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10th Anniversary of Processes: Design of the Chemical Industry...
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10th Anniversary of Processes: Design of the Chemical Industry of the Future

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Chemical Processes and Systems".

Deadline for manuscript submissions: 31 December 2024 | Viewed by 15974

Special Issue Editor

Prof. Dr. Fausto Gallucci

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Guest Editor
Inorganic Membranes and Membrane Reactors, Sustainable Process Engineering, Department of Chemical Engineering and Chemistry, Eindhoven University of Technology, 5612 AZ Eindhoven, The Netherlands
Interests: Process design and intensification; membranes and membrane reactors; separation
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

We are very proud to celebrate the 10th anniversary of the journal Processes. In light of this occasion, we are launching a Special Issue of the section “Catalysis Enhanced Processes” titled “Design of the chemical industry of the future” and are excited to invite outstanding authors and members of the Editorial Board to submit their papers to this Special Issue. The aim is to celebrate this important anniversary of the journal through exceptional papers fully dedicated to innovative process designs as well as catalytic technologies that will make the chemical industry of the future more sustainable. Academic editors and top authors are invited to submit high-quality papers to this Special Issue.

The subject areas of interest include, but are not limited to, the following:

  • New materials for processes (catalysts, sorbents, membranes etc.);
  • Membrane reactors;
  • Chemical looping systems;
  • Sorption enhanced processes;
  • Microreactor systems;
  • Biobased chemical processes;
  • Additive technologies (3D printing for new processes);
  • Process design;
  • Industry 4.0;
  • LCA;
  • Energy analysis and techno-economics.

Prof. Dr. Fausto Gallucci
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Processes is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

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Published Papers (9 papers)

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Research

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16 pages, 5727 KiB  
Article
Three-Dimensional Morphological Study of MnTe-like Structures by Assessment of Tortuosity Tensor Using Computational Fluid Dynamics
by Giuseppe Prenesti, Edoardo Walter Petrassi, Caterina Guzzo, Silvia Mannella, Francesco Stellato, Laura Crisafulli, Giulia Azzato, Andrea Katovic, Agostino Lauria and Alessio Caravella
Processes 2024, 12(10), 2175; https://doi.org/10.3390/pr12102175 - 7 Oct 2024
Viewed by 902
Abstract
This paper focuses on a morphological study of the MnTe-like structures, carried out by the evaluation of the tortuosity tensor and other related parameters using a computational fluid dynamics approach recently developed by our research group. The present work focuses on all possible [...] Read more.
This paper focuses on a morphological study of the MnTe-like structures, carried out by the evaluation of the tortuosity tensor and other related parameters using a computational fluid dynamics approach recently developed by our research group. The present work focuses on all possible crystals—existing or not developed yet—having the same structure as that of the manganese telluride. This analysis provides new information not present yet in the open literature. The motivation behind this study lies in the importance of this type of structure in physics and material science. In particular, the structures investigated are anisotropic and bi-disperse, with two independent geometrical parameters controlling the structure shape: the ratio of the particle diameters (r1) and the normalised inter-particle distance (r2). Exploiting this fact, several different structures of the same family are created, changing these two parameters independently, also allowing inter-penetration of particles to enlarge the study’s applicability. The results are primarily obtained in terms of the tortuosity tensor, needed to catch and quantify the anisotropy of the structures. Then, other morphological parameters, such as connectivity, principal diffusion directions, and anisotropy factors, are evaluated, obtaining in this way a novel morphological characterisation of the structure. It is found that high values of tortuosity are observed at lower and higher values of {r1, r2}, which means that there exists a minimum value between them. Additionally, the anisotropy factor is found to be higher at lower values of {r1, r2} and lower at higher ones. This is in accordance with the fact that, as the inter-particle distance and the ratio between particle diameters increase, the structure enlarges, which implies a lower influence of the particle distribution and, thus, a gradually more isotropic structure. Full article
(This article belongs to the Special Issue 10th Anniversary of Processes: Design of the Chemical Industry of the Future)
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14 pages, 3399 KiB  
Article
Metal-Nitrate-Catalyzed Levulinic Acid Esterification with Alkyl Alcohols: A Simple Route to Produce Bioadditives
by Márcio José da Silva and Mariana Teixeira Cordeiro
Processes 2024, 12(9), 1802; https://doi.org/10.3390/pr12091802 - 24 Aug 2024
Viewed by 1068
Abstract
This work developed an efficient route to produce fuel bioadditive alkyl levulinates. Special attention was paid to butyl levulinate, which is a bioadditive with an adequate carbon chain size to be blended with liquid fuels such as diesel or gasoline. In this process, [...] Read more.
This work developed an efficient route to produce fuel bioadditive alkyl levulinates. Special attention was paid to butyl levulinate, which is a bioadditive with an adequate carbon chain size to be blended with liquid fuels such as diesel or gasoline. In this process, levulinic acid was esterified with butyl alcohol using cheap and commercially affordable metal nitrates as catalysts, producing bioadditives at more competitive costs. Iron (III) nitrate was the most active and selective catalyst toward butyl levulinate among the salts evaluated. In solvent-free conditions, with a low molar ratio and catalyst load (1:6 acid to alcohol, 3 mol% of Fe (NO3)3), conversion and selectivity greater than 90% after an 8 h reaction was achieved. A comparison of the iron (III) nitrate with other metal salts demonstrated that its superior performance can be assigned to the highest Lewis acidity of Fe3+ cations. Measurements of pH allow the conclusion that a cation with high Lewis acidity led to a greater H+ release, which results in a higher conversion. Butyl levulinate and pseudobuty levulinate were always the primary and secondary products, respectively. The consecutive character of reactions between butyl alcohol and levulinic acid (formation of the pseudobutyl levulinate and its conversion to butyl levulinate) was verified by assessing the reactions at different temperatures and conversion rates. A variation in Fe(NO3)3 catalyst load impacted the conversion much more than reaction selectivity. The same effect was verified when the reactions were carried out at different temperatures. The reactivity of alcohols with different structures depended more on steric hindrance on the hydroxyl group than the size of the carbon chain. A positive aspect of this work is the use of a commercial iron nitrate salt as the catalyst, which has advantages over traditional mineral acids such as sulfuric and hydrochloric acids. This solid catalyst is not corrosive and avoids neutralization steps after reactions, minimizing the generation of residues and effluents. Full article
(This article belongs to the Special Issue 10th Anniversary of Processes: Design of the Chemical Industry of the Future)
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15 pages, 1935 KiB  
Article
Carbon Molecular Sieve Membrane Reactors for Ammonia Cracking
by Valentina Cechetto, Gaetano Anello, Arash Rahimalimamaghani and Fausto Gallucci
Processes 2024, 12(6), 1168; https://doi.org/10.3390/pr12061168 - 6 Jun 2024
Viewed by 1564
Abstract
The utilization of ammonia for hydrogen storage relies on the implementation of efficient decomposition techniques, and the membrane reactor, which allows simultaneous ammonia decomposition and hydrogen recovery, can be regarded as a promising technology. While Pd-based membranes show the highest performance for hydrogen [...] Read more.
The utilization of ammonia for hydrogen storage relies on the implementation of efficient decomposition techniques, and the membrane reactor, which allows simultaneous ammonia decomposition and hydrogen recovery, can be regarded as a promising technology. While Pd-based membranes show the highest performance for hydrogen separation, their applicability for NH3-sensitive applications, such as proton exchange membrane (PEM) fuel cells, demands relatively thick, and therefore expensive, membranes to meet the purity targets for hydrogen. To address this challenge, this study proposes a solution involving the utilization of a downstream hydrogen purification unit to remove residual ammonia, thereby enabling the use of less selective, therefore more cost-effective, membranes. Specifically, a carbon molecular sieve membrane was prepared on a tubular porous alumina support and tested for ammonia decomposition in a membrane reaction setup. Operating at 5 bar and temperatures ranging from 450 to 500 °C, NH3 conversion rates exceeding 90% were achieved, with conversion approaching thermodynamic equilibrium at temperatures above 475 °C. Simultaneously, the carbon membrane facilitated the recovery of hydrogen from ammonia, yielding recoveries of 8.2–9.8%. While the hydrogen produced at the permeate side of the reactor failed to meet the purity requirements for PEM fuel cell applications, the implementation of a downstream hydrogen purification unit comprising a fixed bed of zeolite 13X enabled the production of fuel cell-grade hydrogen. Despite performance far from being comparable with the ones achieved in the literature with Pd-based membranes, this study underscores the viability of carbon membranes for fuel cell-grade hydrogen production, showcasing their competitiveness in the field. Full article
(This article belongs to the Special Issue 10th Anniversary of Processes: Design of the Chemical Industry of the Future)
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15 pages, 8456 KiB  
Article
Combining Solution-Blowing and Melt-Blowing Techniques to Produce an Efficient Non-Woven Filter
by Agata Penconek, Łukasz Werner and Arkadiusz Moskal
Processes 2024, 12(5), 857; https://doi.org/10.3390/pr12050857 - 24 Apr 2024
Cited by 2 | Viewed by 930
Abstract
New substances and particles appearing in the environment following technological development pose new challenges for separation methods. Moreover, the growing amount of waste also forces us to look for environmentally friendly solutions. One way to create filtration structures with the desired properties is [...] Read more.
New substances and particles appearing in the environment following technological development pose new challenges for separation methods. Moreover, the growing amount of waste also forces us to look for environmentally friendly solutions. One way to create filtration structures with the desired properties is to combine known techniques, thanks to which the advantages of one technique complement the deficiencies and disadvantages of another. Combining the melt-blowing and solution-blowing processes seems to be promising. Fibres created from melt-blowing will provide mechanical strength, while solution-blowing will allow the introduction of nanofibres into the structure with unique filtration and functional properties. Both methods enable working with biodegradable polymers, so the resulting filter can also be environmentally friendly after operation. Our research aimed to check whether combining two fibre production techniques (melt-blown and solution-blowing) is possible and how the joining method will affect the final product. We created a multilayer structure by placing a layer of solution-blowing nanofibres between melt-blown layers, and a mixed structure by simultaneous melt-blowing and solution-blowing. The created multilayer structure was characterised by high filtration efficiency and high-pressure drop. In contrast, the mixed structure achieved a high-quality factor and high mass of deposited droplets per 1 J of energy used for work. Full article
(This article belongs to the Special Issue 10th Anniversary of Processes: Design of the Chemical Industry of the Future)
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23 pages, 2745 KiB  
Article
Resolved Simulation of the Clarification and Dewatering in Decanter Centrifuges
by Helene Katharina Baust, Simon Hammerich, Hartmut König, Hermann Nirschl and Marco Gleiß
Processes 2024, 12(1), 9; https://doi.org/10.3390/pr12010009 - 19 Dec 2023
Cited by 1 | Viewed by 1430
Abstract
Solid–liquid separation is a fundamental operation in process engineering and thus an important part of many process chains in the preparation of slurries in the chemical industry and other parts of the industrial environment. For the separation of micron-sized particles which, due to [...] Read more.
Solid–liquid separation is a fundamental operation in process engineering and thus an important part of many process chains in the preparation of slurries in the chemical industry and other parts of the industrial environment. For the separation of micron-sized particles which, due to their size, do not settle or settle very slowly in the earth’s gravity field, centrifuges are often used. The preferred choice are often decanter centrifuges because they work continuously and stabilize the process against product fluctuations due to their adjustment possibilities. The design of the apparatus is complex: The main components of the apparatus are the cylindrical-conical bowl, which rotates at a high speed, and a screw located inside the bowl, which rotates in the same direction at a low differential speed to transport the separated solids out of the apparatus. Geometrical properties of the apparatus, as well as the adjustable operating parameters, such as rotational speed or differential speed, have a significant influence on the separation. In practice, analytical models and the experience of the manufacturers form the basis for the design. Characteristics of the disperse phase, interactions with the liquid, as well as the influence of the flow on the separation, are not taken into account. As a consequence, the transfer to industrial scale always requires a large number of pilot-scale experiments, which are time-consuming and expensive. Due to the increasing computational power, computational fluid dynamics (CFD) provides one possibility to minimize the experimental effort in centrifuge design. In this work, the open-source software OpenFOAM is used to simulate the multi-phase flow in a laboratory decanter centrifuge. For validation, experiments were carried out on a laboratory scale and the main operating parameters, such as speed, differential speed, and volume flow rate, were varied. The simulation results show a good agreement with the experimental data. Furthermore, the numerical investigations show the influence of the flow on the separation of the particles. To evaluate the transportability of a material, the transport efficiency was introduced as a dimensionless parameter. In addition, the simulation allows the consideration of the individual velocity components, making it possible to generate an impression of the complex three-dimensional flow in the apparatus for the first time. Full article
(This article belongs to the Special Issue 10th Anniversary of Processes: Design of the Chemical Industry of the Future)
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9 pages, 1695 KiB  
Communication
Microwave-Assisted Reductive Amination under Heterogeneous Catalysis for the Synthesis of β-Adrenergic Agonist and Related Structures
by Fabio Bucciol, Mariachiara Colia, Erica Canova, Giorgio Grillo, Emanuela Calcio Gaudino and Giancarlo Cravotto
Processes 2023, 11(9), 2602; https://doi.org/10.3390/pr11092602 - 31 Aug 2023
Viewed by 1355
Abstract
Reductive amination is a powerful tool in sustainable organic synthesis that allows chemists to access a wide range of valuable amine products using renewable feedstocks and mild reaction conditions, with minimal waste generation. Practical applications can be found in various fields, including pharmaceuticals, [...] Read more.
Reductive amination is a powerful tool in sustainable organic synthesis that allows chemists to access a wide range of valuable amine products using renewable feedstocks and mild reaction conditions, with minimal waste generation. Practical applications can be found in various fields, including pharmaceuticals, contributing to greener and more sustainable chemical processes. In this work, we present a heterogeneous (Rh and Pt) catalyzed protocol for the fast and efficient synthesis of ractopamine hydrochloride (β-adrenergic drug) under microwave-assisted reductive amination protocol starting from raspberry ketone and octopamine. Microwave (MW) successfully accelerated the hydrogenation reaction and reduced the reaction time from 13 h to only 3 h under mild conditions (50 °C at 10 bar). The best catalysts were Pt/C and Rh/C, which led to high conversion and selectivity towards ractopamine:HCl. Different solvents and ketone substrates were also experimented. Acetophenone, cyclohexanone, and 2-butanone reacted at lower H2 pressure (5 bar), and highest selectivity was observed with cyclohexanone (99%). These preliminary experiments may be useful for further process improvements in the synthesis of β-adrenergic agonists and related structures and underline the positive synergy between MW and heterogeneous catalysis. Full article
(This article belongs to the Special Issue 10th Anniversary of Processes: Design of the Chemical Industry of the Future)
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16 pages, 4366 KiB  
Article
NiCoAl-Based Monolithic Catalysts for the N2O Intensified Decomposition: A New Path towards the Microwave-Assisted Catalysis
by Olga Muccioli, Eugenio Meloni, Simona Renda, Marco Martino, Federico Brandani, Pluton Pullumbi and Vincenzo Palma
Processes 2023, 11(5), 1511; https://doi.org/10.3390/pr11051511 - 16 May 2023
Cited by 2 | Viewed by 1601
Abstract
Nitrous oxide (N2O) is considered the primary source of NOx in the atmosphere, and among several abatement processes, catalytic decomposition is the most promising. The thermal energy necessary for this reaction is generally provided from the external side of the [...] Read more.
Nitrous oxide (N2O) is considered the primary source of NOx in the atmosphere, and among several abatement processes, catalytic decomposition is the most promising. The thermal energy necessary for this reaction is generally provided from the external side of the reactor by burning fossil fuels. In the present work, in order to overcome the limits related to greenhouse gas emissions, high heat transfer resistance, and energy losses, a microwave-assisted N2O decomposition was studied, taking advantages of the microwave’s (MW) properties of assuring direct and selective heating. To this end, two microwave-susceptible silicon carbide (SiC) monoliths were layered with different nickel–cobalt–aluminum mixed oxides. Based on the results of several characterization analyses (SEM/EDX, BET, ultrasound washcoat adherence tests, Hg penetration technique, and TPR), the sample showing the most suitable characteristics for this process was reproduced in the appropriate size to perform specific MW-assisted catalytic activity tests. The results demonstrated that, by coupling this catalytic system with an opportunely designed microwave heated reactor, it is possible to reach total N2O conversion and selectivity of a highly concentrated N2O stream (50 vol%) at T = 550 °C, the same required in the conventionally heated process to remove N2O from a less concentrated gas stream (20 vol%). Full article
(This article belongs to the Special Issue 10th Anniversary of Processes: Design of the Chemical Industry of the Future)
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Review

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26 pages, 8128 KiB  
Review
Recent Progress in Fill Media Technology for Wet Cooling Towers
by Zahra Hashemi, Abdolmajid Zamanifard, Maysam Gholampour, Jane-Sunn Liaw and Chi-Chuan Wang
Processes 2023, 11(9), 2578; https://doi.org/10.3390/pr11092578 - 28 Aug 2023
Cited by 3 | Viewed by 4008
Abstract
Cooling towers are extensively utilized in diverse industries for efficient heat dissipation. Fill media are a critical component, facilitating heat and mass exchange between water and air, impacting overall cooling tower efficiency. Given its vital importance, this study comprehensively reviews recent advancements in [...] Read more.
Cooling towers are extensively utilized in diverse industries for efficient heat dissipation. Fill media are a critical component, facilitating heat and mass exchange between water and air, impacting overall cooling tower efficiency. Given its vital importance, this study comprehensively reviews recent advancements in fill media technology, illuminating cooling tower technology progress and exploring the effects of different fill media configurations and materials on cooling tower performance. It should be noted that the majority of research is focused on the Range of 2.5 °C to 25 °C and Approach of 1 °C to 9 °C. Through comprehensive analysis and evaluation, the effects of various fill media on heat transfer efficiency, water cooling capacity, and energy consumption are intensively summarized. By understanding these effects, engineers and designers can make rational decisions to optimize cooling tower performance and ensure efficient heat dissipation. Notably, in some reported cases, new fill media enhanced cooling range, effectiveness, and the Merkel number by 28%, 85%, and 131%, respectively. Ultimately, this paper serves as a valuable resource for academics, researchers, and professionals in the field of cooling tower design and thermal management. The insights provided in this study can help industries achieve greater energy efficiency, sustainability, and overall operational excellence. Full article
(This article belongs to the Special Issue 10th Anniversary of Processes: Design of the Chemical Industry of the Future)
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14 pages, 2065 KiB  
Review
Alternative Electron Sources for Cytochrome P450s Catalytic Cycle: Biosensing and Biosynthetic Application
by Victoria V. Shumyantseva, Polina I. Koroleva, Tatiana V. Bulko and Lyubov E. Agafonova
Processes 2023, 11(6), 1801; https://doi.org/10.3390/pr11061801 - 13 Jun 2023
Cited by 2 | Viewed by 1588
Abstract
The functional significance of cytochrome P450s (CYP) enzymes is their ability to catalyze the biotransformation of xenobiotics and endogenous compounds. P450 enzymes catalyze regio- and stereoselective oxidations of C-C and C-H bonds in the presence of oxygen as a cosubstrate. Initiation of cytochrome [...] Read more.
The functional significance of cytochrome P450s (CYP) enzymes is their ability to catalyze the biotransformation of xenobiotics and endogenous compounds. P450 enzymes catalyze regio- and stereoselective oxidations of C-C and C-H bonds in the presence of oxygen as a cosubstrate. Initiation of cytochrome P450 catalytic cycle needs an electron donor (NADPH, NADH cofactor) in nature or alternative artificial electron donors such as electrodes, peroxides, photo reduction, and construction of enzymatic “galvanic couple”. In our review paper, we described alternative “handmade” electron sources to support cytochrome P450 catalysis. Physical-chemical methods in relation to biomolecules are possible to convert from laboratory to industry and construct P450-bioreactors for practical application. We analyzed electrochemical reactions using modified electrodes as electron donors. Electrode/P450 systems are the most analyzed in terms of the mechanisms underlying P450-catalyzed reactions. Comparative analysis of flat 2D and nanopore 3D electrode modifiers is discussed. Solar-powered photobiocatalysis for CYP systems with photocurrents providing electrons to heme iron of CYP and photoelectrochemical biosensors are also promising alternative light-driven systems. Several examples of artificial “galvanic element” construction using Zn as an electron source for the reduction of Fe3+ ion of heme demonstrated potential application. The characteristics, performance, and potential applications of P450 electrochemical systems are also discussed. Full article
(This article belongs to the Special Issue 10th Anniversary of Processes: Design of the Chemical Industry of the Future)
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