Bench-scale Reactor Research Articles

Characteristics of Biochar Obtained by Pyrolysis of Residual Forest Biomass at Different Process Scales

In this work, the pyrolysis process and the characteristics of biochar produced using a bench-scale fixed-bed reactor and a prototype-scale auger reactor were studied. Residual forest biomass (RFB) from acacia, broom, gorse, and giant reed was used as feedstock. Besides information on pyrolysis characteristics of these specific biomass species from the Iberian Peninsula, new knowledge on the understanding of how results from small-scale reactors can be used to predict the behavior of higher-scale and continuous-operation reactors is offered. Batch pyrolysis was carried out using 40 g of biomass sample in a fixed-bed reactor with a heating rate of 20 °C∙min−1, pyrolysis temperature of 450 and 550 °C, and a residence time of 30 min, while for the continuous process it was used a prototype of an auger reactor with continuous operation with a biomass flow rate up to 1 kg/h, with temperatures of 450 and 550 °C, and a solids residence time of 5 min. The biochar yield was in the range of 0.26 to 0.36 kg/kg biomass dry basis, being similar for both types of reactors and slightly lower when using the auger reactor. The proximate analysis of the biochar shows volatile matter in the range 0.10 to 0.27 kg/kg biochar dry basis, fixed carbon in the range 0.65 to 0.84 kg/kg biochar dry basis, and ash in the range 0.04 to 0.08 kg/kg biochar dry basis. The carbon, oxygen, and hydrogen content of the biochar was in the range of 0.71 to 0.81, 0.09 to 0.22, and 0.02 to 0.03 kg/kg biochar dry basis, respectively. The results show that the up-scaling of the reactor and regime of operation does not have an important influence on the yield and characteristics of the biochar produced. The biochar obtained in the two types of reactors has characteristics appropriate for environmental applications, such as an additive to improve soil properties. It is possible to see that the characteristics of the biochar are influenced by the type of biomass and the conditions and parameters of the process; therefore, it is of major importance to control and know of these conditions, especially when considering upscaling scenarios.

Pilot-scale study of methane-assisted catalytic bitumen partial upgrading

The direct utilization of heavy and extra-heavy crude oils presents a formidable challenge due to their inherent physical and chemical properties such as high C/H ratio, extremely high viscosity and density, low APIo, super low mobility, high asphaltene and impurity (Fe, Ni, Co, S, N, etc.) contents. To tackle these problems cost-effectively, we have proposed and established a novel technique, distinct from conventional hydrotreating, for catalytic partial upgrading of extra heavy crudes with co-fed methane and a multi-functional catalyst. This technique has been further optimized using lab-scale batch reactors (100 mL, 300 mL), bench-scale and pilot-scale fixed bed reactors with their processing capacity of 250 mL/day and 20 L/day, respectively. The feasibility, stability, and profitability of this technique have been successfully verified using all these facilities and a wide variety of feedstock. Yet, further scale-up is necessary to advance this technique towards commercialization in industry. In this study, a pilot-scale prototype unit (processing capacity of 1 barrel/day) was designed and manufactured based upon the previous achievements, and a bitumen sample recovered from the Steam Assisted Gravity Drainage (SAGD) process was chosen as a typical extra heavy crude for the upgrading. A 30-day upgrading has been conducted smoothly without clogging and a liquid yield of 96.7 % was observed with remarkable enhancements in product quality. The notable decreases in density, viscosity, TAN, asphaltene content, and sulfur content were confirmed and consistent with previous results. A low olefin content implies excellent stability and compatibility of the liquid product. Additionally, a preliminary TEA (Techno-Economic Assessment) and LCA (Life-Cycle Analysis) have been conducted and the beneficial features of this novel technique have been confirmed with higher profitability, lower cost, and lower carbon footprint. This study further consolidates the advantages of this promising technique as a cost-effective and environmentally friendly alternative to hydrotreating for processing extra heavy crudes.

Artificial intelligence-driven control for enhancing carbon dioxide-based wastewater pH regulation in tubular reactor

Alkaline wastewater treatment using carbon dioxide can reduce chemical costs and provide a safer alternative to traditional methods. However, complex gas-liquid reactions and narrow operating pH ranges present challenges. This research develops an artificial intelligence-driven control system for treating alkaline wastewater using carbon dioxide in a bench-scale tubular reactor. The proposed control system employs an inverse neural network to regulate the carbon dioxide gas based on the desired setpoint, along with a Smith predictor and a linear controller to compensate for natural delays, model mismatches, and pH disturbances. The inverse neural controller was trained using experimental data from a bench-scale reactor pH treatment of synthetic alkaline wastewater and verified on real influent from an electroplating wastewater treatment plant. The results show that the proposed method efficiently enforces the desired reactor outlet pH setpoint with up to 51.36% faster settling time than a proportional-integral controller while improving pH-adjusting efficiency by 72.24%.

Coke formation and mineral accumulation on HZSM-5/Al2O3 catalysts during in-situ catalytic fast pyrolysis of microalgae over multiple regeneration cycles

Catalyst deactivation caused by coke formation and mineral accumulation occurs simultaneously and intensively during the catalytic pyrolysis of biomass. A comprehensive understanding of their distinction and interactions during the deactivation and regeneration process of shaped catalysts are essential for catalyst advancement and longevity in industrial application. In this study, we report the reversible and non-reversible catalyst deactivation caused by coke formation, mineral accumulation and the interactions thereof by a multi-technique characterization of a HZSM-5/Al2O3 catalyst (crushed extrudates; particle size 1–3 mm) in fast pyrolysis. A total of 5 cycles of catalyst reaction/regeneration were performed in a bench scale reactor (60 g/h feedstock feeding rate; pyrolysis temperature of 500°C) using both raw microalgae (Scenedesmus almeriensis, or SA) and citric acid treated microalgae (CA-SA). The measured properties of the fresh and used catalysts (SA-R5, 5th recycled and reacted catalyst mixed with SA) disclosed the anticorrelation of the metal contents (increased by a factor of 2.5 times) with surface area (-4.4 %) and Brønsted acid (-70.4 %). The presence of minerals in the feedstock might catalytically alter the pyrolysis chemistry, interfere with the shape selectivity and acidity of the catalysts, thus reduced the formation of coke. Additionally, metal species from the microalgae ash that ended up on the catalyst could promote coke combustion during the regeneration process. This work revealed the demineralization of the microalgae prior to fast pyrolysis minimized the rate of irreversible catalyst deactivation. Whereas, the trade-off between promoted coke formation after the ash removal of microalgae and accelerated minerals accumulation without microalgae demineralization should be evaluated.

Scaling a bifunctional catalytic Fixed-Bed reactor for acetone-to-mesitylene Jet-Fuel additive production

De-fossilization of the aviation sector will require the use of renewable synthetic jet fuels and additives that comply with strict regulations. One such additive, mesitylene, can be produced using a novel sustainable process based on the fermentation of biomass waste to acetone, followed by the self-condensation of acetone to mesitylene. This study addresses the viability of gas-phase self-condensation of acetone, catalyzed by TiO2 and Al-MCM-41 acid catalysts, at a technological readiness level of TRL-4.The reactor used was a bench-scale fixed-bed reactor (28 mm diameter and 500 mm height) loaded with commercial-sized catalyst pellets (1/8″ diameter). It was equipped with a jacket for heat transfer using flowing thermal oil. The performance of commercial-scale reactors was approximated under conditions of 275 °C, 280 kPa, and a space velocity of 50–500 mol/kg·h.The catalyst pellets exhibited significant mass transfer resistances, which limited the reaction rate. This, in turn, reduced the deactivation rate caused by the adsorption of high-molecular-weight condensation products on the strongest acid sites. Additionally, the product distribution differed between pellet and powder forms of the catalysts, with higher yields of isophorone and mesitylene being observed on TiO2 and Al-MCM-41 pellets, respectively. A reaction and mass transfer model was proposed and fitted to the bench-scale data.The study also considered the combination of both catalyst pellets in the same reactor for the bench-scale unit. It was demonstrated that mesitylene yield could be improved, with the best configuration being two separate beds placed consecutively in the reactor with a catalyst ratio of 1:2 (TiO2:MCM-41).

Unrefined and Milled Ilmenite as a Cost-Effective Photocatalyst for UV-Assisted Destruction and Mineralization of PFAS.

Per- and polyfluoroalkyl substances (PFAS) are fluorinated and refractory pollutants that are ubiquitous in industrial wastewater. Photocatalytic destruction of such pollutants with catalysts such as TiO2 and ZnO is an attractive avenue for removal of PFAS, but refined forms of such photocatalysts are expensive. This study, for the first time, utilized milled unrefined raw mineral ilmenite, coupled to UV-C irradiation to achieve mineralization of the two model PFAS compounds perfluorooctanoic acid (PFOA) and perfluoro octane sulfonic acid (PFOS). Results obtained using a bench-scale photocatalytic reactor system demonstrated rapid removal kinetics of PFAS compounds (>90% removal in less than 10 h) in environmentally-relevant concentrations (200-1000 ppb). Raw ilmenite was reused over three consecutive degradation cycles of PFAS, retaining >80% removal efficiency. Analysis of degradation products indicated defluorination and the presence of shorter-chain PFAS intermediates in the initial samples. End samples indicated the disappearance of short-chain PFAS intermediates and further accumulation of fluoride ions, suggesting that original PFAS compounds underwent mineralization due to an oxygen-radical-based photocatalytic destruction mechanism induced by TiO2 present in ilmenite and UV irradiation. The outcome of this study implies that raw ilmenite coupled to UV-C is suitable for cost-effective reactor operation and efficient photocatalytic destruction of PFAS compounds.

Kinetic Model Implementation of Fluidized Bed Devolatilization

Computational modeling is a powerful tool for studying and investigating the behavior of fluidized bed gasifiers and the modeling of the initial devolatilization step is necessary to provide a reliable description of the whole process involving the feedstock decomposition and the subsequent gasification reaction. In this work, a bench-scale fluidized bed reactor was used to examine the devolatilization of different carbonaceous materials within the temperature range from 650 to 850 °C. The experimental test campaign was used to derive the linear correlation factor to describe the devolatilization in terms of product distribution as a function of temperature and highlight the different behavior between lignocellulosic and plastic feedstocks. Furthermore, the experimental data were used to develop concise kinetic expressions able to fit the experimental devolatilization times ranging from 75 in the case of poplar at a lower temperature and 22 s for the Organic Fraction of Municipal Solid Waste (OFMSW) at a higher temperature. The obtained model produces a simple kinetic expression where the size of the particle is enclosed in the kinetic parameters. The kinetic model sided by the application of linear correlations describes the overall thermal decomposition in a fluidized bed, simplifying its modeling in commercial simulation software, even when particles are considered as point-like bodies.

Pilot-scale electrochemical advanced oxidation (EAOP) system for the treatment of Ni-EDTA-containing wastewater

Electrochemical advanced oxidation processes (EAOP) have shown great potential for the abatement of complexed heavy metals, such as metal-EDTA complexes, in recent studies. While removal of metal-EDTA complexes has been extensively examined in bench-scale reactors, much less attention has been given to the efficacy of this process at larger scale. In this study, we utilize a 72 L pilot-scale continuous flow system comprised of six serpentine flow channels and 90 pairs of flow-through electrodes for the degradation of Ni-EDTA complexes and removal of Ni from solution. The influence of a range of key operating parameters including flow rate, current density and initial Ni-EDTA concentration on rate and extent of Ni-EDTA degradation and Ni removal were examined. Our results showed that at a feed flow rate of 36 L h−1, current density of 5 mA cm−2 and initial Ni-EDTA concentration of 1 mM, the pilot-scale system achieved 74 % total Ni removal, 78 % total EDTA removal and 40 % TOC removal with energy consumption of 13.6 kWh m−3 order−1 and energy efficiency of 7.9 g kWh−1 for total Ni removal. A mechanistically-based kinetic model, which was developed in our previous bench-scale study, provides a satisfactory description of the experimental results obtained in the pilot-scale unit. Long term operation of the pilot-scale unit resulted in corrosion of PbO2 anode along with inorganic scaling as well as organic fouling on the PbO2 surface resulting in an obvious decline in Ni-EDTA degradation. Overall, the results of this study suggest that large scale anodic oxidation of wastewaters containing metal-organic complexes is an effective means of degrading organic ligands thereby enabling removal of the metal at the cathode. However, additional efforts are required to enhance the durability of the anode material and reduce material costs and energy consumption.

Simultaneous veterinary antibiotics reduction and biomass production from pig slurry by microalgae co-immobilization in moving bed biofilm reactors

The objective of the study was to assess, for the first time, the effectiveness of using either freely suspended or co-immobilized microalgae on Moving Bed Biofilm Reactor carriers in removing lincomycin from the liquid fraction of pig slurry, while ensuring the safe production of biomass. To this end, continuous-mode (HRT = 8 d) and batch-mode (10 d) experiments were conducted on bench-scale reactors. In the continuous-mode experiment, co-immobilized microalgae removed 99 % of lincomycin and 94 % of ammonium, whereas the control reactors and free-microalgae reactors showed significantly lower ammonium removals (69 % and 87 %, respectively). The removal rates for lincomycin and ammonium in co-immobilized microalgae reactors were higher (0.85 and 0.32 d−1, respectively) than the removal rates of the free-microalgae reactors (0.32 and 0.19 d−1) and control reactor (0.18 and 0.12 d−1). Furthermore, the microalgae reactors were linked with the production of lincomycin transformation products following ammonium and nitrate removal. In contrast to the control reactors, the suspended biomass of both free microalgae and co-immobilized microalgae reactors showed no accumulation of lincomycin. This characteristic makes this biomass particularly appealing in the context of a circular economy. The study introduces an innovative method for producing biomass from pig slurry, with the goal of obtaining high-value products while minimizing pollutant content.

Conversion of beechwood organosolv lignin via fast pyrolysis and in situ catalytic upgrading towards aromatic and phenolic-rich bio-oil

Lignin, an abundant renewable biopolymer found in plant cell walls, is enriched in phenolic units within its complex molecular structure. Unlocking its potential as alternative feedstock in (bio)refining has posed a long-standing challenge, even though it holds immense promise for replacing fossil-derived phenolic and aromatic compounds. This study focuses on fast pyrolysis as effective thermochemical depolymerization method of lignin, coupled with the in situ catalytic upgrading aiming to produce valuable bio-oil enriched in dealkoxylated (alkyl)phenolic and aromatic compounds. Lignin was isolated via the organosolv process from beechwood sawdust (hardwood biomass). Various acidic aluminosilicate catalysts (e.g., zeolites, such as ZSM-5, Beta and USY, and amorphous silica alumina) were applied, having different Si/Al ratio, porous and acidic properties. Fast pyrolysis experiments were conducted on a fixed-bed bench-scale reactor at two distinct temperatures (500 and 600 °C), employing different contact times and lignin-to-catalyst ratios. Non-catalytic pyrolysis experiments revealed that higher temperature, significantly influences bio-oil’s composition and yield, resulting in the conversion of initially formed alkoxy-phenols to alkyl-phenolic compounds, reaching a 47% relative concentration at 600 °C, while also yielding high amount of bio-oil up to 43 wt%. Among the catalysts tested, zeolite ZSM-5 (Si/Al=40) proved to be the most efficient, shifting the chemical profile of bio-oil from phenolic to aromatic (mainly BTX) with relative concentration of 57%, owing to its unique microporous structure and acidity. Depending on the catalyst type, a balance between BTX monomer aromatics and naphthalenes was observed. Lignin, as well as the obtained products (bio-oil, non-condensable gases, char/coke-on-catalyst) were thoroughly characterized using various analytical techniques. The catalytic upgrading results were associated with the physicochemical properties of the catalysts, providing valuable insights into the underlying reaction mechanisms.

Grindability of Torrefied Camelina Straw and Microparticle Evaluation by Confocal Laser Scanning Microscopy for Use as Biofuel

This study examined the combined effect of torrefaction and microwave absorbers on improving biomass thermochemical characteristics and grindability for heat, power, and value-added products. Camelina straw in two grinds, ground (6.4 mm screen size) and chopped with biochar addition (0%, 10% and 20%), was torrefied in a bench-scale microwave reactor at torrefaction temperatures of 250 °C and 300 °C with residence times of 10, 15 and 20 min under inert conditions and nitrogen-activated. After torrefaction, the geometric mean particle and size distribution, moisture content, ash content, bulk and particle densities were determined, and the grinding performance values of torrefied ground and chopped with and without biochar were determined and compared with the raw camelina straw. The results showed that the geometric diameter decreased after torrefaction in both grinds. The specific energy required for grinding torrefied biomass decreased significantly with biochar addition, longer residence times, and increased torrefaction temperatures. Torrefied ground camelina straw with biochar after grinding had the lowest grinding energy of 34.30 kJ at 300 °C/20 min. The surface morphology by confocal laser scanning microscopy of torrefied camelina straw particles indicated that biochar addition (>10%) and a torrefaction temperature at 250 °C can create profound surface distortion, and beyond 300 °C, colossal surface damage and carbonized weight fractions were produced.

Degradation and mineralization of anti-cancer drugs Capecitabine, Bicalutamide and Irinotecan by UV-irradiation and ozone

The degradation of three anti-cancer drugs (ADs), Capecitabine (CAP), Bicalutamide (BIC) and Irinotecan (IRI), in ultrapure water by ozonation and UV-irradiation was tested in a bench-scale reactor and AD concentrations were measured through ultra-high-performance liquid chromatography tandem mass spectrometry (UHPLC-MS/MS). A low-pressure mercury UV (LP-UV) lamp was used and degradation by UV (λ = 254 nm) followed pseudo-first order kinetics. Incident radiation in the reactor was measured via chemical actinometry using uridine. The quantum yields (φ) for the degradation of CAP, BIC and IRI were 0.012, 0.0020 and 0.0045 mol Einstein−1, respectively. Ozone experiments with CAP and IRI were conducted by adding ozone stock solution to the reactor either with or without addition of tert-butanol (t-BuOH) as radical quencher. Using this experimental arrangement, no degradation of BIC was observed, so a semi-batch setup was employed for the ozone degradation experiments of BIC. Without t-BuOH, apparent second order reaction rate constants for the reaction of the ADs with molecular ozone were determined to be 3.5 ± 0.8 ∙ 103 L mol−1 s−1 (CAP), 7.9 ± 2.1 ∙ 10−1 L mol−1 s−1 (BIC) and 1.0 ± 0.3 ∙ 103 L mol−1 s−1 (IRI). When OH-radicals (∙OH) were quenched, rate constants were virtually the same for CAP and IRI. For BIC, a significantly lower constant of 1.0 ± 0.5 ∙ 10−1 L mol−1 s−1 was determined. Of the tested substances, BIC was the most recalcitrant, with the slowest degradation during both ozonation and UV-irradiation. The extent of mineralization was also determined for both processes. UV irradiation was able to fully degrade up to 80% of DOC, ozonation up to 30%. Toxicity tests with Daphnia magna (D. magna) did not find toxicity for fully degraded solutions of the three ADs at environmentally relevant concentrations.

Thermally manageable and scalable reactor configurations towards efficient hydrogen release from liquid organic hydrogen carriers

In the global pursuit to minimize carbon emissions, hydrogen has emerged as a prominent alternative energy solution. This research introduces a thermally efficient, scalable, and potentially carbon–neutral system for releasing hydrogen, employing methylcyclohexane as a liquid organic hydrogen carrier (LOHC). Our heat supply mechanism utilizes benzyltoluene as a liquid–gas phase change material (PCM) to facilitate effective heat transfer from the heating units to the reactor. We have developed catalysts with high dispersion and Pt loading of Pt/γ-Al2O3 that maintain performance over extended periods, achieving a hydrogen extraction rate of 2.3 Nm3H2(g)/h (equivalent to 5 kgH2/day) in a bench-scale reactor. The bench-scale setup achieves near-equilibrium conversion at a space velocity of 2 LLOHC/(Lcat-h) and 310 °C. The PCM-enhanced system supports a scalable catalytic bed design and simplifies heat supply and startup through the use of various heating methods. We then compare catalytic dehydrogenation reactor setups using single and hybrid heat sources; the former includes an internal Joule heater, offering simplicity and reduced heat loss but depends heavily on electrical energy, while the latter combines the internal Joule heater with an external fuel combustor, facilitating rapid startup albeit with increased heat loss. Lastly, we suggest future research directions to address existing technological hurdles and to expand the application of this system in scaling up hydrogen release processes.

Integrated nutrient recycling: Ammonia recovery from thermophilic composting of shrimp aquaculture sludge via self-heated bench-scale reactor and mango plant growth enhancement by the compost

Due to the rapid growth of the aquaculture industry, large amounts of organic waste are released into nature and polluted the environment. Traditional organic waste treatment such as composting is a time-consuming process that retains the ammonia (NH3) in the compost, and the compost produced has little economic value as organic fertilizer. Illegal direct discharge into the environment is therefore widespread. This study investigates the recovery of NH3 through thermophilic composting of shrimp aquaculture sludge (SAS) and its application as a soil conditioner for the growth of mango plants. A maximum composting temperature of 57.10 °C was achieved through self-heating in a 200 L bench-scale reactor, resulting in NH3 recovery of 224.04 mol/ton-ds after 14 days. The addition of calcium hydroxide and increased aeration have been shown to increase NH3 volatilization. The recovered NH3 up to 3 kg-N can be used as a source of clean nitrogen for high-value microalgae cultivation, with a theoretical yield of up to 34.85 kg-algae of microalgae biomass from 1 ton-ds of SAS composting. Despite the high salinity, SAS compost improved mango plant growth and disease resistance. These results highlight the potential of SAS compost as a sustainable source of clean nitrogen for microalgae cultivation and soil conditioner, contributing to a waste-free circular economy through nutrient recycling and sustainable agriculture.

Morphologically tuned CuO-ZnO-CeO2 catalyst for CO2 hydrogenation to methanol.

Morphologically modified composite CuO-ZnO-CeO2 catalysts were synthesized using a single-step hydrothermal technique. The study highlights the influence of solvent on the structural and physico-chemical properties of the catalysts. Various techniques, such as XRD, FE-SEM, BET, XPS, and H2-TPR, were used to analyze the catalyst properties. Among the synthesized materials, the catalyst, prepared with a N,N-dimethyl formamide (DMF)-to-metal nitrates ratio of 20 (named as CZC-1), showed enhanced active sites in the form of surface features such as nanowire-like morphology, large surface area, low crystallite size, increased oxygen vacancies, and high CuO dispersion. A bench-scale fixed-bed flow reactor was used to examine the catalytic performance of the catalysts. At 225 °C reactor temperature, 30 bar reactor pressure, and with a space velocity of 6000 cm3 gcat-1 h-1, the CZC-1 catalyst showed 13.6% CO2 conversion and 74.1% methanol selectivity. In situ diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) analysis confirmed the carbonate-formate-methoxy reaction pathway for methanol formation using the CZC-1 catalyst.

Source-Separated Industrial Wastewater Is a Candidate for Biogas Production through Anaerobic Digestion

Anaerobic digestion is a potential treatment for industrial wastewater that provides valuable end-products, including renewable energy (biogas). However, waste streams may be too variable, too dilute at high volumes, or missing key components for stable digestion; all factors that increase costs and operational difficulty, making optimisation crucial. Anaerobic digestion may benefit from process intensification, particularly the novel combination of high-strength source-separated wastewater to minimise volume, together with the use of biosolids biochar as a chemical and microbial stabiliser. This study investigates the stability, yield, and microbial community dynamics of the anaerobic digestion of source-separated industrial wastewater from a food manufacturer and a logistics company, using biosolids biochar as an additive, focusing on gas and volatile fatty acid (VFA) production, process stability, and the microbial community using bench-scale semi-continuous reactors at 30- and 45-day hydraulic retention time (HRT). While gas yields were lower than expected, stability was possible at high HRT. Methane production reached 0.24 and 0.43 L day−1 per litre reactor working volume at 30- and 45-day HRT, respectively, despite high VFA concentration, and was linked to the relative abundance of Methanosarcina in the microbial community. Interactions between substrate, VFA concentration, and the microbial community were observed. Biochar-assisted anaerobic digestion holds promise for the treatment of source-separated wastewater.

Steam cracking of sulfur containing compounds: A fundamental modelling study

Sulfur-containing additives are commonly used in industrial steam cracking to mitigate carbon monoxide (CO) formation. Their impact on solid coke deposition in reactors is well-studied but not fully understood. This study investigates the decomposition of five common sulfur compounds (DMDS, DMS, DMSO, CS2, COS) in both inert and hydrocarbon environments within the steam cracking industry. To achieve this, an in-house automated network generation tool called Genesys and a validated ab initio methodology at the CBS-QB3 level are used. This combination generates a comprehensive kinetic model with precise thermodynamic and kinetic parameters. The kinetic model is rigorously validated against experimental data from prior studies under various conditions, including inert nitrogen atmospheres and hydrocarbon matrices (using ethane and heptane). Experimental setups involve bench-scale annular quartz reactors and pilot-scale stainless steel reactors. Remarkably, the kinetic model accurately predicts primary products and captures secondary product trends across diverse conditions without parameter adjustments. Rate of production analyses reveal critical decomposition pathways during sulfur-containing additive pyrolysis and the influence of hydrocarbon matrices. Notably, these additives primarily yield H2S upon decomposition, with CS2, SO2 and thiophene as minor products. In conclusion, the developed fundamental kinetic model accurately predicts product formation during the pyrolysis of DMS, DMDS, DMSO, CS2 and COS, whether in nitrogen or a hydrocarbon matrix, without altering core thermodynamic and kinetic parameters.

Unleashing the potential of leather waste: Biogas generation and cost savings through semi-continuous anaerobic co-digestion

Leather processing is notorious for generating substantial amounts of polluting and putrescible organic waste, usually ending up in landfills or incineration. This study aimed to assess the potential of biogas production, waste treatment efficiency, and energy and cost savings benefits when scaling up the anaerobic co-digestion of leather processing wastes. The study focused on three waste types: tannery primary sludge (TPS), leather fleshings waste (LFW), and tannery wastewater (TWW). Semi-continuous anaerobic digestion experiments were conducted using three bench-scale reactors (R1-R3) over five phases; phases I and II were the startup and stabilization. In phase III, with an organic loading rate (OLR) of 0.6 kgVS/m3/d, the R2 reactor achieved an average of 0.323 m3 methane/kgVS added/day. This performance surpassed the other reactors by 39.14% (R1) and 41.29% (R3). In phases IV and V, using TWW instead of tap water for substrate dilution at different ratios (25–100%) reduced methane yield by 3.32–11.73% compared to the reactor that used tap water. The study further revealed that a medium-sized anaerobic reactor treating tannery wastes could reduce electric energy consumption by 3.64% and thermal energy consumption by 5.20%. This showcases the energy-saving benefits of co-digesting tannery wastes rather than disposing them in landfills. Using tannery wastes instead of traditional disposal methods resulted in approximately 94.68% savings in electric consumption and 45.03% in thermal energy consumption. This study offers a promising approach for sustainable leather waste treatment, biogas production, and considerable energy and cost savings compared to conventional disposal methods like landfilling.

Continuous co-treatment of mine drainage with municipal wastewater

Acid mine drainage (AMD) and municipal wastewater (MWW) are commonly co-occurring waste streams in mining regions. Co-treating AMD at existing wastewater facilities represents an innovative solution for simultaneous AMD reclamation and improved MWW treatment. However, unknowns related to biological processes and continuous treatment performance block full-scale use. The overarching goal of this work was to address questions related to efficacy and performance of continuous processing of AMD in a biological MWW treatment system. Synthetic AMD was co-treated with synthetic MWW in a continuously-operating bench-scale sequencing batch reactor (SBR). SBRs treated MWW with two strengths of AMD (91 and 720 mg/L as CaCO3 Acidity) to capture the variations of coal AMD chemistry and strength observed in the field. Each co-treatment phases lasted 40+ days, during which clarified effluent and settled sludge quality was routinely monitored to determine impacts of co-treatment relative to conventional MWW treatment performance. Co-treatment produced effluent that met key standards for secondary treatment including biochemical oxygen demand (BOD) < 5 mg/L, total suspended solids (TSS) < 20 mg/L, and pH ∼7.0. Addition of AMD also improved treatment performance, increasing Phosphate (PO4) removal by >60% and pathogen removal by an order of magnitude. Furthermore, AMD co-treatment did not exhibit any major impacts on the overall diversity of the wastewater microbial community. Co-treatment sludge had slightly higher settleability and a lower bound water content, but notable changes in sludge morphology was observed. This study demonstrates co-treatment allows for continuous mitigation of AMD without adversely impacting MWW treatment performance in conventional biological MWW processes.

Analysis of biogas production from sewage sludge combining BMP experimental assays and the ADM1 model.

The Anaerobic Digestion Model No. 1 (ADM1) was employed to simulate methane (CH4) production in an anaerobic reactor (AR), and the associated bench-scale biochemical methane potential (BMP) assay, having sewage sludge (SWS) from a municipal wastewater treatment plant (WWTP) as feedstock. The SWS presented the following physical-chemical characteristics: pH (7.4-7.6), alkalinity (2,382±100mg CaCO3 L-1), tCOD (21,903±1,000 mg L-1), TOC (895±100 mg L-1), TS, TVS, and VSS (2.0%, 1.1%, and 0.8%, respectively). The BMP assay was conducted in six replicates under anaerobic mesophilic conditions (37±0.1°C) for 11 days with a CH4 yield registered of 137.6±6.39 NmL CH4 or 124±6.72 CH4 g-1 VS-1. When the results obtained with the BMP bench-scale reactors were compared to the output generated with computational data by the ADM1 model having as input data the same initial sewage tCOD, similar cumulative CH4 production curves were obtained, indicating the accuracy of the ADM1 model. This approach allowed the characterization of the sludge and estimation of its biogas production potential. The combination of BMP assays, experimental data, and ADM1 model simulations provided a framework for studying anaerobic digestion (AD) processes.