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    28 December 2021, Volume 21 Issue 12
    Contents
    Cover and contents
    The Chinese Journal of Process Engineering. 2021, 21(12):  0. 
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    Reviews
    Research progress on CO2 separation in ionic liquid?graphene oxide membrane materials
    Yandong GUO Yanjing HE Xiaochun ZHANG
    The Chinese Journal of Process Engineering. 2021, 21(12):  1373-1382.  DOI: 10.12034/j.issn.1009-606X.220344
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    Ionic liquid (IL) is a kind of green solvent with low saturated vapor pressure, good designability, strong stability, and wide liquid temperature range. Moreover, ionic liquid has high CO2 solubility, which has become a research hotspot in the field of CO2 separation. The separation membrane material obtained by combining ionic liquid and two-dimensional nanomaterials has the advantages of both ionic liquid and two-dimensional nanomaterials, which shows a good application prospect in gas separation. Among them, the combination of ionic liquid and graphene oxide (GO) has attracted much attention. In order to explore the application of ionic liquid-graphene oxide (IL-GO) membrane materials in the field of CO2 separation, this article reviews the research and progress in CO2 separation through graphene, ionic liquid and ionic liquid-graphene oxide membrane materials. From three perspectives based on IL-GO mixed matrix membrane, IL membrane supported by GO, and IL-GO composite membrane, the mechanisms in terms of selectivity, permeability, mechanical properties, thermal stability, high-pressure stability, and membrane thickness of the IL-GO membrane materials is mainly discussed. Relevant studies suggest that the IL-GO membrane materials has good selectivity, permeability mechanical properties, thermal stability, and high-pressure stability, and shows as a potential material for CO2 separation. Finally, future research challenges and prospects in CO2 capture and separation using ionic liquid, graphene oxide and IL-GO membrane materials are proposed.
    Research progress on adsorption and reduction of Cr(VI) by biomass adsorption materials
    Shaojie WU Cheng GUO Jia HU Xiangpeng GAO Mingyang LI Hongming LONG
    The Chinese Journal of Process Engineering. 2021, 21(12):  1383-1394.  DOI: 10.12034/j.issn.1009-606X.220412
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    The traditional methods for treating chromium-containing wastewater include chemical precipitation, electro deposition, membrane filtration, and ion exchange. These methods are generally simple and convenient; however, some drawbacks such as secondary pollution and high treatment cost remain unsolved. Hence it is of urgent need to find a low-cost and efficient heavy metal containing wastewater treatment method. Biosorption is an emerging technology for the treatment of heavy metal containing wastewater, which has received numerous attention from researchers. Due to its simplicity and low-cost, biosorption is regarded as one of the green and environmental friendly methods to remove heavy metals from aqueous solutions. Biomass material surface contains a large number of active functional groups, which exhibits high metal uptake capacity and affinity towards industrial effluents. After modification, the adsorption capacity and adsorption rate of the adsorbent can be improved significantly. However, due to some shortcomings in physical and chemical properties, the application of biomass adsorbents in industrial wastewater is still limited. This review introduces the research on the treatment of chromium containing wastewater by biomass adsorption, and compared biosorption with conventional treatment methods in the field of metal adsorption and recovery, followed by focusing on the current research progress and development of biosorption materials with conventional physical and chemical modifications. The adsorption characteristics and influencing factors for the removal of heavy metal ions by modified biomass are analyzed, with the comparison of modified biomaterials with other adsorbents on the efficiency of removing hexavalent chromium ions. Afterwards, according to the type of interaction between the surfactant and the adsorbent, it can be concluded four adsorption mechanisms of biomass adsorbents towards hexavalent chromium, which are complexation/chelation, electrostatic interaction, ion exchange, and oxidation-reduction reaction. According to the activity and electron-donating ability of the groups on the adsorption materials, active functional groups including amino, hydroxyl, and thiol are generally act as electron donors during the adsorption process.
    Radiochemical upgrading of cellulose and its application
    Xiaohan DONG Keyan SHENG Zhiyan CHEN Yanlong GU Jiang HUANG
    The Chinese Journal of Process Engineering. 2021, 21(12):  1395-1402.  DOI: 10.12034/j.issn.1009-606X.220409
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    Cellulose irradiation technology uses high-energy ionizing rays as the energy source, such as α?rays, β?rays, γ?rays, X?rays, electron beams, etc., by which, cellulose is radiated so that it produces free radicals and further initiates a series of reactions such as polymerization, cleavage, crosslinking, grafting, and so on, followed by cellulose degradation or modification. The extent of cellulose polymerization, cleavage, grafting, crosslinking can be adjusted by changing the irradiation dose and reaction conditions. Unlike traditional chemical modification methods such as thermal cross?linking and polymerization, cellulose irradiation modification technology can accomplish the modification task that is difficult to achieve by traditional methods without the addition of other catalysts or chemical reagents. The modification of cellulose using irradiation technology has the advantages of easy pretreatment and post?treatment, energy?saving, and little waste. The application of irradiation technology in cellulose modification has become a hot spot in the field of nuclear technology in recent years. Irradiation technology utilizes physical or chemical reaction induced by ionizing radiation (such as crosslinking, polymerization, grafting, degradation, etc.) to produce or modify materials, and irradiation technology is different from traditional chemical methods, which utilize the radiation of high?energy electrons or rays into the interior of matter so that they generate free radicals and initiate a series of irreversible changes that alter material properties at the molecular level. By this physical means, reactions such as cellulose polymerization, cleavage, or graft crosslinking can be achieved without the use of catalysts. More critically, the series of chemical reactions evoked under an irradiation environment is expected to provide cellulose products that are difficult to synthesize by other methods, providing opportunities for the improvement of natural cellulose with the development of new products from downstream derivatives. In this work, an overview of current irradiation techniques for cellulose and their underlying reaction mechanisms is given, which includes cellulose film materials, cellulose hydrogels, cellulose crystallites/nanomaterials, and the irradiation environment for the irradiation modification process of cellulose, including solvents, sensitizers, temperature, irradiation dose, ambient atmosphere, crystallinity, etc., is summarized.
    Research progress on reactive oxygen species and its detection methods
    Yaoyu HE Zhi JIANG Wenfeng SHANGGUAN Yunfa CHEN
    The Chinese Journal of Process Engineering. 2021, 21(12):  1403-1418.  DOI: 10.12034/j.issn.1009-606X.220423
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    Reactive oxygen species are kinds of highly reactive substances, including superoxide radicals, hydrogen peroxide, singlet oxygen, and hydroxyl radicals. Oxygen molecules, as oxidants, are more stable and need to be converted to highly reactive species before they can further react with other substances. In chemical reactions, especially catalytic oxidation reactions, the type of reactive oxygen species, its formation, and its diffusion behavior determine the direction and rate of the reaction. In the field of life sciences, reactive oxygen is involved in energy conversion, oxygen balance and other important physiological processes, which are closely related to aging and disease. However, due to its short half-life and strong reactivity, qualitative and quantitative testing of reactive oxygen species is difficult. Choosing suitable detection methods and improving the temporal and spatial accuracy of the detection is important for environmental chemistry and life science research. This work introduces and compares the basic principles, research advances, and applications of reactive oxygen detection methods in environmental and life fields, and compares the advantages, disadvantages, and applicability of various methods. The theoretical calculation and detection of oxygen species in heterogeneous catalysis are also introduced, and the future research direction of reactive oxygen species in catalytic oxidation and other fields is discussed.
    Flow & Transfer
    Particle-resolved simulation of typical packing structures in olefin catalytic cracking reactor
    Fei XU Feiguo CHEN Xiaoxing LIU Hao WU Bona LU Zhicheng LIU Jiawei TENG
    The Chinese Journal of Process Engineering. 2021, 21(12):  1419-1429.  DOI: 10.12034/j.issn.1009-606X.221006
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    Understanding the flow behaviors and pressure distribution in the interstitial void space among particles is of great importance for improving operating parameters of fixed bed chemical processes, like OCC (olefin catalytic cracking) process. Particle-resolved simulation method is extensively adopted in simulations of fixed bed reactors due to its ability of accurate describing fluid dynamics in packing structures, but its mesh generation process is rather difficult when the packing structure is complex. This study realized a particle-resolved simulation method of typical packing structures in the OCC fixed bed reactor through developing an immersed boundary method, which was based on the porous media model (PMM-IBM) and mesh adaption technology. This method simplified mesh generation process and reduces the computational cost. Compared to the uniform mesh, the total mesh number of the packing structure was reduced about 80% after the mesh adaption. The key parameters of the PMM-IBM were first determined by comparing the forces acting on the particle surface between PMM-IBM and body-fitted mesh method. Further, for three different bed-to-particle diameter ratios, the voidage, pressure and velocity distribution of the packing structures were simulated. It was found that the maximum local axial velocity in the packing structures was 10 times higher than the inlet velocity. The radial distribution of the average axial velocity was consistent with that of the average axial voidage, which showed an oscillation attenuation trend along the center of the bed. Moreover, the pressure drop was almost consistent with the results from Reichelt empirical correlation. Finally, the mass transfer and the main reaction of OCC were considered. The mass fraction variation of the reactant according to pore size and porosity was predicted, which provided the possibility for including the external flow structures and variations in future work.
    Numerical simulation of multi-stage side-blowing mixing characteristics in iron bath reactor
    Yibo HE Wenke GUO Yihong LI Guangming LIU Xin CUI
    The Chinese Journal of Process Engineering. 2021, 21(12):  1430-1439.  DOI: 10.12034/j.issn.1009-606X.221279
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    Based on the water model experiment of an iron bath smelting reduction reactor with thick slag layer, numerical simulation is taken out to study the stirring characteristics of the molten bath by double-layer side-blowing lance under different injection angles (40°, 45°, 50°) and different horizontal insertion depths (60, 120, 180 mm), and the accuracy of numerical simulation is verified by the results of water model experiment. By observing the flow field of the molten pool in the gas-liquid two-phase flow and the diffusion of the tracer, the proportion of the weak flow zone and the dead zone and the mixing time under different side-blowing conditions are analyzed, the results show that: the horizontal insertion angle of the side-blowing lance has a more significant influence on the stirring characteristics of the molten pool than the horizontal insertion depth. The horizontal injection angle and insertion depth of the side-blowing lance affect the swirling flow area and the number of swirling flows generated in the molten pool. When the horizontal injection angle of the side-blowing lance is larger and the horizontal insertion depth is deeper, the volume of the weak flow zone or the dead zone in the molten pool is smaller, which is more conducive to the stirring and mixing of the molten pool. The best injection conditions are obtained from the numerical simulation: the upper injection angle is 50°, the insertion depth is 60 mm, the lower injection angle is 50°, and the insertion depth is 120 mm. In addition, the mixing time of molten bath under different gas flow rates are also studied. It is obtained that the mixing time of molten bath is the shortest when the single gas flow rates of upper and lower lance are 8.58 and 10.43 Nm3/h, respectively.
    Uniformity of flow field in SCR denitrification reactor of cement kiln
    Xiaofei XU Yangyang GUO Hong GAO Xue WANG Tingyu ZHU
    The Chinese Journal of Process Engineering. 2021, 21(12):  1440-1450.  DOI: 10.12034/j.issn.1009-606X.220370
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    Fluent software was used to simulate the flow field in the selective catalytic reduction (SCR) denitrification reactor, based on the standard k-ε model, porous media model, material transport model, DPM model. A single gas phase flue gas was used to analyze the effects of different rectifying grids spacing, rectifying grid height, rectifying grid position and baffle number, baffle angle on the uniformity of the flue gas flow field. The influence of the smoke with different components in a single gas phase under the optimal scheme can be concluded. The gas verified under different loads, as well as different loads under DPM dual-phase coupling conditions. The results showed that the maximum incident angle was less than 90° from the absence of the rectification grid to the addition of the rectification grid, and the vortex above the catalyst disappeared. When the spacing of the rectifying grid was 107 mm, the height of the rectifying grid was 200 mm, and the rectifying position was flushed with the lower edge of the entrance, the velocity distribution deviation coefficient at 100 mm of the upper layer of the first catalyst layer reduced to 19%. When the number of baffles was 7, and the baffle angle was 18.2°, the most suitable situation, the velocity distribution deviation coefficient at 100 mm above the first layer of catalyst was 11.91%, and the maximum incident angle was 3.14°. When the flue gas with different components in a single gas phase and different loads were simulated under the best parameters, it met with the engineering requirements. Using DPM two-phase coupling, comparing the particles with a single gas phase under the Rosin-Rammler distribution condition, it was found that the average velocity at 100 mm above the first layer of catalyst increased to a certain extent, the velocity standard deviation had a small change, and the velocity distribution deviation coefficient was correspondingly reduced.
    Functional mechanism and performance of gas wave ejector feedback structure
    Yiming ZHAO Haoran LI Minghao LIU Dapeng HU
    The Chinese Journal of Process Engineering. 2021, 21(12):  1451-1462.  DOI: 10.12034/j.issn.1009-606X.221016
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    The gas wave ejector is a new type of dynamic equipment that uses gas pressure waves to realize the pressure energy exchange process. Because of high efficiency, simple structure and low energy consumption, the gas wave ejector has broad application prospects in many production processes.According to the working principle of this equipment, the reversed compression waves formed at the medium pressure port could result in a large decrease of the equipment performance or even lead to the loss of function at high medium backpressure. Therefore, a workable feedback structure was proposed in this work to optimize the performance of the gas wave ejector by avoiding the formation of redundant compression waves under high medium backpressure conditions. The functional mechanism and performance of this structure were studied in detail by numerical simulation and experimental methods. By means of numerical simulation, the functional mechanism of the feedback structure to weaken the reversed compression waves through pre-compression was demonstrated. Meanwhile, the effective and evaluating criteria of this structure were proposed by the results of numerical simulation. To ensure the efficient operation of this structure, the minimum pressure in the flow channel of the stable-pressure region should be less than the medium port backpressure. And the efficiency improvement of this structure was positively correlated with the average pressure difference in the flow channel of stable-pressure region with or without feedback structure. By the experimental methods, the correctness of the numerical simulation was verified, and the actual application consequence of the feedback structure was obtained. By the application of this feedback structure, the maximum lifting capacity of equipment efficiency and ejection rate could reach about 6.93% and 5.43%, respectively. The investigation results demonstrated that the feedback structure was easy to implement and supplied a positive application effect under high medium backpressure conditions, which proved its promising application value.
    Process & Technology
    Effect of particle size on thermal decomposition kinetics of micron magnesium hydroxide
    Yingchun CHEN Hang CHEN Jianguo YU
    The Chinese Journal of Process Engineering. 2021, 21(12):  1463-1472.  DOI: 10.12034/j.issn.1009-606X.220362
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    The non-isothermal pyrolysis kinetics of micron Mg(OH)2 is studied with the thermogravimetric analyzer under nitrogen atmosphere. It mainly focuses on clarifying the effects of particle size on the pyrolysis process. The measured thermogravimetric curves show a stepwise characteristic. At the main decomposition stage, the pyrolysis of Mg(OH)2 is rapid with a sudden mass loss. At the subsequent stage where conversion rate is larger than 0.8, the rate of weight loss decreases significantly because the diffusion of product water vapor is hindered by the product of MgO film. As for the main decomposition stage with conversion rate of 0~0.8, the Starink method and combined kinetic analysis are applied to fit and analyze its kinetic model. It is found that particle size has no distinct effect on the pyrolysis kinetics of micron Mg(OH)2. The model fitting results show that the pyrolysis reaction activation energy of micron Mg(OH)2 is 129.4 kJ/mol, the pre exponential factor is 1.820×1010 min?1, the pyrolysis reaction process follows the mechanism of random nucleation and growth of nuclei (A1.5). Compared to the experimental results, the thermogravimetric curves reconstructed based on these fitting parameter have the deviation less than 5%, which indicates that the kinetic model is reasonable. Meanwhile, it can be concluded that the pyrolysis process is controlled by decomposition reaction in the investigated range with the conversion rate from 0 to 0.8. The resistance effect of particle heat conduction and product water vapor diffusion is weak relatively. The main process of Mg(OH)2 weight loss is approximate to a homogeneous reaction. Considering the current investigation mainly focuses on the main decomposition stage of Mg(OH)2 with the conversion rate from 0 to 0.8, the kinetics of second stage of weight loss process remains to be studied further.
    Investigation on direct to blister copper smelting for high?grade copper concentrate
    Shiwei ZHOU Xiang GUO Kelun ZHANG Ba ZHANG Bo LI Yonggang WEI
    The Chinese Journal of Process Engineering. 2021, 21(12):  1473-1480.  DOI: 10.12034/j.issn.1009-606X.220421
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    Conventional copper smelting technology combines two steps of smelting and converting, with oxygen-enriched smelting as a typical representative. Intermittent operations would inevitably cause common issues such as long operation procedures and low-level sulfur dioxide pollution. Therefore, development of short-process for copper smelting technology is particularly necessary. Direct to blister copper smelting technology was carried out in a single furnace. It has the advantages of short process, good environmental benefits, and low investment cost, which is in line with the development direction of modern short-process smelting technology. The high-grade copper concentrate was used as raw ore for direct to blister copper smelting in present, and the method of theoretical calculations combined with experiments in lab-scale was adopted to investigate the phase transformation, blister copper yield, and copper content in the slag during the smelting process. Theoretical calculations indicated that the spinel phase in the melt can be avoided by adding CaO, as the ratio of iron to silicon was controlled to be 0.6 in the raw material. The corresponding chemically dissolved copper content in the slag at 1300℃ was approximately 8.6wt%. The effects of the amount of injected oxygen and settling time on the weight of blister copper and slag properties was discussed. For 80 g raw material, the oxygen-enriched air (50vol% O2) with a rate of 0.4 L/min was injected for 70 min, and then settling for 2 h. The experimental results indicated that the blister copper with a recovery rate of 82.12% could be obtained from a high-grade copper concentrate containing 45.94% Cu via direct to blister copper smelting at 1300℃. SEM-EDS analysis method was used to investigate the microstructure of the slag, which indicated that a large amount of spinel phase existed in the slag, hindering the sedimentation of copper particle. The copper in the form of mechanical entrainment was observed as a result.
    Effect of external magnetic field on cleanliness of electroslag ingot
    Xiaofang SHI Chunli ZHU Tao XU Lizhong CHANG
    The Chinese Journal of Process Engineering. 2021, 21(12):  1481-1490.  DOI: 10.12034/j.issn.1009-606X.221010
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    In order to further remove the large inclusions, an electroslag remelting furnace with electromagnetic stirring is designed and the effects of external magnetic field and different electrical parameters on the cleanliness of electroslag ingot are studied. The gas content is analyzed by oxygen and nitrogen analyzer, and the morphology, composition and size of inclusions are observed and analyzed by scanning electron microscope. It is found that the oxygen content in ESR ingot increases obviously after electroslag remelting whether the external magnetic field is applied or not, but the nitrogen content decreased slightly. The oxygen content in consumable electrode increased from 0.0007% to 0.0052%, and the growth rate is as high as 7 times. However, the types of inclusions are basically unchanged, which are mainly composed of alumina, manganese sulfide, manganese sulfide oxide composite inclusions and oxides, among which alumina is the most. After remelting with external magnetic field, the diameter of the largest inclusion in the consumable electrode decreased from 89.6 μm to 12.1 μm in ESR ingot (1.1 kA/108 Gs), the proportion of small inclusions increases and the number of large inclusions decreases. However, excessive electromagnetic force is not conducive to the removal of large inclusions. When the remelting current is 1.5 kA and the magnetic induction is 108 Gs, the electromagnetic force is the largest, and the maximum diameter of inclusions is up to 30.6 μm which is larger than that in electroslag ingot without magnetic field. The increase of oxygen content after electroslag remelting is caused by air pollution and unstable oxides in slag. The electromagnetic force generated by external magnetic field increases the contact area between slag and metal, thus absorbing large inclusion.
    Process System Integration & Chemical Safety
    A robust method for chemical process monitoring based on Johnson transformation
    Ji WANG Nan LIU Minggang HU Wende TIAN
    The Chinese Journal of Process Engineering. 2021, 21(12):  1491-1502.  DOI: 10.12034/j.issn.1009-606X.220340
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    A tiny fault in chemical plants is likely to cause an enormous accident possibly with heavy losses of personnel, property, and environment. Therefore, process monitoring is demanded to timely detect faults and identify fault variables, so as to avoid deterioration of tiny faults into accidents. Nowadays principal component analysis (PCA) is the most widely used method in chemical process monitoring practice with its simplicity and effectiveness. However, it has some drawbacks. First, it roughly assumes process data as Gaussian distribution. But sometimes it is not satisfied. Furthermore, PCA uses variance and covariance (also called Pearson correlation coefficients) as criterion to choose principal components, however they are not robust in capturing nonlinear data variation. To alleviate these problems, an improved PCA-a Johnson transformation based robust method for process monitoring (JSPCA) was proposed in this work. First, Johnson transformation was introduced to make process data obey Gaussian distribution. Second, the Spearman correlation coefficient matrix instead of covariance matrix was established to extract principal components and span feature space. Finally, process data were projected into feature space where T2 and SPE statistics were obtained for process monitoring. The proposed method had its fault detection ability tested in the benchmark TE process with comparison of PCA and KPCA. The results showed that the proposed method had higher fault detection rates than PCA and KPCA when using T2 as detection indicator. However, the proposed method with SPE as detection indicator had higher false alarm rates than PCA and KPCA. As for fault diagnosis ability, the proposed method was tested against fault 5 and fault 10 of TE process and diagnoses fault variables more precisely than PCA and KPCA. The proposed method was better than PCA and KPCA and it was worth promoting.