global energy transition, particularly in the transportation sector. However, the flammable and explosive nature of hydrogen makes leakage risks in enclosed environments a core challenge for the safe [...] Read more.
As an efficient and low-carbon renewable energy source, hydrogen plays a strategic role in the global energy transition, particularly in the transportation sector. However, the flammable and explosive nature of hydrogen makes leakage risks in enclosed environments a core challenge for the safe promotion of hydrogen fuel cell vehicles. Catalytic combustion sensors are ideal choices due to their high sensitivity and long lifespan. Nevertheless, they face technical bottlenecks under vehicle operational conditions, such as high-power consumption caused by elevated working temperatures, slow response rates, weak anti-interference capabilities, and catalyst poisoning. This paper systematically reviews the research status of catalytic combustion hydrogen sensors for vehicle applications, summarizes technical difficulties and development strategies from the perspectives of hydrogen-sensitive material design and integration processes, and provides theoretical references and technical guidance for the development of catalytic combustion hydrogen sensors suitable for vehicle use. Full article
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31 pages, 9977 KiB  
Article
Novel Deep Learning Framework for Evaporator Tube Leakage Estimation in Supercharged Boiler
by Yulong Xue, Dongliang Li, Yu Song, Shaojun Xia and Jingxing Wu
Energies 2025, 18(15), 3986; https://doi.org/10.3390/en18153986 - 25 Jul 2025
Viewed by 261
Abstract
The estimation of leakage faults in evaporation tubes of supercharged boilers is crucial for ensuring the safe and stable operation of the central steam system. However, leakage faults of evaporation tubes feature high time dependency, strong coupling among monitoring parameters, and interference from [...] Read more.
The estimation of leakage faults in evaporation tubes of supercharged boilers is crucial for ensuring the safe and stable operation of the central steam system. However, leakage faults of evaporation tubes feature high time dependency, strong coupling among monitoring parameters, and interference from noise. Additionally, the large number of monitoring parameters (approximately 140) poses a challenge for spatiotemporal feature extraction, feature decoupling, and establishing a mapping relationship between high-dimensional monitoring parameters and leakage, rendering the precise quantitative estimation of evaporation tube leakage extremely difficult. To address these issues, this study proposes a novel deep learning framework (LSTM-CNN–attention), combining a Long Short-Term Memory (LSTM) network with a dual-pathway spatial feature extraction structure (ACNN) that includes an attention mechanism(attention) and a 1D convolutional neural network (1D-CNN) parallel pathway. This framework processes temporal embeddings (LSTM-generated) via a dual-branch ACNN—where the 1D-CNN captures local spatial features and the attention models’ global significance—yielding decoupled representations that prevent cross-modal interference. This architecture is implemented in a simulated supercharged boiler, validated with datasets encompassing three operational conditions and 15 statuses in the supercharged boiler. The framework achieves an average diagnostic accuracy (ADA) of over 99%, an average estimation accuracy (AEA) exceeding 90%, and a maximum relative estimation error (MREE) of less than 20%. Even with a signal-to-noise ratio (SNR) of −4 dB, the ADA remains above 90%, while the AEA stays over 80%. This framework establishes a strong correlation between leakage and multifaceted characteristic parameters, moving beyond traditional threshold-based diagnostics to enable the early quantitative assessment of evaporator tube leakage. Full article
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22 pages, 6823 KiB  
Article
Design Optimization of Valve Assemblies in Downhole Rod Pumps to Enhance Operational Reliability in Oil Production
by Seitzhan Zaurbekov, Kadyrzhan Zaurbekov, Doszhan Balgayev, Galina Boiko, Ertis Aksholakov, Roman V. Klyuev and Nikita V. Martyushev
Energies 2025, 18(15), 3976; https://doi.org/10.3390/en18153976 - 25 Jul 2025
Viewed by 252
Abstract
This study focuses on the optimization of valve assemblies in downhole rod pumping units (DRPUs), which remain the predominant artificial lift technology in oil production worldwide. The research addresses the critical issue of premature failures in DRPUs caused by leakage in valve pairs, [...] Read more.
This study focuses on the optimization of valve assemblies in downhole rod pumping units (DRPUs), which remain the predominant artificial lift technology in oil production worldwide. The research addresses the critical issue of premature failures in DRPUs caused by leakage in valve pairs, i.e., a problem that accounts for approximately 15% of all failures, as identified in a statistical analysis of the 2022 operational data from the Uzen oilfield in Kazakhstan. The leakage is primarily attributed to the accumulation of mechanical impurities and paraffin deposits between the valve ball and seat, leading to concentrated surface wear and compromised sealing. To mitigate this issue, a novel valve assembly design was developed featuring a flow turbulizer positioned beneath the valve seat. The turbulizer generates controlled vortex motion in the fluid flow, which increases the rotational frequency of the valve ball during operation. This motion promotes more uniform wear across the contact surfaces and reduces the risk of localized degradation. The turbulizers were manufactured using additive FDM technology, and several design variants were tested in a full-scale laboratory setup simulating downhole conditions. Experimental results revealed that the most effective configuration was a spiral plate turbulizer with a 7.5 mm width, installed without axis deviation from the vertical, which achieved the highest ball rotation frequency and enhanced lapping effect between the ball and the seat. Subsequent field trials using valves with duralumin-based turbulizers demonstrated increased operational lifespans compared to standard valves, confirming the viability of the proposed solution. However, cases of abrasive wear were observed under conditions of high mechanical impurity concentration, indicating the need for more durable materials. To address this, the study recommends transitioning to 316 L stainless steel for turbulizer fabrication due to its superior tensile strength, corrosion resistance, and wear resistance. Implementing this design improvement can significantly reduce maintenance intervals, improve pump reliability, and lower operating costs in mature oilfields with high water cut and solid content. The findings of this research contribute to the broader efforts in petroleum engineering to enhance the longevity and performance of artificial lift systems through targeted mechanical design improvements and material innovation. Full article
(This article belongs to the Special Issue Petroleum and Natural Gas Engineering)
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