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    28 October 2021, Volume 21 Issue 10
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    Contents
    Cover and Contents
    The Chinese Journal of Process Engineering. 2021, 21(10):  0. 
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    Reviews
    A review on the approaches to the production of vanadium metal
    Weiliang LU Ying ZHANG Pei SUN Shili ZHENG Shan QIAO Yang ZHANG Ping LI Yi ZHANG
    The Chinese Journal of Process Engineering. 2021, 21(10):  1117-1131.  DOI: 10.12034/j.issn.1009-606X.220294
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    Vanadium metal, known as "industrial monosodium glutamate", is widely used in the fields of metallurgy, chemical engineering, aviation, energy, atomic energy, etc. Vanadium belongs to the rare reactive metals with a high melting point, and its production is difficult and costly. Currently, the main route for the production of high-purity V is the combination of the aluminothermic reduction of vanadium oxide and the vacuum melting purification of the crude V; however, this route is energy-intensive and low-yield. In order to reduce the production cost of metallic vanadium, many approaches to the production of crude vanadium have been proposed based on the thermodynamic stability of vanadium oxides and vanadium chlorides, including calciothermic reduction, magnesiothermic reduction, vacuum carbothermic reduction, silicothermic reduction, carbothermic reduction-nitridation-nitride thermal decomposition, molten salt electrolytic deoxidation, etc. The developed refining approaches includes molten salt electrolytic refining, iodide thermal decomposition, solid-state electro-transport purification, etc. This paper reviews the above methods comprehensively in terms of principles, technical features, effectiveness, and drawbacks. It is expected that this review will provide important guidance for the development and upgrading of the approaches for the production of high-purity V metal. It is believed that the application of vanadium will continue to expand with the achievement of high-end materials, which no doubt promotes the development of high-purity metallic vanadium production industry.
    Progress in numerical simulation of liquid-liquid cyclone separator
    Yanni CHI Xianghai MENG Rui ZHANG Haiyan LIU Zhichang LIU
    The Chinese Journal of Process Engineering. 2021, 21(10):  1132-1141.  DOI: 10.12034/j.issn.1009-606X.220262
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    The cyclone separator is a liquid-liquid separation device that has been developed very rapidly in recent years. The main advantages of cyclone separators are high efficiency, energy saving, economic space occupation, and low cost. It is widely used in such industries as mineral processing and metallurgy, sewage treatment, food, paper making, and petroleum chemistry. Therefore, it is particularly important to study the relevant characteristics of the cyclone separator. Besides, numerical simulation is an important method for the development and research of liquid-liquid cyclone separators. This work systematically introduced the research progress of the numerical simulation of liquid-liquid cyclone separators, where the effects of the selection of cyclone separator model, the variation of geometric structure (including the inlet, the cone section, the overflow pipe, the guide vane and the cylindrical section) and operating parameters (including the split ratio, the total flow and the feed ratio) on the separation efficiency as well as the flow field were analyzed, and the final evaluation indices (including the separation efficiency and the pressure drop) were also proposed. Besides, some opinions on the change of geometrical structure and operating parameters influencing the separation efficiency and the pressure drop were provided, and the numerical simulation of the vortex and the droplet breaking and coalescing, as well as the development of new separation efficiency evaluation formulas were prospected. New ideas for the following up research workers of the cyclone separator were provided.
    Theory of chemical reaction engineering on catalytic decomposition of propellant in packed bed for monopropellant thruster
    Baolin HOU Xue LI Wentao WANG Ting LU Weimin CONG Haolong WANG Deyang GAO Chuande HUANG Jihong SHAN Liangen XIA Xiaodong WANG Tao ZHANG
    The Chinese Journal of Process Engineering. 2021, 21(10):  1142-1155.  DOI: 10.12034/j.issn.1009-606X.220304
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    In 1960s, after the hydrazine based chemical monopropellant was developed, the liquid monopropellant technology has been widely applied in controlling the trajectory of satellite, adjusting the attitude of rocket and the emergency power supply. It is critical for chemical monopropellant to catalytically decompose the high energy liquid chemical propellant in the packed bed of particles. However, up to now, the kind of propellant technology had still been developed by performing a great deal of experiments under the direction of theoretical basement of thermal energy and air dynamics engineering and without considering from the viewpoint of chemical reaction engineering. In this work, from the viewpoint of chemical reaction engineering, the chemical engineering thermodynamics, the catalytic reaction kinetics, the diffusion-reaction in a single catalyst particle, the flow-reaction in the pore of porous catalyst, the flow-transport phenomena-reaction in the macroscopic porous media of packed bed and the meso-scale complicated geometry structure formed by the catalyst particles randomly stacking to be used in designing the component of propellant, optimizing the catalyst structure and the decomposition packed bed of monopropellant thruster were discussed. The review provides the fundamental theory of catalytic reaction engineering for designing, which is hoped as the theoretical direction for designing the propellant component, synthesizing the catalyst structure and the decomposition packed bed in developing the new green chemical monopropellant technology.
    Research progress in preparation of large pore pseudoboehmite and γ-Al2O3 carrier
    Yongjia YANG Xinsheng ZHANG Jin LI Chunguang ZHANG Yuansheng ZHAO Shili ZHENG Ping LI
    The Chinese Journal of Process Engineering. 2021, 21(10):  1156-1166.  DOI: 10.12034/j.issn.1009-606X.220368
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    γ?Al2O3 is widely used as catalyst carrier in petroleum processing realm, owing to its porosity, high dispersibility, adjustable surface acid/base characteristics, attractive mechanical properties and good thermal stability. As the quality of crude oil is increasingly heavy and inferior, more and more attention has been paid on the preparation of macro-mesostructured γ?Al2O3 since the γ?Al2O3 as the catalysts carrier, that used in the heavy oil processing, such as fixed-bed residue hydrotreating or RFCC, need more meso-and macroporous structures to reduce the internal diffusion resistance of large molecules and improve the catalytic activity. Commonly, pseudoboehmite as the raw materials turns decisive significance for the physiochemical properties of γ?Al2O3. For instance, the pore properties of γ?Al2O3 are greatly in?uenced by the size and morphology of pseudoboehmite crystallites and their aggregation. This manuscript thus reviewed the representative preparation methods of pseudoboehmite including precipitation method and aluminium alkoxide hydrolysis method. The advances of Al2(SO4)3?NaAlO2 method and carbonization method, as two main industrial technologies, were emphatically introduced. New reactors and technologies for the precipitation were developed in order to provide su?cient mixing intensity and recirculation of different reactants, which could bring about a homogeneous supersaturation distribution in the instantaneous neutralization reaction, and then lead to uniform crystallites size, thereby pseudoboehmite with large pore volume and narrow pore size distribution. Besides, the relative meso??and macroporous structures control technologies were also highlighted, such as pH swing method, pore-enlarging additives method, and hydrothermal treatment method, etc. The advantages and disadvantages of these methods were also briefly analyzed. At last, the development trend was introduced and some suggestions were proposed.
    Flow & Transfer
    Simulation of gas-liquid two-phase flow and atomization characteristics of Y-type nozzle for heavy oil burner
    Zhiqi WANG Liuming CHEN Bingying XIAO Baoqi XIE
    The Chinese Journal of Process Engineering. 2021, 21(10):  1167-1176.  DOI: 10.12034/j.issn.1009-606X.220336
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    Heavy oil burner is the key component of asphalt mixing equipment. However, heavy oil is not easy to atomize due to its high viscosity and surface tension, which results in low combustion efficiency and high pollutant discharge in heavy oil burners. Y-type atomizing nozzle is widely used in heavy oil atomization because of its simple structure and wide adjustment range. A large number of experiments and simulations were carried out on the atomization characteristics of heavy oil. However, the existing research only analyzed the atomization characteristics from the aspects of structure or atomization parameters, ignoring the gas-liquid two-phase flow characteristics in the nozzle. Therefore, the research on the gas-liquid two-phase flow and atomization characteristics of Y-type atomizing nozzle has an important guiding role in the design of heavy oil burner. In order to improve the quality of heavy oil atomization, computational fluid dynamics software were used to explore the influence of nozzle structure parameters (mixing chamber length, inlet diameter ratio, angle between air and fuel inlet) and atomization parameters (mass flow rate of oil, air inlet pressure, temperature of oil) on the gas-liquid two-phase flow and heavy oil atomization characteristics of Y-type nozzle. The results showed that the structure parameters and atomization parameters directly affected the oil film thickness and gas-liquid two-phase velocity difference in the nozzle. Under different parameters, the change rule of gas-liquid rate and droplet Sauter mean diameter was opposite. Considering the two atomization performance indexes, the optimal length of mixing chamber was 15~20 mm, the reasonable range of inlet angle was 60°~75° and the optimal inlet diameter ratio was 1.0~1.1. In order to ensure the better atomization effect of heavy oil, the air inlet pressure should be greater than 0.5 MPa, the above parameters obtained by simulation provide guidance for the structure optimization design and operation parameter setting of Y-type nozzle.
    Influence of inlet dust concentration on characteristics of a new cyclone particle bed coupling separator
    Jinzhuang FU Ming CHANG Yiping FAN Chunxi LU
    The Chinese Journal of Process Engineering. 2021, 21(10):  1177-1186.  DOI: 10.12034/j.issn.1009-606X.220339
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    Nowadays, the production and combustion of fossil fuels make the emission of particulate pollutants increasing day by day. Researchers are actively developing new high efficiency dust removal separator to reduce the emission of pollutants. The studies on the separation technology of single cyclone separator and single particle bed filter are extensive but on the coupling separator of cyclone separator and particle bed are scarce. Therefore, the study of the cyclone particle bed coupling separator has broad application prospect. In order to investigate the influences of the inlet dust concentration on the pressure drop and the dust removal efficiency of a new cyclone-granular bed coupling separator, a large scale cold model experiment was carried out. The results showed that with an increase of the inlet dust concentration, the pressure drop of the separator tenders large and the speed of pressure drop increased rapidly when reaching an equilibrium state. The reason is that the inlet dust concentration increases, the dust in the built-in particle bed increases, the bed porosity decreases and the pressure drop increases. With the decrease of the inlet dust concentration, the separation efficiency of the separator increased. The dust content in the particle bed of the separator was also related to the regeneration efficiency. As the concentration of the regeneration dust source decreased, the time duration of the pressure drop reaching equilibrium became short. Furthermore, based on the experimental data, the empirical formula of separator pressure drop and regeneration dust source concentration was given. When the concentration of regeneration dust source reduced from 58.18% to 23.67%, the pressure drop reduced from 1.5 kPa to 1.2 kPa. With the decrease of the concentration of the regeneration dust source, the dust removal efficiency of the separator decreased slightly. The influence of inlet dust concentration and the regeneration dust source concentration on the pressure drop of separator coincided with each other, while the effect on the separator efficiency was different.
    Process & Technology
    Dilution of Isa copper smelting slag by carbothermic reduction with waste cathode carbon
    Guodong WU Lei LI Kongzhai LI Yong YU
    The Chinese Journal of Process Engineering. 2021, 21(10):  1187-1195.  DOI: 10.12034/j.issn.1009-606X.220327
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    Massive waste cathode carbon block are produced from the electrolytic aluminum process each year, which is mainly composed of carbon, sodium fluoride and other compounds. The fluoride and cyanide components in it cause serious environment pollution if it accumulated and exposed to air for a long time. It is regarded as a hazardous waste by various environmental bodies. An innovative method for resource processing of this waste cathode carbon block was proposed in this work. Using this waste cathode carbon block as the reducing agent can realize the effective dilution and recovery of copper from the smelting slag of Isa copper through a reduction process. According to thermodynamic analysis, the influence of the amount of waste cathode carbon addition, reduction temperature, holding time and CaO addition on the recovery ratio of copper dilution in Isa copper smelting slag was studied. The results showed that the recovery ratio of copper dilution can reach 98.24% under the conditions of waste cathode carbon addition amount of 2.0%, reduction temperature of 1300℃ and holding time of 60 min. At the same time, the F in the waste cathode carbon can be transferred and fixed in the diluted tailings in the form of CaF2. The toxic leaching concentrations of F? and CN? in the tailings were far lower than the national permissible emission standard. The research has realized the high-efficiency recovery of copper from Isa copper smelting slag and the resource utilization of waste cathode carbon.
    Structure design and optimization of thin plate static mixer for dilution water mixing
    Jianqiu LU Jiaqing CHEN Wenjin LIU Quan LUO Guodong DING Xiaoping WANG
    The Chinese Journal of Process Engineering. 2021, 21(10):  1196-1206.  DOI: 10.12034/j.issn.1009-606X.220322
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    The dilution water blending is a key link in the crude oil electrical desalination system of oil fields or refineries, which directly affects the efficiency and operating energy consumption of electrical desalination. In order to further simplify the equipment structure, reduce costs and increase system efficiency, a thin plate static mixer for dilution water mixing was proposed. On the basis of the preliminary structural design of the thin plate static mixer, computational fluid dynamics (CFD) was used to perform three-dimensional numerical simulation of oil-water mixing, the square root of segregation strength (IOS0.5) in a uniform mixing state and pipeline pressure drop (Δp) were used as evaluation parameter, which can indicate the influence of structural parameters on the uniformity of oil-water mixing and the running energy. The structural parameters were the length of water injection pipe, the distance between water injection pipe and thin plate, thin plate guide position and the thickness of bending sheet. Subsequently, with the inner diameter D of the hybrid pipeline as a reference, the key structural parameters were optimized by the response surface method (RSM), and the mixing performance under the optimal combination of structural parameters was predicted. The optimal combination of structural parameters obtained by optimization was as follow: the length of the injection pipe was 1/3D, the distance between the center of the injection pipe and the orifice was 4/25D, the guiding position of the orifice was 1/8π, and the thickness of the orifice was 1/25D. By comparing and analyzing the mixing effect of the thin plate static mixer before and after optimization, it was found that the optimized structure of IOS0.5 was 43.06%, which was lower than before optimization. Qualitative analysis of the water phase velocity cloud diagram and streamline diagram in the thin plate mixer showed that when the water injection ratio was 2%, the oil and water two phases can reach a uniform mixing state at the 3D downstream of the water injection pipe. It can be seen that the thin plate static mixer can quickly achieve uniform mixing of oil and water at a small water injection ratio.
    Materials Engineering
    Processing and characterization of Fe-(9~11)Cr-Y2O3 as ITER structural material
    Zhenzhen WANG Yi′na HUANG Yucheng WU Laima LUO
    The Chinese Journal of Process Engineering. 2021, 21(10):  1207-1215.  DOI: 10.12034/j.issn.1009-606X.220271
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    Oxide dispersion strengthened (ODS) steel has excellent radiation properties and is considered a candidate for the first wall structure of fusion reactors. Adding Y element to the material can improve thermal stability, and Cr element can improve corrosion resistance, because the high oxide density inside will cause needle-like dislocations, the material has higher strength and lower toughness to brittle transition temperature. The nano-precipitation phase can trap helium and make it in the form of nano-scale helium bubbles, avoiding the production of large helium bubbles to reduce possibility of expansion. Reducing helium embrittlement can make the material have a longer service life in the fusion reactor. In this work, based on mechanical alloying (MA) and spark plasma sintering (SPS), binary alloys with Fe(9~11)Cr content and ODS alloys were prepared successfully. The morphology and phase analysis of MA powders were characterized by scanning electron microscope (SEM), X-ray diffraction (XRD), micro Vickers-hardness tester and energy dispersive spectrum (EDS), and the precipitation phase of the alloy sample was observed by transmission electron microscope (TEM). The results showed that the fine grain size enabled the material to have good tensile and creep properties at high temperatures. The MA powder was continuously refined after being crushed and deformed under a rotational speed of 300 r/min and the ball-to-powder mass ratio was 10:1. The MA powder reached the cold welding-crushing balance at 40 h. The powder grain size decreased to about 16.1 nm and tended to be stable with the increase of ball grinding time. After spark plasma sintering and solidification of the MA powder for 40 h, the grain size did not increase significantly, and the trace elements were uniformly distributed in the matrix. The Vickers-hardness of binary alloy samples increased with the addition of Cr content. The grain boundaries of ODS alloy samples proved to be fine and uniform after being eroded by corrosive liquid.
    Effect of pressurized carbonization system on the particle size and dispersion of nano calcium carbonate
    Xixi LIU Xiaopeng CHEN Chenmin LIU Liubin SHI Dankui LIAO Cui LIU Zhangfa TONG
    The Chinese Journal of Process Engineering. 2021, 21(10):  1216-1224.  DOI: 10.12034/j.issn.1009-606X.220278
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    Nano calcium carbonate with uniform particle size and high dispersion was prepared by pressurized carbonization system. The effects of calcium hydroxide concentration, surfactant addition amount, reaction temperature and CO2 pressure on the size and dispersion degree of prepared nano CaCO3 particles were investigated. X-ray diffraction (XRD), scanning electron microscope (SEM), Zeta potential and Fourier transform infrared spectroscopy (FT-IR) were used to characterize the prepared nano CaCO3 particles. The results showed that the optimum conditions for pressure carbonization are Ca(OH)2 mass concentration of 2%, surfactant dosage of 3% (percentage of theoretical production of calcium carbonate), reaction temperature of 40℃ and CO2 pressure of 6 MPa, the average particle size of the cubed calcium carbonate was 117 nm, and the crystal type was calcite calcium carbonate. The addition of surfactant cetyl trimethyl ammonium bromide (CTAB) to the carbonization reaction increased the positive charge formed on the surface of CaCO3 to +37.7 mV and higher than the standard value of 30 mV, indicating that the prepared CaCO3 product has good dispersibility and stability. FT-IR and Zeta potential were used to characterize CaCO3 nanoparticles before and after the modification of CTAB, and the influence mechanism of CTAB on the dispersion of synthetic CaCO3 nanoparticles was discussed, providing a new method for the preparation of nano CaCO3 .
    Environment & Energy
    Benchmarking analysis on energy efficiency performance of temperature swing adsorption carbon capture system
    Lijin CHEN Shuai DENG Junyao WANG Ruikai ZHAO Li ZHAO Shuangjun LI Zhihao GUO
    The Chinese Journal of Process Engineering. 2021, 21(10):  1225-1235.  DOI: 10.12034/j.issn.1009-606X.220264
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    An accurate and reasonable energy efficiency analysis is significant to the scale-up development of carbon capture technology. It is not only a preliminary preparation to the final energy-saving proposal of carbon capture technology, but also an important data basis to sustainable performance evaluation of carbon capture process with aims on green, clean and low-carbon. Therefore, in addition to exploring the mechanism on energy conversion of carbon capture process, it is urgent to establish a benchmarking analysis methodology of energy efficiency performance which features on easy-to-operate for the demand of engineering sector, so that the performance cognition of typical capture technologies could be accumulated and compared on a reasonable and unified evaluation platform. Based on the benchmarking analysis method, the methodology of energy efficiency performance on temperature swing adsorption (TSA) is presented, including processes, parameters, model, etc. The effect of adsorption temperature and desorption temperature on the energy efficiency performance of TSA was analyzed, the feasibility of proposed method is demonstrated and quantified, and the influence of boundary changes on the evaluation results was discussed as well. The proposed method could provide a generalized guidance to the benchmarking evaluation of energy efficiency performance of carbon capture with specific case.
    Analysis and optimization of air cooling performance of battery pack based on air volume regulated by filter plate
    Guangxin CHU Mengtao YU
    The Chinese Journal of Process Engineering. 2021, 21(10):  1236-1244.  DOI: 10.12034/j.issn.1009-606X.220283
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    With the global trend of advocating environmental protection, energy conservation and emission reduction, and low-carbon travel, electric vehicles have been vigorously developed. As the power source of electric vehicle, power battery pack is one of the core components of electric vehicle. At present, the mainstream battery used in electric vehicles at home and abroad is lithium-ion battery, which has the advantages of high power density and energy density, low cost, long service life and no memory effect. But its performance is greatly affected by temperature. Therefore, it is imperative to carry out thermal management of electric vehicles. Firstly, the capacity, resistance and temperature rise of 18650 lithium-ion battery were tested by building a test platform; then, the consistency between the simulation results of single temperature rise and the experimental results was compared; finally, the power lithium-ion battery pack model was established, through single factor analysis and orthogonal experiment, the effects of filter plate free area ratio, battery spacing, wind speed and battery bottom distance on the battery were studied. The influence of maximum temperature and temperature difference were studied. When the battery was discharged at 1 C, it was concluded that adding filter plate improves the consistency of temperature field of battery pack, and the temperature difference of battery pack was the minimum when the free area ratio of filter plate was 0.1, 0.9 and 0.9. With the increase of wind speed, the maximum temperature decreased,temperature difference of battery pack first increased and then decreased. With the increase of battery spacing, the maximum temperature of battery pack first increased and then decreased, the temperature difference first increased, then decreased and increased at last.With the increase of the distance from the bottom of the battery, the maximum temperature of the battery pack first decreased and then increased. Finally, the best combination of 6 m/s, 4 mm and 4 mm was obtained by orthogonal experiment, which decreased 22.5% and 74.8% respectively compared with the maximum temperature and temperature duffurence before optimization.