Search Results (19)

Thermochemical energy storage (TCES) has emerged as one of the pivotal technologies for enhancing the stability and efficiency of energy systems, owing to its advantages including high energy storage density, low heat loss and long-term energy storage capability. Among various TCES technologies, solid–gas reaction-based TCES exhibits tremendous potential in medium- and high-temperature applications. This paper first overviews the research progress of solid–gas reaction-based TCES technologies. Focusing on four major TCES material systems, namely hydroxides, carbonates, metal oxides and metal hydrides, it discusses their energy storage mechanisms, material modification strategies, and reaction kinetics, as well as approaches to improve thermal conductivity and cycling stability. Subsequently, reactor types (including fixed bed, moving bed and fluidized bed reactors) applicable to different materials and the latest research progress of diverse reaction systems are elaborated in detail, and the optimal designs of heat transfer performance for the four reaction materials in corresponding reactors are clarified. Based on the comparative analysis, the Ca(OH)₂/CaO system is identified as the most promising material system for engineering deployment, owing to its moderate operating temperature, low material cost, and validated pilot-scale performance. The intrinsic complementarity between material modification strategies and reactor heat transfer enhancement is also elucidated, providing a theoretical foundation for scalable implementation. Full article

The performance of a Mayenite-supported nickel-based catalyst were investigated by using an in-house-designed, assembled and set-up chemical pilot plant, which was developed to provide experimental insights relevant to industrial scale up. In particular, the proposed heterogeneous catalytic system was structured in mm-sized spheres and tested in a large-scale experiment, in a fixed-bed reactor for the CO₂ methanation process, and the results were compared with the output achieved with a Ni/alumina catalyst produced by an analogous route as the benchmark. The obtained findings highlighted the effective potential of the Mayenite structure supporting metallic active sites in promoting CO₂ reduction under the selected operating conditions (450 °C, 4 bar), along with long-term stability and high CH₄ selectivity. Moreover, the available experimental equipment was optimized to achieve accurate estimations of amounts of reaction by-product, as confirmed by the optimal agreement with the mass balance retrieved from the measured gaseous outlet composition. Such an achievement, notable for a large-scale chemical plant, plays a capital role in terms of industrial applications due to the critical impact of residual carbon and water in establishing the viability of innovative catalyst systems for the CO₂ recycling process. Full article

The increasing demand for sustainable materials has driven interest in biocomposites that incorporate low-value agricultural residues to offset the use of virgin plastics. The study investigated the production of blend pellets from raw and torrefied almond shells and post-consumer plastic waste as a potential feedstock for biocomposite and biofuels applications. Almond shells were torrefied in a lab-scale fixed-bed reactor at 300 °C for 30 min prior to the pelleting tests. High-density polyethylene (HDPE) and polypropylene (PP) wastes were size-reduced in a Crumbler (rotary shear grinder) fitted with a 2 mm head and a 2 mm screen to remove the fines. A portion of the crumbled HDPE, and torrefied almond shells were further ground in a Wiley mill fitted with 2 and 1 mm screens for flat die pelleting tests. The flat die pellet mill used for testing had a 6 mm die and a length-to-diameter (L/D) ratio of 2.0. The blend ratio consisted of 30% torrefied almond shells and 70% HDPE, with a 10% starch binder. The measured pellet properties include unit, bulk and tap densities, durability, and expansion ratio. The bulk density of the blend pellets ranged from 360 to 410 kg/m³, and durability ranged from 80% to 88%. The blend pellet unit density ranged from 830 to 880 kg/m³. The blend pellets produced using crumbled HDPE, PP and raw and torrefied almond shells in a ring die pilot-scale pellet mill with an L/D ratio of 6 and steam conditioning exhibit similar densities to those of HDPE pellets produced using a flat die pellet mill, albeit with lower durability. The study indicated that a smaller grind size and preheating the blend before pelleting produce blend pellets with higher density and greater durability. Full article

A multiscale 3D CFD model of CO₂ methanation over Ni/Al₂O₃ was developed in COMSOL Multiphysics 6.3 for a lab-scale isothermal fixed-bed Sabatier reactor and validated against published data. The multiscale approach integrated bulk convection–diffusion, fluid flow, and pressure distribution with intraparticle diffusion–reaction phenomena coupled with Langmuir–Hinshelwood–Hougen–Watson-based kinetics, thus solving mass-transfer limitations without empirical effectiveness factors. Model validation was carried out by (i) kinetics, (ii) reactor performance, and (iii) hydrodynamics. Simulation results showed strong diffusion-dominated species transport at the bed entrance that lessened downstream as partial pressures decreased and products accumulated, resulting in a diffusion-relieved regime near the outlet. Sensitivity studies identified 320–350 °C and up to 10 bar as favorable conditions for high CH₄ yield. Additionally, slightly H₂-rich feed accelerated approach to equilibrium, while lower flow rates achieved near-complete conversion within the first half of the reactor bed. Simulations were carried out in COMSOL Multiphysics 6.3 on a dual Intel Xeon Platinum 8168 (48 cores at 2.7 GHz) workstation with 512 GB RAM to solve a 12-million-element mesh. The developed framework identifies a practical operating window and quantifies the conversion–throughput trade-off with flow rate, guiding operating condition selection and providing a basis for process intensification and lab-to-pilot scale-up of CO₂ methanation. Full article

This study examines the chemical recycling of polymethylmethacrylate (PMMA) dental waste in semi-batch fixed-bed reactors via pyrolysis, aiming to convert this waste into the valuable monomer methyl methacrylate (MMA). First, the effect of temperature is analyzed in a laboratory-scale (30 g) semi-batch reactor at 350, 400 and 450 °C. In order to visualize the combined effect of temperature and increase in bed volume, experiments conducted at 350 °C in the laboratory (30 g) and on a pilot scale (20 kg) are compared. Experiments conducted at 475°C on technical and pilot scales are also compared to elucidate this behavior. A detailed process analysis is presented, considering different experiments conducted in a semi-batch technical-scale reactor. Experiments were conducted in a 2 L reactor at temperatures of 425 °C, 450 °C and 475 °C to understand the effects of heating rate and temperature on product yield and composition. The results show that at 425 °C, MMA was the primary liquid component, with minimal by-products, suggesting that lower temperatures enhance monomer recovery. Higher temperatures, however, increased gas yields and reduced MMA yield due to intensified thermal cracking. This study also highlights that char formation and non-condensable gases increase with the reactor scale, indicating that heat transfer limitations can influence MMA purity and yield. These findings emphasize that for effective MMA recovery, lower temperatures and controlled heating rates are optimal, especially in larger reactors where heat transfer issues are more prominent. This research study contributes to scaling up PMMA recycling processes, supporting industrial applications to achieve efficient monomer recovery from waste. Full article

In quest of a substantial reduction in potentially toxic gas emissions into the air from industrial plants, dry flue gas desulfurization (FGD) systems offer several advantages, such as reduced operational costs, adaptability, ease of use, and the elimination of liquid waste. This study describes the development of a laboratory-scale pilot system for conducting SO₂ abatement experiments using a fixed-bed reactor. To validate the experimental setup, the reactor was equipped with a control system for measuring and monitoring relative humidity, temperature, and total flux composition. The study utilized two standards, slaked lime and 13X zeolite, under identical experimental conditions to ensure comparability. This research will significantly advance the understanding of adsorbent materials for capturing low SO₂ concentrations by measuring adsorption kinetics and equilibrium data. The findings highlight the impact of distinct morphological, chemical, and crystallographic properties on the efficiency of dry FGD systems. Full article

In this study, we report the development of an electro-Fenton (EF) process at a semi-pilot scale plant using an open undivided electrochemical reactor design. To do so, a series of three-dimensional (3D) cathodes constituted of packed and fixed beds of glassy carbon pellets and dimensionally stable anodes (DSAs) were employed. To highlight the treatment efficiency of the EF process, bisphenol A (BPA), which is known to be a persistent molecule, was used as the model molecule. First, the applied current intensity was studied and optimized to determine the limiting current of the O₂ reduction under hydrodynamic conditions of 0.6 m³·h⁻¹. The limiting current intensity under hydrodynamic conditions corresponding to 10 L·min⁻¹ (600 L/h) was determined to be near 17.5 A (0.51 A/100 g of glassy carbon pellets). Then, the effect of the number of cathodes on the removal efficiency of BPA versus the time of the electro-Fenton treatment was investigated. The value of K_app in the typical reactor configuration was found to be 0.076 min⁻¹. Many parameters were carried out using the EF reactor, i.e., the effect of the initial pollutant concentration as well as the effect of the treatment flow rate. The obtained results demonstrate that the degradation efficiency of BPA increases as the number of cathodes increases and the pollution charge decreases. Only a few seconds of treatment by EF process were needed to eliminate BPA from the dilute solutions (≤10 mg·L⁻¹). The biodegradability of the treated solution and its mineralization were also investigated by referring to the measurements of COD, TOC, and BOD₅. Finally, strategy of scaling-up the reactor design to an industrial pilot plant is discussed. Full article

This research explores the depolymerization of waste polymethyl methacrylate (PMMAW) from dental material in fixed bed semi-batch reactors, focusing on three production scales: laboratory, technical and pilot. The study investigates the thermal degradation mechanism and kinetics of PMMAW through thermogravimetric (TG) and differential scanning calorimetry (DSC) analyses, revealing a two-step degradation process. The heat flow during PMMAW decomposition is measured by DSC, providing essential parameters for designing pyrolysis processes. The results demonstrate the potential of DSC for energetic analysis and process design, with attention to standardization challenges. Material balance analysis across the production scales reveals a temperature gradient across the fixed bed negatively impacting liquid yield and methyl methacrylate (MMA) concentration. Reactor load and power load variables are introduced, demonstrating decreased temperature with increased process scale. The study identifies the influence of temperature on MMA concentration in the liquid fraction, emphasizing the importance of controlling temperature for efficient depolymerization. Furthermore, the research highlights the formation of aromatic hydrocarbons from the remaining char, indicating a shift in liquid composition during the depolymerization process. The study concludes that lower temperatures below 450 °C favor liquid fractions rich in MMA, suggesting the benefits of lower temperatures and slower heating rates in semi-batch depolymerization. The findings contribute to a novel approach for analyzing pyrolysis processes, emphasizing reactor design and economic considerations for recycling viability. Future research aims to refine and standardize the analysis and design protocols for pyrolysis and similar processes. Full article

This work highlights the frustration that a researcher may face when trying to convince people in industries to use a new technology that has been developed in a small-scale laboratory. A moderate-reaction-severity process for hydrotreating of heavy crude oil (HIDRO-IMP technology) in fixed-bed reactors is used as an example. Although the development of such a technology has been scaled-up from bench and pilot-plant scales to a semi-commercial level with positive technical and economical results, the people in petroleum refinery who make decisions on the suitability of technologies for commercial implementation always ask for previous applications of the process developed. The different stages of development of the HIDRO-IMP technology are commented on, and some results that corroborate its feasibility for commercial application are discussed. Full article

In this study, conditions were determined to obtain a solid wax with a waxy ester content of more than 25% from the hydrotreating of palm oil. The experiments were conducted in a pilot-scale fixed-bed reactor. The influence of temperature, liquid hourly space velocity (LHSV), and pressure on the conversion of triglycerides were evaluated using a nickel molybdenum catalyst (NiMo/Al₂O₃). The variables were evaluated between 240 and 260 °C, 1 and 2 h⁻¹ and 41 and 55 bar, respectively. Based on these results, the best conditions were T:240–260 °C; P: 90 bar; LHSV: 1.5 h⁻¹; hydrogen/oil ratio 472 LN/L with a conversion around 60 wt%; and a selectivity towards waxy esters of 40 wt%. These conditions were then validated with a second catalyst (NiMoB/Al₂O₃), yielding a triglyceride conversion of about 60 wt% and a waxy ester concentration of around 30 wt%. Full article

This paper aims to briefly overview gasification technologies of biomass and heterogeneous wastes as a means for syngas production. For this purpose, an overview of the existing technologies, their main advantages, limitations, and costs, as well as commercial plants and projects (lower TRL) operating with these technologies and syngas applications is presented. The type of technology and operating parameters should be selected considering the quality of the syngas as it will dictate its end use. Syngas quality is determined by the combination of feedstock properties, type of technology and process operating conditions, and the scale of operation. For smaller projects with a capacity of up to 10 MWth, fixed-bed technologies have been a recurring choice, while fluidized bed reactors can have an installed capacity above 100 MWth and are, therefore, more suitable for medium- and large-scale projects. Fluidized bed gasification technology supports feedstock flexibility, has scale-up potential, and presents relatively low cost, making it a suitable solution and a frequent choice for heterogeneous waste gasification in medium- or large-scale projects. Commercializing waste gasification technology is already a reality. However, more efforts need to be made so that pilot and demonstration projects can overcome the technological and economic problems and move towards commercialization. Full article

Catalytic upgrading of vapors from pyrolysis of triglycerides materials is a promising approach to achieve better conversions of hydrocarbons and production of liquid biofuels. Catalytic cracking often shows incomplete conversion due to distillation of initial reaction products and the addition of a second catalytic reactor, whereas pyrolytic vapors are made in contact to a solid catalyst was applied to improve the physical-chemical properties and quality of bio-oil. This work investigated the effect of catalyst content and reaction time by catalytic upgrading from pyrolysis vapors of residual fat at 450 °C and 1.0 atmosphere, on the yields of reaction products, physicochemical properties (density, kinematic viscosity, refractive index, and acid value), and chemical composition of organic liquid products (OLP), over a catalyst fixed bed reactor, in semi pilot scale. Pellets of red mud chemically activated with 1.0 M HCl were used as catalysts. The thermal catalytic cracking of residual fat show OLP yields from 54.4 to 84.88 (wt.%), aqueous phase yields between 2.21 and 2.80 (wt.%), solid phase yields (coke) between 1.30 and 8.60 (wt.%), and gas yields from 11.61 to 34.22 (wt.%). The yields of OLP increases with catalyst content while those of aqueous, gaseous and solid phase decreases. For all experiments, the density, kinematic viscosity, and acid value of OLP decreases with reaction time. The GC-MS of liquid reaction products identified the presence of hydrocarbons and oxygenates. In addition, the hydrocarbon content in OLP increases with reaction time, while those of oxygenates decrease, reaching concentrations of hydrocarbons up to 95.35% (area.). The best results for the physicochemical properties and the maximum hydrocarbon content in OLP were obtained at 450 °C and 1.0 atmosphere, using a catalyst fixed bed reactor, with 5.0% (wt.) red mud pellets activated with 1.0 M HCl as catalyst. Full article

This work investigated the influence of the reaction time and catalyst-to-residual fat ratio by catalytic upgrading from pyrolysis vapors of residual fat at 400 °C and 1.0 atmosphere, on the yields of reaction products, physicochemical properties (density, kinematic viscosity, and acid value) and chemical composition of bio-oils, over a catalyst fixed-bed reactor of activated carbon pellets impregnated with 10.0 M NaOH, in semi-pilot scale. The experiments were carried out at 400 °C and 1.0 atmosphere, using a process schema consisting of a thermal cracking reactor of 2.0 L coupled to a catalyst fixed-bed reactor of 53 mL, without catalyst and using 5.0%, 7.5%, and 10.0% (wt.) activated carbon pellets impregnated with 10.0 M NaOH, in batch mode. Results show yields of bio-oil decreasing with increasing catalyst-to-tallow ratio. The GC-MS of liquid reaction products identified the presence of hydrocarbons (alkanes, alkenes, ring-containing alkanes, ring-containing alkenes, and aromatics) and oxygenates (carboxylic acids, ketones, esters, alcohols, and aldehydes). For all the pyrolysis and catalytic cracking experiments, the hydrocarbon selectivity in bio-oil increases with increasing reaction time, while those of oxygenates decrease, reaching concentrations of hydrocarbons up to 95.35% (area). Full article

The one-dimensional (1D) mathematical model of fixed bed reactor was developed for dimethyl ether (DME) synthesis at pilot-scale (capacity: 25–28 Nm³/h of syngas). The reaction rate, heat, and mass transfer equations were correlated with the effectiveness factor. The simulation results, including the temperature profile, CO conversion, DME selectivity, and DME yield of the outlet, were validated with experimental data. The average error ratios were below 9.3%, 8.1%, 7.8%, and 3.5% for the temperature of the reactor, CO conversion, DME selectivity, and DME yield, respectively. The sensitivity analysis of flow rate, feed pressure, H₂:CO ratio, and CO₂ mole fraction was investigated to demonstrate the applicability of this model. Full article

This work presents the numerical analysis and validation of a fixed bed reactor model for 2,3-butanediol (2,3-BDO) dehydration. The 1D heterogeneous reactor model considering interfacial and intra-particle gradients, was simulated and numerical analysis of the model was conducted to understand the characteristics of the reactions in a catalyst along the reactor length. The model was also validated by comparing predicted performance data with pilot-scale plant data operated at 0.2 bar, 299–343 °C and 0.48–2.02 h⁻¹ of weight hourly space velocity (WHSV). The model showed good agreement with the temperature profile, 2,3-BDO conversion and selectivity of target products. In addition, sensitivity analyses of the model were investigated by changing feed flow rate, feed composition, and inlet temperature. It was found that stable and efficient operation conditions are lower than 0.65 h⁻¹ of WHSV and 330–340 °C of inlet temperature. Additionally, the reactor performance was not affected by 2,3-BDO feed concentration above 70%. Full article