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    28 May 2024, Volume 24 Issue 5
    Contents
    Cover and Contents
    The Chinese Journal of Process Engineering. 2024, 24(5):  0. 
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    Review
    Research progress in preparation of silicon-based anode materials for lithium-ion batteries by radio-frequency induction thermal plasma
    Zongxian YANG Yuanjiang DONG Chang LIU Huacheng JIN Fei DING Baoqiang LI Liuyang BAI Fangli YUAN
    The Chinese Journal of Process Engineering. 2024, 24(5):  501-513.  DOI: 10.12034/j.issn.1009-606X.223230
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    As one of the next-generation anode materials with the most promising application prospects, silicon anode benefits from a high theoretical specific capacity, a sufficient working potential, abundant and inexpensive sources, environmental friendliness, safety, and dependability. However, Si will experience significant volume variations throughout the lithiation and delithiation processes. This will result in significant internal stress, which will cause issues including material pulverization, repetitive growth of the solid electrolyte interface (SEI), and electrode failure. Through the utilization of nano-silicon-based anode materials, it is possible to effectively mitigate the volume impact, enhance both conductivity and stability. The utilization of radio-frequency (RF) induction thermal plasma offers several notable benefits, including elevated temperatures, rapid cooling, precise control, and uninterrupted operation. Thermal plasma has the ability to provide particles a unique growth environment and process that is helpful in the creation of products with special morphologies, such as zero-dimensional nanospheres and one-dimensional nanowires. Additionally, the extremely high temperatures can totally evaporate raw materials, guarantee uniformity of product, and be advantageous for doping second-phase materials. Consequently, it serves as a significant method for the production of nano-silicon-based anodes with a controllable morphology and structure, as well as high purity and excellent dispersibility. This work provides a review of the scientific advancements pertaining to silicon-based anode materials for lithium-ion batteries that are fabricated using RF thermal plasma. To commence, a concise introduction is provided for the thermal plasma technology. Then, this work focuses on the synthesis of various essential materials using thermal plasma, including silicon nanospheres (Si NSs), silicon nanowires (Si NWs), silicon monoxide nanowires (SiO NWs), silicon monoxide nanonetworks (SiO NNs), high-silicon silicon suboxide nanowires (SiOx NWs), silicon-based ferrosilicon alloy nanospheres (Si/FeSi2 NPs). Furthermore, the work emphasizes the applications of these materials in the anode electrode of lithium-ion batteries. Finally, the development of thermal plasma technology is prospected.
    Research Paper
    Study on the heat transfer characteristics of nanofluid spray cooling with ethylene glycol aqueous solution as base fluid
    Nianyong ZHOU Yingjie ZHAO Yang LIU Youxin ZOU Guanghua TANG Qingguo BAO Wenyu LÜ
    The Chinese Journal of Process Engineering. 2024, 24(5):  514-522.  DOI: 10.12034/j.issn.1009-606X.223205
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    In recent years, due to the improvement of power density, compact packaging and high performance requirements, the heat dissipation demand of high heat flux devices has increased significantly. In view of the above problems, this work plans to use the spray cooling technology to conduct heat transfer research on the Al2O3 nanofluid with ethylene glycol water as the base fluid, focusing on the analysis of the influence of the concentration of the base fluid, the concentration of nanoparticles, and the concentration of the added dispersant on the heat transfer performance of the working medium spray cooling at three different operating conditions of 300, 500, and 700 W. The experimental results show that due to the decrease of specific heat capacity and thermal conductivity and the deterioration of spray characteristics, the mass fraction of ethylene glycol increases from 30wt% to 80wt%, and the surface heat transfer coefficient of Al2O3 nanofluid solution decreases continuously, with an average decrease of 41.63%. The surface heat transfer coefficient of Al2O3 nanofluid shows a trend of first decreasing, then increasing, and then slowly decreasing with the increase of nanoparticle mass fraction. When the mass fraction of Al2O3 nanoparticles increases from 0 to 2wt%, the overall average surface heat transfer coefficient of Al2O3 nanofluid solution decreases by 6.94%. The deposition and bubbling effect are the main reasons for weakening the heat transfer. At the same time, the increase in the mass fraction of nanoparticles improves the thermal conductivity of the nanofluid solution, which to some extent enhances heat transfer. In addition, the addition of a low-quality non-ionic surfactant (Tween-20) can improve the foaming effect, making the heat transfer coefficient of spray cooling increase by about 1.52%, but still lower than that of pure base liquid; Adding a higher mass fraction of dispersant can cause aggregation between nanoparticles and further weaken the heat transfer performance of the thermal conductivity solution.
    Numerical simulationon centrifugal granulation characteristics of slag optimized by gas quenching winds
    Xinyi ZHANG Ningwen XU Xiaoming LI Shuzhong WANG
    The Chinese Journal of Process Engineering. 2024, 24(5):  523-532.  DOI: 10.12034/j.issn.1009-606X.223233
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    The liquid slag dry granulation and waste heat recovery technology solves the problem of waste heat loss and environmental pollution caused by the existing water quenching process of liquid slag in metallurgical industry, which plays an important role in the implementation of energy saving and emission reduction strategy. In order to improve the resource utilization of slag pellets and reduce the equipment investment, the addition of auxiliary gas quenching wind at the edge of the pelletizer is proposed to enhance the palletizations effect and improve the waste heat recovery efficiency. However, the mechanism of the effect of gas quenching wind on centrifugal granulation and the influence pattern are still unclear in the current study. A three-dimensional granulation model with gas quenching wind was established using the SST k-ω turbulence model. And the effects of gas quenching wind on the granulation effect, the flight velocity of waste particles and the cooling effect of rotor cup were investigated by using the VOF method. The changing rule of the horizontal flight speed of liquid droplets under different gas quenching wind conditions was investigated to provide reference basis for optimizing the flight trajectory of liquid droplets and the spatial design of granulation silo. Findings indicated that while increasing air volume shifted particle size distribution to larger ranges, it benefited the slag particles' sphericity. The gas quenching wind effectively induced particle fragmentation within the air flow range of 4~6 m3/h, with enhanced cooling effects when air flow surpassed 2 m3/h. When selecting the air flow, the air flow of 1 m3/h can be selected when considering the granulation effect and flight speed only, and the flow of 2 m3/h was the best when considering the cooling effect comprehensively. Using a ring slit for air venting resulted in the smallest average diameter of slag particles, lower wall temperatures near the rotating cup, moderate flight speed, and superior sphericity compared to a state without gas quenching wind.
    Process optimization and crystallization kinetics for preparation of nesquehonite by impinging stream-coprecipitation technology
    Jianwei ZHANG Xianhong ZOU Xin DONG Ying FENG
    The Chinese Journal of Process Engineering. 2024, 24(5):  533-545.  DOI: 10.12034/j.issn.1009-606X.223240
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    Impinging stream is a technique to enhance heat and mass transfer in process engineering. Due to the characteristics of its high and uniform supersaturation, it is widely used in powder preparation. Nesquehonite (MgCO3?3H2O) can be used to combine with materials and increase the strength and toughness of materials because of its special rod-like structure. In this work, MgCO3?3H2O crystal was prepared from magnesium chloride and sodium carbonate by a new impinging stream technology combined with co-precipitation method, and the preparation process conditions and crystallization kinetics of MgCO3?3H2O were studied. The effects of reactant concentration c, reaction temperature T, cyclic impact flow rate Q and cyclic impact time t on the crystal morphology and structure of MgCO3?3H2O were discussed by taking the aspect ratio of rod-like MgCO3?3H2O as the index. The optimal conditions were as follows: the reactant concentration was 0.25 mol/L, the reaction temperature was 50℃, the cyclic impact flow rate was 500 L/h, and the cyclic impact time was 50 min. Under these conditions, the MgCO3?3H2O crystal with the aspect ratio of 20 and an average crystal length of 57.3 μm can be obtained. The particle size distribution data under different conditions were measured by laser particle size meter, and the crystal nucleus number density, growth rate and nucleation rate of the product were analyzed according to the population balance model. Under the optimal conditions, the nucleation rate of the crystals was 2.061×106 #/(mL?min) and the growth rate was 0.148 μm/min. The nucleation and growth kinetic equations of each factor in the system of impinging stream-coprecipitation reaction were obtained, and the sensitivity coefficient i of each factor on crystal growth was determined. iQ<iT<0<it<ic is the relationship of sensitivity coefficients obtained by each influencing factor. Cyclic impact flow rate and reaction temperature can promote crystal growth.
    Experimental study on optimization of direct-reverse flotation of a phosphate ore by response surface methodology
    Shengdong ZHANG Zhongbao HUA Yu ZHAO Xiong TONG Xian XIE
    The Chinese Journal of Process Engineering. 2024, 24(5):  546-557.  DOI: 10.12034/j.issn.1009-606X.223291
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    The contents of P2O5, SiO2 and CaO in a phosphate mine in Yunnan are 18.59%, 37.37%, and 27.55%, respectively. It can be seen that this ore belongs to silica-calcareous collophanite. According to the properties and characteristics of this ore, the flotation test was carried out by using the direct-reverse flotation flow. Firstly, the optimal dosage of each reagent was determined by a single factor condition test. On this basis, the response surface methodology was used to further optimize the dosage of three kinds of regulators in positive flotation. Finally, based on the results of the single factor condition test and response surface methodology optimization, closed-circuit flotation test was carried out. The results of the single factor condition test showed that the optimal dosage of Na2CO3, Na2SiO3, YP6-1 in direct flotation, YP6-1 in reverse flotation, modified starch DZ, H2SO4 and H3PO4 were determined to be 3000, 1500, 2400, 600, 700, 5000, and 4000 g/t, respectively. Under the optimum dosage of these reagents, phosphorus concentrate with P2O5 grade and recovery of 30.19% and 73.06% can be obtained by a direct-reverse flotation. The response surface optimization experiment revealed that the optimal dosages of Na2CO3, Na2SiO3, and modified starch DZ in direct flotation were 3016.15, 1986.72, and 877.33 g/t, respectively. Actual flotation tests conducted under these conditions resulted in a concentrate with a P2O5 grade of 30.08% and a recovery of 75.81%, which was found to be in good agreement with the predicted results. Compared with the results of the traditional single factor condition test, the recovery can be increased by 2.75 percentage points while maintaining the same grade by using the response surface methodology. Finally, the closed-circuit flotation test was carried out based on the result of the single factor condition test and response surface optimization. The phosphorus concentrate with P2O5 grade of 32.07% and recovery of 72.83% was obtained, which indicates that a good flotation effect of the refractory fine collophanite has achieved.
    Research on Cu-assisted leaching process of zinc leaching residue and zinc calcine
    Limin ZHANG Yunyan WANG Weiping LIU Xiaobo MIN Wenjun LIN Yong KE
    The Chinese Journal of Process Engineering. 2024, 24(5):  558-565.  DOI: 10.12034/j.issn.1009-606X.223327
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    To reduce the amount of zinc leaching residue and improve the metal recycling rate in the traditional zinc smelting process, a Cu-assisted reductive leaching process of zinc leaching residue and zinc calcine was proposed in this study. In the presence of sufficient copper powder, effect of factors including sulfuric acid concentration, liquid-solid ratio, leaching temperature, and the amount of H2SO4 on the zinc leaching efficiency, the residual rate of the solid, and the residual amount of H2SO4 for zinc leaching residue and zinc calcine was investigated. The results of leaching experiment showed that for zinc leaching residue, the zinc leaching efficiency was enhanced from 32.82% to 92.82% assisted by copper, compared to the pure acid leaching process (100 g/L H2SO4, 20 mL/g, 60℃). The residual rate of the solid was decreased from 62.34wt% to 25.20wt%. Values of pH of the leaching solution were increased from 0.12 to 0.36. For zinc calcine, the zinc leaching efficiency was enhanced from 86.52% to 98.82% assisted by copper, compared to the pure acid leaching process (200 g/L H2SO4, 10 mL/g, 60℃). The residual rate of the solid was decreased from 26.56wt% to 6.28wt%. Values of pH of the leaching solution were increased from 0 to 0.19. The least concentration of the residual H2SO4 was 25~26 g/L for sufficient extraction of zinc. The Cu-assisted leaching process has advantages in metal recycling, residue reduction, and low concentration of the residual H2SO4. It supplies a new idea about in situ treatment of zinc leaching residue in zinc smelters.
    Removal performance and mechanism of humic acid by persulfate activated with ultraviolet light combined with magnetic ion exchange resin
    Wenlong WU Yuchen GAO Jinwei ZHANG Ling LI Yan LI Yuchen ZENG Chun YANG Jiapeng LU Lei DING
    The Chinese Journal of Process Engineering. 2024, 24(5):  566-579.  DOI: 10.12034/j.issn.1009-606X.223268
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    Humic acid (HA) in water was removed by activating persulfate with ultraviolet light combined with magnetic ion exchange resin. The removal efficiency of HA, the environmental factors affecting the removal of HA, the generation mechanism of active oxidizing species and the removal mechanism of HA in the ultraviolet light/persulfate/magnetic ion exchange resin (UV/PMS/MIEX) system were explored. The UV/PMS/MIEX synergistic system had a significant removal efficiency for HA in water, and the removal efficiency reached 91.71% after 120 minutes of reaction. The increase in resin dosage and temperature promoted HA removal, and increasing the concentration of persulfate could improve the removal efficiency of HA to a certain extent, but the effect of solution pH on the removal of HA was not obvious. In this system, the removal of HA was mainly through oxidation, and the adsorption effect WAs not significant. The iron oxides on the surface of the resin, the oxygen-containing functional groups and the addition of ultraviolet rays could effectively activate persulfate to produce various active oxidizing species such as ?OH, SO4?-, O2?-, and 1O2. In this system, HA fractions were degraded by the radical and non-radical pathways, and the activation mainly occurs through the radical pathway. Based on the characterization of N2 adsorption-desorption isotherms, Fourier transform infrared spectroscopy, X-ray diffraction spectroscopy, and X-ray photoelectron spectroscopy before and after the reaction, it can be found that the magnetic ion exchange resin exhibits good reusability and stability, and can effectively adsorb and remove various by-products in the system. This study provides a new method for HA removal in water, and the constructed oxidation system shows a good application prospect.
    Investigation of phase structure stability and thermal expansion coefficient of ytterbia stabilized hafnia
    Fei ZHOU Hao LAN Xiaoming SUN Huifeng ZHANG Yonghui SUN Lingzhong DU Weigang ZHANG
    The Chinese Journal of Process Engineering. 2024, 24(5):  580-588.  DOI: 10.12034/j.issn.1009-606X.223074
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    Improvement of the thrust weight ratio of gas turbine engine rely on increased engine operating temperature. At present, it is a priority to find new thermal barrier coating ceramic materials with a higher temperature tolerance than the traditional YSZ (Yttria partially stabilized zirconia) material and match thermal expansion coefficient of Ni-based superalloy matrix. A series of ytterbia stabilized hafnia (YbSH) were prepared with hydrothermal nano-powders by solid-state sintering. Effects of the ytterbia on the microstructure, phase stability, and thermal expansion coefficient of the doped hafnia ceramics were investigated. The microstructure and phase stability mechanism of Yb2O3-doped HfO2 powders and ceramics were analyzed by XRD, Raman, and TEM. DSC-TG and TMA were used to test the high temperature phase structure stability and thermal expansion coefficient of cubic phase structure of YbSH ceramics. The results showed that the grain size of the hydrothermal nano-powder was less than 10 nm, with a uniform distribution and a great crystal state. Most of the powers were cuboid and the density of the sintered ceramics can reach more than 95%. Crystallography analysis revealed that the Yb(III) ion distorted the lattice by replacing Hf(IV) ion position which made the space group of HfO2 from monoclinic phase distortion of P21/c to the cubic phase Fmˉ3m. The hafnia gradually lost its monoclinic phase structure with increasing doping amount of ytterbia, once the doping concentration of ytterbia raised up to 12 mol/mol. By expanding cationic network and generating oxygen vacancy, oxygen overcrowding was effectively alleviated. The cubic phase structure showed good stability from room temperature to 1500℃ by high temperature heat treatment and monitoring enthalpy change of YbSH nanopowders and ceramics during heating process. Average thermal expansion coefficients of YbSH ceramics increased with cubic phase content increasing from 6.016×10-6℃-1 to 10.14×10-6℃-1 (from room temperature to 1500℃). The thermal expansion coefficient of YbSH ceramics doped with 20 mol/mol ytterbia can reach 10.5×10-6℃-1 (from 1000℃ to 1200℃), which was 67.22% higher than that of pure hafnia.
    Preparation and photocatalytic performance of Bi2MoO6/Bi7O9I3 heterojunction
    Benping LIN Yongxiang LI Hanbo YU Chunhua LIU
    The Chinese Journal of Process Engineering. 2024, 24(5):  589-598.  DOI: 10.12034/j.issn.1009-606X.223229
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    Bismuth oxide bismuth molybdate (Bi2MoO6) is a typical Bi(III) based semiconductor with visible light driving characteristics, which has advantages such as good ion conductivity, narrow bandgap, and environmental friendliness. However, the practical application of Bi2MoO6 monomer is severely limited due to its poor intrinsic photo-generated carrier separation, high recombination rate, and narrow light response range. Constructing heterojunctions is an effective method to improve their photocatalytic performance, which not only expands the light absorption range but also promotes the separation of photo-generated charge carriers. However, the construction of heterojunctions has the drawback of lattice mismatch at the interface of two substances, which hinders charge transfer between the interfaces. The one-step synthesis of composite catalysts can effectively reduce the lattice mismatch at the interface, promote the spatial separation of photo-generated electrons and holes, and expand the light absorption range of catalytic materials. In this study, Bi2MoO6/Bi7O9I3 heterojunction materials were synthesized by one-step method. The morphology, chemical composition and photoelectric properties of the heterojunction materials were characterized by instrumental analysis. The effect of material adsorption and photocatalytic degradation of ciprofloxacin (CIP) was studied. The results showed that compared with the single component, Bi2MoO6/Bi7O9I3 composite improved the visible light absorption capacity of Bi2MoO6 monomer, reduced its band gap width, and improved the activity of CIP adsorption and photocatalytic degradation. When the molar ratio of Bi2MoO6 to Bi7O9I3 was 7:3, the best removal rate of CIP was obtained. The absorption removal and photocatalytic degradation rates of CIP were 82.6% and 94.7%. Under the same conditions, the adsorption and degradation rates of monomer Bi2MoO6 and Bi7O9I3 were only 57.4% and 66.4%, 35.2% and 43.6%, respectively. Free radical capture experiments showed that the main active species of Bi2MoO6/Bi7O9I3 photocatalytic degradation of ciprofloxacin were h+ and ?O2-.
    Study on preparation and properties of electrospinning nanofiber membrane for air filtration
    Simin CHENG Fuping QIAN Chen ZHU Lumin CHEN Wei DONG Huaiyu ZHONG
    The Chinese Journal of Process Engineering. 2024, 24(5):  599-608.  DOI: 10.12034/j.issn.1009-606X.223252
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    It has been proved by long-term practice that because the source of atmospheric aerosol particles is very wide, small size, the composition is very complex, the harm to the environment and human health is very serious. Although the government has taken a series of effective measures to control the pollution sources, it still takes a long time to completely solve the PM2.5 pollution problem. If the public wants to reduce the harm caused by particulate matter, specific measures must be taken to conduct individual protection and indoor air purification. At present, the simplest and most effective method for individual protection and indoor air purification is to filter the particles in the air through fiber filtration materials, thus reducing their content in the air. However, traditional fiber filtration materials have the disadvantages of low filtration efficiency, high filtration pressure drop and high energy consumption in the process of use. Meanwhile, filtration fibers with high filtration efficiency are often accompanied by higher filtration resistance. In order to develop high efficiency and low resistance fiber membrane for air filtration, polyacrylonitrile (PAN) electrospinning nanofibers were prepared by electrospinning. In the preparation process, the mass fraction of PAN and the duration of electrospinning were changed, and the electrospinning nanofiber films with different morphologies and filtration properties were obtained. The morphologies and filtration properties of electrostatic spinning nanofibers were tested and analyzed by field emission scanning electron microscopy and filtration test platform, and the preparation parameters of the best performance PAN electrostatic spinning nanofiber membranes were obtained with PAN mass fraction of 9wt%, electrospinning time of 5.0 h. Under the optimum condition, the film thickness of electrospinning nanofibers was 0.0240 mm, the average fiber diameter was 396 nm, the PM2.5 filtration efficiency was 99.99%, the filtration pressure drop was 67 Pa, and the highest quality factor was 0.137 Pa-1.
    A structured assessment method of human error probability for chemical systems
    Qianlin WANG Shicheng CHEN Xiaodong HU Jianwen ZHANG Liangchao CHEN Jinghai LI Zhan DOU
    The Chinese Journal of Process Engineering. 2024, 24(5):  609-617.  DOI: 10.12034/j.issn.1009-606X.223251
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    At present, the essential reliability of chemical equipment has been increasingly improved with a development of automation and information technology, and human error has become the main factor over chemical accidents. Hence it is necessary to conduct human reliability analysis (HRA) on chemical systems to ensure their safe and stable operations. However, the chemical systems have a high non-linearity and complex coupling. The existing HRA technologies cannot be directly applied on them, and the effectiveness and accuracy of analysis results are poor. Therefore, this work proposes a structured assessment method of human error probability for chemical systems. This method particularly combines the human-hazard and operability analysis (human-HAZOP) with Bayesian network (BN). Firstly, according to the operation manual, process flow diagram, and other information of a chemical system, the tasks are summarized for human-HAZOP and further subdivided into several operation steps and behaviors. Secondly, meaningful deviations are selected using the operation behaviors and guide words. Accordingly, the potential causes, possible consequences, existing measures, and suggested measures are analyzed to form a structured human-HAZOP report for this chemical system. Thirdly, based on the human-HAZOP results, the potential causes and possible consequences are considered as leaf nodes and root nodes, respectively. A structured BN model is finally established to calculate the human error probability in the chemical system. The esterification reaction of one methyl-acrylate virtual simulation factory is taken as a test case. The probability of human error for the esterification reaction is calculated to be 0.0004 and the main human error behavior is maintenance staff stealing work omission of maintenance staff. Traditional CREAM analysis of this chemical system results in human error probability results of 0.0001 to 0.01. Results show that this structured method can effectively and accurately assess the human error probability of chemical systems in comparison with the traditional CREAM.
    Fault diagnosis based on DA-CycleGAN for multimode chemical processes
    Wenjing CHEN Changchun DAI Yagu DANG Yiyang DAI Xu JI
    The Chinese Journal of Process Engineering. 2024, 24(5):  618-626.  DOI: 10.12034/j.issn.1009-606X.223316
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    In modern chemical processes, timely and accurate fault diagnosis is important for enhancing the safety and reliability. Data-driven fault diagnosis methods have been regarded as a promising approach in the last decades of research for increasingly complex chemical processes. Data-driven fault diagnosis methods can greatly reduce the dependence on human experience, and realize end-to-end fault diagnosis by automatically extracting features. However, most existing research assumes training and testing data come from the same distribution, while a chemical process may have multiple working conditions. On the one hand, the fault diagnosis performance of the model will deteriorate when the process is run under new working conditions. On the other hand, due to the low probability of failure, some operating conditions may have few fault data in history. To address these issues, in this work, a novel fault diagnosis method, DA-CycleGAN, is proposed for multimode chemical processes. This study is the first to overcome the degradation of model diagnosis performance when only normal data are available under new working conditions. It notes that the normal data is available under any working condition. A two-dimensional CycleGAN is used to capture the temporal and spatial features of fault data. And fault data is generated by combining fault features and normal data under new operating conditions, thus filling a blank in new working conditions for fault data. Furthermore, the domain adaptation method is used to minimize the distribution differences between historical fault data and generated data and to improve the fault diagnostic performance under new operating conditions. To test the performance of this method, four working conditions of the Tennessee-Easthman (TE) process are used in the experiment. The results on twelve condition-changed fault diagnosis tasks show that this method can improve the average fault diagnosis rate by more than 3% compared to the model trained using only historical fault data.