Editorial Overview of the Special Issue “Innovation in Chemical Plant Design”

Innovation in chemical plant design stands at the forefront of transformative advancements in the dynamic field of chemical engineering [1]. The intricate process of designing and constructing chemical plants holds pivotal significance, as it fundamentally governs the trifecta of efficiency, safety, and environmental sustainability within the realm of chemical manufacturing operations. Over the course of years, this field has borne witness to a striking metamorphosis, catalyzed by an intricate interplay of factors including the evolution of stringent safety standards, increasingly demanding environmental regulations, shifting market dynamics, and the advent of groundbreaking technological marvels [2,3,4].

From the pioneering embrace of process intensification and modular design principles to the seamless integration of cutting-edge automation, data analytics, and sustainability-centric solutions, the landscape of chemical plant design has undergone profound evolution. This evolution is an ardent response to the multifaceted challenges and golden opportunities in the contemporary era. The papers presented in this Special Issue provide a vivid and dynamic panorama of innovative approaches, breakthrough technologies, and groundbreaking methodologies that are actively shaping the future of chemical plant design. Collectively, they pave the way for the realization of chemical processes that are not only more efficient and competitive but also significantly more sustainable, in alignment with the pressing needs of our modern world.

The topics involved in this Special Issue concern different fields of applications, such as the production of drug delivery systems, textile technologies, spray drying, extraction, active packaging, land surface temperature monitoring, microelectronics industry, neural networks, sustainability indicators, economics, and drug release modeling. A brief description of these topics is provided in the following paragraphs.

The field of pharmaceutical and biomedical research continues to push the boundaries of innovation and precision to develop novel drug delivery systems that can revolutionize medical treatments [5]. Among these groundbreaking endeavors, the production of liposomes loaded with antibodies using a supercritical fluid-assisted process is a pivotal pursuit [6]. This intricate undertaking involves a meticulous optimization process, wherein researchers embark on a journey to masterfully adjust various critical variables. These variables include temperature, pressure, flow rates, and the composition of supercritical fluids, all of which play important roles in shaping the outcome of this cutting-edge technique. Through rigorous and systematic experimentation coupled with comprehensive data analysis, researchers are committed to achieving a delicate equilibrium that yields liposomal formulations of the utmost quality. The promise of this endeavor extends far beyond the laboratory, holding the potential to enhance therapeutic outcomes and deepening our comprehension of the transformative power of supercritical fluid technology in the realm of drug delivery applications. The production of liposomes loaded with antibodies via a supercritical fluid-assisted process is a crucial endeavor in pharmaceutical and biomedical research. This complex optimization process involves meticulously fine-tuning various variables, such as temperature, pressure, flow rates, and the composition of supercritical fluids. Using systematic experimentation and data analysis, researchers strive to strike a delicate balance that yields the highest quality liposomal formulations, promising improved therapeutic outcomes and a deeper understanding of the potential of supercritical fluid technology in drug delivery applications.

Supercritical fluid technologies can be used to produce liposomes loaded with various compounds. Supercritical fluids, often carbon dioxide in a supercritical state, offer a unique set of properties that make them ideal for liposome production [7]. In their supercritical state, these fluids exhibit both gas-like and liquid-like properties, enabling precise control over critical parameters such as temperature and pressure. This level of control is paramount for crafting liposomal formulations with exceptional precision and consistency. The beauty of supercritical fluid technology lies in its ability to serve as a clean and green solvent, eliminating the need for toxic organic solvents typically used in traditional liposome production methods. This not only enhances the safety of the process but also aligns with sustainability goals by reducing the environmental impact. Furthermore, the versatility of supercritical fluids allows researchers to encapsulate a wide array of compounds within the liposomes. The controlled expansion of supercritical solutions into aqueous phases or other suitable media facilitates liposome formation. This controlled encapsulation process ensures high encapsulation efficiency, uniform liposome size distribution, and enhanced stability of the loaded compounds.

The utilization of supercritical fluid technologies to produce liposomes loaded with diverse compounds represents a pivotal convergence of science and technology, offering a promising pathway for the development of advanced, efficient, and environmentally friendly drug delivery systems and other innovative products across multiple industries. This approach not only enhances the precision and sustainability of liposome production but also expands the horizons of what can be achieved in the realms of pharmaceuticals, biotechnology, and beyond. In particular, the supercritical-assisted production of lutein-loaded liposomes and the modeling of drug release represent an innovative approach in drug delivery systems [8]. Moreover, modeling the drug release kinetics is essential to predict and control the release profile over time. This combination of supercritical technology and drug release modeling not only enhances the precision and efficiency of drug delivery but also opens avenues for the development of targeted and patient-specific therapies, promising significant advancements in the pharmaceutical field. However, supercritical-assisted processes need to be evaluated in terms of sustainability. The environmental and sustainability analysis of supercritical carbon dioxide (scCO₂)-assisted processes for pharmaceutical applications is a crucial aspect of modern drug manufacturing. The analysis encompasses various factors, including energy consumption, waste generation, and overall process efficiency. By evaluating these parameters, it was possible to quantify the environmental benefits, such as reduced greenhouse gas emissions and waste disposal costs, associated with scCO₂-based processes.

The incorporation of antibacterial properties via enhanced natural dyeing processes not only adds value to textiles but also extends their potential applications to innovative therapeutics, where infection control and patient comfort are of paramount importance. The enhanced natural dyeing and antibacterial properties of cotton using physical and chemical pretreatments represent significant advancements in textile technology. This innovation not only offers sustainable alternatives to synthetic dyes but also addresses hygiene concerns, making cotton fabrics ideal for various applications, including healthcare and fashion. These combined advancements underscore the potential of interdisciplinary research at the intersection of textiles, chemistry, and microbiology, opening doors to more environmentally friendly and versatile cotton-based products in the market.

Spray-drying and extraction processes are also objects of this issue. Spray-drying and extraction processes are closely intertwined in the field of chemical engineering, as spray-drying can be employed to extract valuable compounds from various substances, making them integral steps in the development of many products and materials. Understanding the mechanism of particle agglomeration in spray drying, particularly in the context of both single- and multi-nozzle atomization techniques, is a critical topic explored in various research studies. Insights gained from such studies contribute significantly to optimizing spray-drying processes for a wide range of applications, including the production of powders, pharmaceuticals, and food products, ultimately leading to improved product quality and process efficiency. The high-performance extraction process of anthocyanins represents a promising approach in the field of natural product extraction and bioactive compound recovery. This methodology not only ensures the preservation of the integrity and bioactivity of the extracted compounds but also aligns with the principles of green chemistry and sustainable extraction practices.

This Special Issue began with topics regarding purely therapeutic approaches and continued with the definition and description of innovative ways of food preservation. The optimization of poly(ε-caprolactone) loaded with alpha-tocopherol polymeric films as an active packaging component via a combination of green processes represents a significant advancement in sustainable packaging technology. The resulting active packaging material offers effective protection against the oxidative degradation of packaged goods while minimizing the environmental footprint associated with conventional packaging processes, emphasizing the importance of green chemistry and sustainable practices in the packaging industry.

Other topics are related to the advancement of the integration of remote sensing and microelectronics industries. Earth observations can mitigate the limitations of each sensor individually and produce a more reliable representation of the surface temperature across different landscapes. This evaluation not only enhances our ability to monitor and understand the dynamics of land surface temperature but also contributes to various applications, including agriculture, urban planning, and climate change studies, and provides a more robust and comprehensive Earth observation dataset. In the microelectronics industry, joints serve as critical connections within electronic devices, and their integrity directly influences the overall performance and durability of the components. The evaluation of the interfacial microstructure involves examining the composition, morphology, and distribution of the phases at the solder-to-substrate interface. This assessment is pivotal for understanding the bonding mechanisms and potential issues like intermetallic compound formation, preventing premature failure in electronic devices, and maintaining their functionality throughout their intended lifespan.

The classification of graphite based on an improved Convolutional Neural Network (CNN) represents a cutting-edge approach in material science and image analysis. The use of CNNs, a type of deep learning algorithm, allows researchers to train models capable of recognizing subtle differences in graphite morphology, layering, and other important features. This innovative approach not only expedites material identification but also contributes to advancements in fields such as energy storage, lubrication, and composite materials by facilitating precise material selection and quality control.

The techno-economics of gas-to-liquid (GTL) processes for the associated natural gas, biogas, and landfill gas are pivotal in the realm of energy and environmental sustainability. These GTL technologies provide a viable solution to harness and convert these gas resources into valuable liquid fuels, such as diesel or synthetic crude oil. The economic analysis involves assessing the capital investment, operating costs, and revenue potential associated with each gas feedstock, considering factors like gas composition, availability, and market demand.

In conclusion, innovation in chemical plant design is a dynamic and essential aspect of the chemical engineering landscape. It is clear from the various innovative approaches and technologies discussed that the industry is continuously evolving to meet the challenges of safety, sustainability, and efficiency. The adoption of modular design, process intensification, digitalization, and sustainable practices all contribute to a more resilient and competitive chemical manufacturing sector. These innovations not only improve the economic viability of chemical processes but also reduce environmental impacts and enhance safety standards. However, it is important to emphasize that innovation should not be viewed as a one-time effort but rather as an ongoing commitment to staying at the cutting edge of technology and best practices. The future of chemical plant designs holds tremendous promise. By embracing innovative approaches and technologies, the chemical engineering community is poised to create safer, more sustainable, and economically viable chemical processes that meet the ever-evolving needs of society while minimizing their environmental footprint. This journey of innovation is not only exciting but also imperative in the pursuit of a more sustainable and prosperous future for the chemical industry and our planet.

In conclusion, this insightful analysis underscores the dynamic and indispensable nature of innovation in chemical plant design within the broader landscape of chemical engineering. It is evident from the diverse array of innovative approaches and cutting-edge technologies discussed that the industry is in a perpetual state of evolution, driven by the imperatives of safety, sustainability, and efficiency. The strategic embrace of modular design principles, the implementation of process intensification strategies, the integration of digitalization, and the promotion of sustainable practices collectively contribute to forging a chemical manufacturing sector that is not only robust but also highly competitive. One notable aspect of these innovations is their potential to yield significant economic benefits concurrently with their capacity to mitigate environmental impacts and elevate safety standards. This dual focus on profitability and responsibility reflects a conscientious commitment to balancing progress with ethical stewardship. However, it is paramount to emphasize that innovation should not be perceived as a one-time endeavor but rather as an enduring dedication to remaining at the forefront of technological advancements and best practices. The ever-evolving nature of science and technology necessitates a perpetual quest for improvement to keep chemical engineers vigilant and adaptable in the face of new challenges and opportunities.

The future of chemical plant design is promising, holding the potential to reshape the landscape of industrial chemistry [9,10]. By embracing innovative approaches and cutting-edge technologies, the chemical engineering community stands poised to usher in a new era of safer, more sustainable, and economically viable chemical processes. This transformation is vital not only for meeting the evolving demands of society but also for minimizing the environmental footprint of the industry, thereby contributing to a more sustainable and prosperous future for both the chemical sector and our planet. The journey of innovation is not only exciting but also imperative as we strive for harmonious coexistence with our environment and seek solutions that benefit both industry and society.

List of Contributions

• Ennaceur, S.; Bouaziz, A.; Gargoubi, S.; Mnif, W.; Dridi, D. Enhanced Natural Dyeing and Antibacterial Properties of Cotton by Physical and Chemical Pretreatments. Processes 2022, 10, 2263.
• Trucillo, P.; Martino, M.; Reverchon, E. Supercritical assisted production of lutein-loaded liposomes and modelling of drug release. Processes 2021, 9, 1162.
• Zbicinski, I.; Ciesielski, K.; Ge, B. Mechanism of particle agglomeration for single and multi-nozzle atomization in spray drying: a review. Processes 2022, 10, 727.
• Vannuchi, N.; Braga, A.R.C.; De Rosso, V.V. High-performance extraction process of anthocyanins from jussara (Euterpe edulis) using deep eutectic solvents. Processes 2022, 10, 615.
• Drago, E.; Campardelli, R.; Marco, I.D.; Perego, P. Optimization of PCL polymeric films as potential matrices for the loading of alpha-tocopherol by a combination of innovative green processes. Processes 2021, 9, 2244.
• Li, S.; Wang, J.; Li, D.; Ran, Z.; Yang, B. Evaluation of Landsat 8-like land surface temperature by fusing Landsat 8 and MODIS land surface temperature product. Processes 2021, 9, 2262.
• Chen, C.; Wang, C.; Sun, H.; Yin, H.; Gao, X.; Xue, H., Ni, B; Bian, K.; Gu, Q. Interfacial microstructure and mechanical reliability of Sn-58Bi/ENEPIG solder joints. Processes 2022, 10, 295.
• Liu, G.; Xu, X.; Yu, X.; Wang, F. Graphite classification based on improved convolution neural network. Processes 2021, 9, 1995.
• Trucillo, P.; Campardelli, R.; De Marco, I. Environmental and Sustainability Analysis of a Supercritical Carbon Dioxide-Assisted Process for Pharmaceutical Applications. Processes 2021, 9, 1788.
• Galli, F.; Lai, J.J.; De Tommaso, J.; Pauletto, G.; Patience, G.S. Gas to liquids techno-economics of associated natural gas, biogas, and landfill gas. Processes 2021, I, 1568.