Search Results (234)

In this study, non-isothermal pyrolysis of a mixture of disposable surgical face masks (FMs) and nitrile gloves (NGs) was conducted, using a heating rate of 100 °C/min, N₂ flowrate of 100 mL/min, and temperatures between 500 and 800 °C. Condensable product yield peaked at 600 °C (76.9 wt.%), with gas yields rising to 31.0 wt.%, at 800 °C. GC-MS of the condensable product confirmed the presence of aliphatic compounds (>90%), while hydrogen, methane, and ethylene dominated the gas composition. At 600 °C, gasoline (C₄ to C₁₂)-, diesel (C₁₃ to C₂₀)-, motor oil (C₂₁ to C₃₅)-, and heavy hydrocarbon (C₃₅₊)-range compounds accounted for 23.7, 46.7, 12.5, and 17.1%, of the condensable product, respectively. Using model-free methods, the average activation energy and pre-exponential factor were found to be 309.7 ± 2.4 kJ/mol and 2.5 ± 3.4 × 10²⁵ s⁻¹, respectively, while a 2-dimensional diffusion mechanism was determined. Scale-up runs confirmed high yields of condensable product (60–70%), with comparable composition to that obtained from lab-scale tests. The pyrolysis oil exceeds acceptable oxygen, nitrogen, chlorine, and fluorine levels for industrial steam crackers—needing pre-treatment—while other contaminants like sulphur and metals could be managed through mild blending. In summary, this work offers a sustainable approach to address the environmental concerns surrounding disposable FMs and NGs. Full article

Accurate fault diagnosis in marine steam turbine condensate systems is challenged by insufficient real fault samples and dynamic operational conditions. To address this limitation, DTL-DFD, a novel framework integrating digital twins (DTs) and deep transfer learning (DTL), is proposed, wherein a high-fidelity physics-constrained digital twin model is constructed through the systematic injection of six diagnostic classes (1 normal + 5 faults), including insufficient circulation water flow.Through an innovative all-layer parameter initialization with a partial fine-tuning (ALPT-PF) strategy, all weights and biases from a pre-trained one-dimensional convolutional neural network (1D-CNN) were fully transferred to the target model, which was subsequently fine-tuned via a hierarchical learning rate mechanism to adapt to real-world distribution discrepancies. Experimental results demonstrate 94.34% accuracy on cross-distribution test sets with a 4.72% improvement over state-of-the-art methods, confirming significant enhancements in generalization capability and diagnostic stability under small-sample conditions with significant real data reduction, thereby providing an effective solution for the intelligent operation and maintenance of marine steam turbine systems. Full article

High-efficiency design solutions for cogeneration steam power plants are studied for different steam consumer requirements (steam pressures between 3.6 and 40 bar and heat flow rates between 10 and 40% of the fuel heat flow rate into the steam generators). Using a genetic algorithm, optimum designs for schemes with extraction-condensing steam turbines, reheat, and supercritical parameters were found considering four objective functions (high global efficiency, low specific investment in equipment, high exergetic efficiency, and high power-to-heat ratio in full cogeneration mode). A second Pareto front was computed from the prior solutions, considering the first two objective functions, resulting in the high-efficiency cogeneration schemes with a primary energy savings (PES) ratio higher than 10%. The results showed that the PES ratio depends strongly on the steam consumer requirements, rising from values under 10% for low heat flow rates and few preheaters to over 25% for a higher number of preheaters, high heat flow rates, and low steam pressures to the consumer. At the same heat flow rate to the consumer, the power-to-heat ratio in full cogeneration mode increases with the decrease in the required steam pressure to the consumer. Full article

Water scarcity is a growing global challenge, intensified by climate change, seawater intrusion, and pollution. While conventional desalination methods are energy-intensive, solar-driven interfacial evaporators offer a promising low-energy solution by leveraging solar energy for water evaporation, with the resulting steam condensed into purified water. Despite advancements, challenges persist, particularly in addressing volatile contaminants and biofouling, which can compromise long-term performance. The integration of photocatalysts into solar-driven interfacial evaporators has been proposed as a solution, enabling pollutant degradation and microbial inactivation while enhancing water transport and self-cleaning properties. This review critically assesses testing methodologies for solar-driven interfacial evaporators incorporating both photothermal and photocatalytic functions. While previous studies have examined materials and system design, the added complexity of photocatalysis necessitates new testing approaches. First, solar still setups are analyzed, particularly concentrating on the selection of materials and geometry for the transparent cover and water-collecting surfaces. Then, performance evaluation tests are discussed, with focus on the types of tested pollutants and analytical techniques. Finally, key challenges are presented, providing insights for future advancements in sustainable water purification. Full article

District heating systems in northern China predominantly rely on coal-fired heat sources, necessitating sustainable alternatives to reduce carbon emissions. This study investigates a biomass combined heat and power (CHP) system integrated with cascaded absorption heat pump (AHP) technology to recover waste heat from semi-dry flue gas desulfurization exhaust and turbine condenser cooling water. A multi-source operational framework is developed, coordinating biomass CHP units with coal-fired boilers for peak-load regulation. The proposed system employs a two-stage heat recovery methodology: preliminary sensible heat extraction from non-saturated flue gas (elevating primary heating loop (PHL) return water from 50 °C to 55 °C), followed by serial AHPs utilizing turbine extraction steam to upgrade waste heat from circulating cooling water (further heating PHL water to 85 °C). Parametric analyses demonstrate that the cascaded AHP system reduces turbine steam extraction by 4.4 to 8.8 t/h compared to conventional steam-driven heating, enabling 3235 MWh of annual additional power generation. Environmental benefits include an annual CO₂ reduction of 1821 tonnes, calculated using regional grid emission factors. The integration of waste heat recovery and multi-source coordination achieves synergistic improvements in energy efficiency and operational flexibility, advancing low-carbon transitions in district heating systems. Full article

Electrification is a highly effective decarbonization and environmental incentive strategy for the chemical industry. Nevertheless, it may lead to downstream challenges in the process. This study analyzes the consequences of electrifying compressors within the steam cracker (SC) condensate system, focusing on the reduction in greenhouse gas (GHG) emissions and energy consumption without compromising the process’s energy efficiency. The aim is to study the impact that the reduction in steam expanded by turbines has on boiler feedwater (BFW) temperature and, subsequently, the behavior it triggers in fuel gas (FG) consumption and carbon dioxide (CO₂) emissions in furnaces. It was concluded that condensate imports from the Energies and Utilities Plant (E&U) would increase by a factor of four, with approximately 60% of the imported condensate being cold condensate. The study revealed a mitigation of CO₂ emissions, resulting in a 1.3% reduction and a reduction in FG consumption of 1.8% preventing an increase in site energy consumption by 795.4 kW in furnaces. Condenser optimization reduces CO₂ emissions by 60%. Energy integration with quench water resulted in heat saving of 1824 kW in hot utility consumption and generating annual savings of EUR 2.3 M. The global carbon dioxide balance can achieve up to a 25% reduction. Full article

The critical consequence of climate change resulting from global warming is the increase in temperature. In combined cycle power plants (CCPPs), the Electric Power Output (PE) is affected by changes in both Ambient Temperature (AT) and Sea Surface Temperature (SST), particularly in plants utilizing seawater cooling systems. As AT increases, air density decreases, leading to a reduction in the mass of air absorbed by the gas turbine. This change alters the fuel–air mixture in the combustion chamber, resulting in decreased turbine power. Similarly, as SST increases, cooling efficiency declines, causing a loss of vacuum in the condenser. A lower vacuum reduces the steam expansion ratio, thereby decreasing the Steam Turbine Power Output. In this study, the effects of increases in these two parameters (AT and SST) due to global warming on the PE of CCPPs are investigated using various regression analysis techniques, Artificial Neural Networks (ANNs) and a hybrid model. The target variables are condenser vacuum (V), Steam Turbine Power Output (ST Power Output), and PE. The relationship of V with three input variables—SST, AT, and ST Power Output—was examined. ST Power Output was analyzed with four input variables: V, SST, AT, and relative humidity (RH). PE was analyzed with five input variables: V, SST, AT, RH, and atmospheric pressure (AP) using regression methods on an hourly basis. These models were compared based on the Coefficient of Determination (R²), Mean Absolute Error (MAE), Mean Absolute Percentage Error (MAPE), Mean Square Error (MSE), and Root Mean Square Error (RMSE). The best results for V, ST Power Output, and PE were obtained using the hybrid (LightGBM + DNN) model, with MAE values of 0.00051, 1.0490, and 2.1942, respectively. As a result, a 1 °C increase in AT leads to a decrease of 4.04681 MWh in the total electricity production of the plant. Furthermore, it was determined that a 1 °C increase in SST leads to a vacuum loss of up to 0.001836 bar_a. Due to this vacuum loss, the steam turbine experiences a power loss of 0.6426 MWh. Considering other associated losses (such as generator efficiency loss due to cooling), the decreases in ST Power Output and PE are calculated as 0.7269 MWh and 0.7642 MWh, respectively. Consequently, the combined effect of a 1 °C increase in both AT and SST results in a 4.8110 MWh production loss in the CCPP. As a result of a 1 °C increase in both AT and SST due to global warming, if the lost energy is to be compensated by an average-efficiency natural gas power plant, an imported coal power plant, or a lignite power plant, then an additional 610 tCO₂e, 11,184 tCO₂e, and 19,913 tCO₂e of greenhouse gases, respectively, would be released into the atmosphere. Full article

As the integration of renewable energy sources continues to increase, thermal power units are increasingly required to enhance their operational flexibility to accommodate grid fluctuations. However, frequent load variations in conventional thermal power plants result in decreased efficiency, accelerated equipment wear, and high operational costs. In this context, molten-salt thermal energy storage (TES) has emerged as a promising solution due to its high specific heat capacity and thermal stability. By enabling the storage of surplus energy and its regulated release during peak demand periods, molten salt TES contributes to improved grid stability, reduced start-up frequency, and minimized operational disturbances. This study employs comprehensive thermodynamic simulations to investigate three representative schemes for heat storage and release. The results indicate that the dual steam extraction configuration (Scheme 3) offers the highest thermal storage capacity and peak-load regulation potential, albeit at the cost of increased heat consumption. Conversely, the single steam extraction configurations (Scheme 1 and 2) demonstrate improved thermal efficiency and reduced system complexity. Furthermore, Scheme 3, which involves extracting feedwater from the condenser outlet, provides enhanced operational flexibility but necessitates a higher initial investment. These findings offer critical insights into the optimal integration of molten-salt thermal-storage systems with conventional thermal power units. The outcomes not only highlight the trade-offs among different design strategies but also support the broader objective of enhancing the efficiency and adaptability of thermal power generation in a renewable-dominated energy landscape. Full article

Increasing the efficiency and capacity of nuclear power units is a promising direction for the development of power generation systems. Unlike thermal power plants, nuclear power plants operate at relatively low temperatures of the steam working fluid. Due to this, the thermodynamic efficiency of such schemes remains relatively low today. The temperature of steam and the efficiency of nuclear power units can be increased by integrating external superheating of the working fluid into the schemes of steam turbine plants. This paper presents the results of a thermodynamic analysis of thermal schemes of NPPs integrated with hydrocarbon-fueled plants. Schemes with a remote combustion chamber, a boiler unit and a gas turbine plant are considered. It has been established that superheating fresh steam after the steam generator is an effective superheating solution due to the utilization of heat from the exhaust gases of the GTU using an afterburner. Furthermore, there is a partial replacement of high- and low-pressure heaters in the regeneration system, with gas heaters for condensate and steam superheating after the steam generator for water-cooled and liquid-metal reactor types. An increase in the net efficiency of the hybrid NPP is observed by 8.49 and 5.11%, respectively, while the net electric power increases by 93.3 and 76.7%. Full article

To address the challenge of heat transfer enhancement in the condensation of steam with non-condensable gases on a vertical wall under natural convection conditions, an improved boundary layer model with coupled multi-physics field was proposed in this paper, and traditional theoretical limitations were broken through by innovations. The particle swarm optimization algorithm was first introduced into the solution of the condensation boundary layer, and the convergence difficulty in the laminar–turbulent transition region under infinite boundary conditions was overcome. A coupled momentum–energy–mass equation system that simultaneously considered temperature–concentration dual-driven gravity terms and liquid film drag–suction dual effects was established, and higher computational efficiency and accuracy were achieved. A new mechanism where the concentration boundary layer dominated heat transfer resistance under the coupled action of the Prandtl number (Pr) and Schmidt number (Sc) was revealed. Experimental validation demonstrated that a prediction error of less than 5% was exhibited by the model under typical operating conditions of passive containment cooling systems (pressures of 1.5–4.5 atm and subcooling temperatures of 14–36 °C), and a theoretical tool for high-precision condensation heat transfer design was provided. Full article

The global shortage of freshwater resources and the energy crisis have propelled solar-driven interfacial evaporation (SDIE) coupled with photocatalytic technology to become a research focus in efficient and low-carbon water treatment. Graphene-based materials demonstrate unique advantages in SDIE–photocatalysis integrated systems, owing to their broadband light absorption, ultrafast thermal carrier dynamics, tunable electronic structure, and low evaporation enthalpy characteristics. This review systematically investigates the enhancement mechanisms of graphene photothermal conversion on photocatalytic processes, including (1) improving light absorption through surface morphology modulation, defect engineering, and plasmonic material compositing; (2) reducing water evaporation enthalpy via hydrophilic functional group modification and porous structure design; (3) suppressing heat loss through thermal insulation layers and 3D structural optimization; and (4) enhancing water transport efficiency via fluid channel engineering and wettability control. Furthermore, salt resistance strategies and structural optimization significantly improve system practicality and stability. In water treatment applications, graphene-based SDIE systems achieve synergistic “adsorption–catalysis–evaporation” effects, enabling efficient the degradation of organic pollutants, reduction in/fixation of heavy metal ions, and microbial inactivation. However, practical implementation still faces challenges including low steam condensation efficiency, insufficient long-term material durability, and high scaling-up costs. Future research should prioritize enhancing heat and mass transfer in condensation systems, optimizing material environmental adaptability, and developing low-cost manufacturing processes to promote widespread application of graphene-based SDIE–photocatalysis integrated systems. Full article

The production of fruit brandies is based on distilling fermented fruit juices. Distillation equipment is usually made of copper. In traditional manufacturing, it consists of a boiler (batch) distiller, a boiler (pot), a steam pipe, and a condenser, all of which are made of pure copper. This study determined the corrosion parameters for copper (Cu) and Cu72Zn28 (in wt%) alloy in fermented apricot juice at room temperature. The fermentation process examined in this research utilized natural strains of yeast and bacteria, supplemented by active dry yeast Saccharomyces cerevisiae strains. This research used the following methods: open circuit potential (OCP), linear polarization resistance (LPR), and Tafel extrapolation to identify corrosion parameters. Cu had a 3.8-times-lower value of corrosion current density than brass, and both were within the range of 1–10 μA·cm⁻², with an excellent agreement between LRP and Tafel. This study proved that Cu is an adequate material for the distillation of fruit brandies from a corrosion perspective. Despite this, there are occasional reports of corrosion damage from the field. Significant corrosion impacts can arise, as evidenced by laboratory tests discussed in this paper. In the absence of a highly corrosive environment, this study indicates that, to some extent, microbiologically influenced corrosion (MIC) can influence the degradation of the equipment material. Full article

Steam traps are essential for industrial systems, ensuring steam quality and energy efficiency by removing condensate and preventing steam leakage. However, their failure results in energy loss, operational disruptions, and increased greenhouse gas emissions. This paper proposes a novel predictive maintenance system for steam traps that integrates statistical time series features and transformer encoder–decoder models for fault diagnosis and visualization. The proposed system combines IoT sensor data, operational parameters, open data (e.g., weather information and public holiday calendars), machine learning, and two-dimensional diagnostic projection to improve reliability and interpretability. Experiments were conducted in two industrial plants: an aluminum processing plant and a food manufacturing plant, and the system achieved superior defect detection accuracy and diagnostic reliability compared to existing methods. The transformer-based model outperformed traditional methods, including random forest, gradient boosting, and variational autoencoder, in classification and clustering. The system also demonstrated an average 6.92% reduction in thermal energy across both sites, highlighting its potential to improve energy efficiency and reduce carbon emissions. This research highlights the transformative impact of AI-based predictive maintenance technologies in industrial operations and provides a framework for sustainable manufacturing practices. Full article

Biomass tar, an inevitable byproduct of biomass pyrolysis and gasification, poses a significant challenge due to its tendency to condense in pipelines, causing clogging and operational issues. Catalytic steam reforming can convert tar into syngas, addressing the tar issue while simultaneously producing hydrogen. However, the reforming catalyst is highly susceptible to deactivation by coking, especially when dealing with highly concentrated polymeric hydrocarbons such as tar. This study focused on enhancing the durability of tar-reforming catalysts. Nickel-based catalysts were prepared using carbon supports known for their high coking resistance, such as carbon black (CB), activated carbon (AC), and low-rank coal (LRC). Their performance was then tested for the steam reforming of high-concentration toluene, a representative tar. All three carbon supports (CB, AC, LRC) showed high catalytic performance with NiMg catalysts at 500 °C. Among them, the mesoporous CB support exhibited the highest stability when exposed to steam, with NiMg on CB (NiMg/CB) remaining stable for long-term continuous operation without any deactivation due to coking or thermal degradation. Full article

The SAGP (steam and gas push) process is an effective enhanced oil recovery (EOR) method for heavy oil reservoirs. Understanding the microscopic interactions among steam, non-condensable gasses (NCGs), and heavy oil under reservoir conditions in SAGP processes is important for their EOR applications. In this study, molecular simulations were performed to investigate the microscopic interactions among steam, NCG, and heavy oil under reservoir conditions in SAGP processes. In addition, the microscopic EOR mechanisms during SAGP processes and the effects of operational parameters (NCG type, NCG–steam mole ratio, temperature, and pressure) were discussed. The results show that the diffusion and dissolution of CH₄ molecules and the extraction of steam molecules cause the molecules of saturates with light molecular weights in the oil globules to stretch and gradually detach from one another, resulting in the swelling of heavy oil. Compared with N₂, CH₄ has a stronger ability to diffuse and dissolve in heavy oil, swell the heavy oil, and reduce the density and viscosity of heavy oil. For this reason, compared with cases where N₂ is used, SAGP processes perform better when CH₄ is used, indicating that CH₄ can be used as the injected NCG in the SAGP process to improve heavy oil recovery. As the NCG–steam mole ratio and injection pressure increase, the diffusion and solubility abilities of CH₄ in heavy oil increase, enabling CH₄ to perform better in swelling the heavy oil and reducing the density and viscosity of heavy oil. Hence, increasing the NCG–steam mole ratio and injection pressure is helpful in improving the performance of SAGP processes in heavy oil reservoirs. However, the NCG–steam mole ratio and injection pressure should be reasonably determined based on actual field conditions because excessively high NCG–steam mole ratios and injection pressures lead to higher operation costs. Increasing the temperature is favorable for increasing the diffusion coefficient of CH₄ in heavy oil, swelling heavy oil, and reducing the oil density and viscosity. However, high temperatures can result in intensified thermal motion of CH₄ molecules, reduce the interaction energy between CH₄ molecules and heavy oil molecules, and increase the difference in the Hildebrand solubility parameter between heavy oil and CH₄–steam mixtures, which is unfavorable for the dissolution of CH₄ in heavy oil. This study can help readers deeply understand the microscopic interactions among steam, NCG, and heavy oil under reservoir conditions in SAGP processes and its results can provide valuable information for the actual application of SAGP processes in enhancing heavy oil recovery. Full article