Design Of Pilot Plant Research Articles

Design and development of pilot plant applied to wind and light abandonment power conversion: Electromagnetic heating of solid particles and steam generator

With the rising capacity of renewable energy electricity but incomplete supporting dissipation equipment, this work develops a new charging and discharging device for electromagnetic heating of solid particles to convert electricity from renewable sources into superheated steam, which achieves battery storage efficiency with sufficient safety, terrain-independent and scalable through paralleling. The study reveals that the electro-thermal conversion efficiency of electromagnetically heated iron ore particles increases with particle mass flow rate at different wall temperatures, reaching a maximum of 93.8% at 500 °C. In contrast, the efficiency trend for quartz sand particles is inconsistent, peaking at 68% due to poor thermal conductivity causing inefficiencies at higher mass flow rates. A dimensionless mathematical model (Re-Nu, Re < 10) for both particles is derived from experimental data, offering theoretical guidance for industrialization. Experiments with a shell-and-tube solid particle-packed bed yield continuous production of 35 kg/h, 300 °C superheated steam for 12 min with an 86.4% discharge efficiency and achieve an 81% cycle efficiency, which surpasses compressed air storage(60%), approaches battery and flywheel efficiency(85%). Economic feasibility analysis for a 5MW/5MWH system under two business models demonstrates a short payback period of 2.62 years when providing industrial steam and 6.4 years when used in thermal power plant flexibility transformation. Technological innovations to improve equipment efficiency are critical to the first business mode (selling steam), while grid-determined peak prices are critical to the latter (thermal flexibility retrofits). The study underscores the technical and economic superiority of the proposed devices for utilizing abandoned wind and light, providing a novel solution for carbon reduction and peak shaving in the context of new energy.

Design and Implementation of a Biogas Pilot Plant for Bioaugmentation Strategies in a rural municipality

The transition towards renewable energy sources is imperative for achieving sustainability and mitigating climate change impacts. Among various renewable energies, biogas stands out for its dual role in waste management and energy production. This study introduces the design and implementation of a biogas pilot plant aimed at exploring bioaugmentation strategies to enhance biogas yield and quality. The pilot plant, located at Aras de los Olmos, features two independent 3.4m3 digesters, allowing for parallel comparison between standard anaerobic digestion and digestion with microbial enhancements. The plant is equipped with monitoring and control systems for precise regulation of environmental conditions, such as temperature, and for real-time measurement of biogas composition. Some initial experiments using a mix of agricultural wastes demonstrated the plant's capability to adapt to varied feedstock. Despite suboptimal temperature conditions, preliminary results indicated a high methane content, suggesting significant potential for bioaugmentation to improve biogas production efficiency. The study highlights the importance of controlled environmental conditions and introduces a novel bioaugmented digestion approach using selected microbial consortia. This research contributes to the broader goal of enhancing biogas technology's efficiency and sustainability, offering insights into the practical application of bioaugmentation in biogas production.

Design and Optimization of an Azeotropic Distillation Pilot Plant for the Production of Pure Ethanol

Design and Optimization of an Azeotropic Distillation Pilot Plant for the Production of Pure Ethanol

Guide for Optimization of Olive Leaf Extraction and Silver Nanoparticles Biosynthesis as an Initial Step for Pilot Plant Design.

This account presents the results of two successful optimization processes. First, a polyphenol-rich aqueous olive extract was obtained and then silver nanoparticles (AgNPs) synthesized with high efficiency. Selected parameters for both processes were optimized based on the procedure of the Box-Behnken multifactorial design. The independent variables in the extraction process were the biomass/water ratio, temperature, and time. For AgNPs synthesis, the independent variables were the volume of olive extract, temperature, and process duration. The relationship between the process parameters was visualized graphically by using the response surface methodology. A high fit of the experimental data with the predicted models was shown. The regression coefficients were high, 0.9936 for extraction and 0.9757 for AgNPs biosynthesis. The extraction efficiency under its optimal conditions was as follows: biomass/solvent ratio 0.016, temperature 80 °C for 80 min, and yield 160.67 [μg GAE (gallic acid equivalent)/mL]. The highest yield of AgNPs synthesis, equal to 1.955, was obtained when it was carried out for 50 min at 75 °C with the application of 11 mL of extract. Studies on the AgNPs suspension's stability depending on the extract amount were demonstrated. A physicochemical analysis using dynamic light scattering, transmission electron microscopy images, and Fourier transform infrared spectroscopy for AgNPs obtained under optimal conditions was shown. Finally, a pilot-scale biosynthesis of AgNPs was designed.

ТРИБОТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ СМАЗКИ «ЛИТОЛ-24» С ДОБАВКАМИ ГЕОМОДИФИКАТОРОВ ТРЕНИЯ И ГРАФЕНА

In the technical service of machines and equipment, additives to lubricants are used that reduce the coefficient of friction and wear, and extend the life of tribocouplings. The article examined the tribological characteristics of the Litol-24 grease with additives of a friction geomodifier and graphene. (Research purpose)To evaluate the prospects for using a friction geomodifier and graphene in the commercially produced lubricant “Litol-24”. (Materials and methods) Litol-24 grease, manufactured in accordance with the state standard, was used as the base lubricant. Penetration and dropping point were determined using standard methods. Laboratory tests for wear resistance were carried out on a friction machine 2070. Bench tests - on a specially designed pilot plant, on serial rolling bearings. During the tests, the bearing temperature, noise level, friction torque, and radial clearance were monitored. (Results and discussion) Experimental studies have shown that the combined introduction of a friction geomodifier and graphene in an amount of 0.2 percent leads to a greater reduction in wear (by 9.7 percent) and temperature (by 19.3 percent), and the friction moment in the contact zone in comparison with only one geomodifier. The study established that the dropping temperature remained constant with increasing concentration of fillers. When controlling mechanical losses with an experimental connection, a reduction in the friction moment of bearings by 11.1-12.5 percent was achieved. (Conclusions) The introduction of a friction geomodifier and graphene into the Litol-24 grease makes it possible to reduce wear, the coefficient of friction, the temperature in the mating zone of parts, operating costs and increase the durability of the bearing.

Numerical modelling and process simulation of a post-combustion CO2 capture pilot plant based on a membrane contactor unit

Hollow fiber membrane contactors (HFMC) have gained prominence in post-combustion CO2 capture applications due to their potential for high mass transfer rates, compactness, modularity and versatility. In this work, two pilot plant design have been proposed, an innovative solution which foresees the membrane contactor as CO2 absorption reactor, and a conventional one based on a packed column absorber. A one-dimensional model based on the resistance-in-series method has been developed for the membrane module and validated against experimental data from literature. The other process units have been simulated in Aspen Plus V11. According to the model results the membrane contactor unit is able to guarantee same levels of CO2 removal rates with improved energy performances compared to the conventional packed column absorber. In particular, if the same reactor volume is considered for the two absorber configurations, a reduction in the specific reboiler duty (SRD) of 8.5% is estimated. On the other hand, if the same liquid-to-gas (L/G) ratio is applied, the HFMC is able to guarantee a required reactor volume almost halved (45% reduction). These substantial improvements of the CO2 capture process could lead to lower investment cost and better economic indicators of the CO2 capture plant.

On the comparative analysis of approaches to the definition and classification of pilot testing infrastructure at the state level

Aim. To compare the current research approaches to the functioning and development of pilot testing infrastructure in the contour of innovation and technological activity in Russia and abroad.Objectives. To identify the role and functions of experimental-industrial testing in the system of research, development and technological works (R&amp;D) of the country; to identify and compare international approaches to the classification of the infrastructure of experimental-industrial testing; to analyze the current domestic legislative and regulatory framework regulating the activities in the field of experimental-industrial testing.Methods. The research applied general scientific methods (system approach, decomposition, analysis and synthesis, induction and deduction), private methods (structural-logical and subjectobject), methods of graphical structuring and data interpretation.Results. The authors described the evolution of approaches to the definition of the term “pilot testing” on the example of studies of domestic and foreign scientists, substantiated the need to distinguish the terms “pilot testing” and “pilot infrastructure”, highlighted and schematically characterized their relationship. The comparison of international and domestic scientific and regulatory approaches has revealed diversity both in the terminology used and their interpretation, and in the types of classification of this type of activity. The article presents three most common approaches to the definition and classification of the material and technical base of pilot tests.Conclusions. Pilot testing is an important stage in the process of implementation and scaling of technological innovations, which allows successful technology transfer from laboratory to industrial environment. Despite the positive experience of the Soviet Union in the aspect of design, construction and operation of pilot plants, the modern innovation and technology policy of the country does not prioritize the development of this area, and the activity has low dynamics of development. Insufficient attention to the improvement of measures and tools to support the development of pilot testing infrastructure may become a constraint for solving the state tasks of import substitution and import substitution. Despite the unambiguous general conclusion of all studies about the exceptional importance of the stage of pilot testing for the process of implementation and scaling of technological innovations in general, in many countries of the world there are limitations for the full development of this area of activity. This determines the relevance of continuing research work, including in the context of analyzing the barriers, public and private initiatives for the development of pilot industrial infrastructure.

Implementation of Bacterial Cellulose in Production Plants for Waste Disposal

Waste management is a globally relevant issue of absolute importance. Awareness of the reuse and use of waste, as well as the implementation of methodologies that promote these ideologies, are vital to solving this problem to a large extent. By merging this project with the issue of waste management, specifically the handling of single-use plastics, the authors focus on researching and developing a material that replaces plastic in product packaging, seeking to take advantage of the waste generated in cassava agriculture and promoting the concept of circular economy. Bacterial cellulose is analyzed, considering it a natural and renewable material capable of replacing polypropylene in single-use packaging. A biocellulose manufacturing plant from cassava is proposed. To do this, the research begins with an analysis of the properties of this product, its production methods, the conditions and factors that influence its growth, and its possible applications. The design of a productive pilot plant of bacterial cellulose is studied, with the necessary machinery, elements, sizing, and raw materials required for the described production volumes. Finally, a simulation of the production lines is carried out using the software program Anylogic Simulation, to obtain validation of the proposed plant. Throughout the work, the relationship with the Sustainable Development Goals, the reduction of CO2 emissions, and the replacement of single-use plastics are considered.

Thermochemical behavior and kinetics study of algae pyrolysis using iron oxide catalyst

AbstractThe shift in emphasis from fossil fuel‐derived energy to waste‐to‐energy technologies has widened the possibility for environmentally sustainable methods such as pyrolysis. Algae collected from local sources that grow in wastewater using atmospheric CO2 is a potential feedstock for pyrolysis. Thus, the work focuses on studying the pyrolysis reaction of macroalgae sourced from regional sources in the presence of Fe2O3 catalyst using the thermogravimetric analysis, followed by kinetic analysis using iso‐conversional methods of Flynn–Wall–Ozawa (FWO), Kissinger–Akahira–Sunose (KAS), and Starink methods, and model free Kissinger method. The kinetic model was developed using master plot method. XRD analysis of the Fe2O3 catalyst confirms the presence of the maghemite and hematite phases in the sample. Based on the conversion profile, DTG trend, and kinetic parameter variation, the overall pyrolysis process can be divided into three different stages of dissociation reactions. The apparent activation energy calculated from different models varies in the range: stage I (∼268 kJ/mol), stage II (∼261 kJ/mol), and stage III (∼328 kJ/mol), respectively. Master plot analysis of the kinetic data confirms the best fit of the nucleation model (A2) to experimental data in stage II. Further, the thermodynamic properties of the reaction, such as change in enthalpy (ΔH), change in Gibbs free energy (ΔG), and change in entropy (ΔS) range between 206 and 405 kJ/mol, 189 and 651 kJ/mol, −450 and 27 J/mol/K, respectively, corroborates the complexity of the reaction. Kinetics and thermodynamic property analysis of complex reactions like pyrolysis is essential for pilot plant design.

Architectural development of an ST fusion device

A recent U.S. National Academy study recommended the development of a next step Sustained High Power Density (SHPD) facility within the U.S. as an intermediate step in designing and building a Pilot Plant device [1]. Several papers have been written describing the physics [2], design [3] and engineering scoping analysis performed in developing this machine design. This paper places emphasis on the continued evolution of the architectural development of past activities to meet the requirements of an ST fusion pilot plant and power plant. The current effort centers on meeting basic physics and component requirements in a machine design that improves the chance of achieving fission level availability (95%) within an arrangement that promotes design simplicity, offsite construction with on-site modular assembly. As a prelude to both the SHPD and Pilot Plant, a scoping design of a 500MWe Spherical Tokamak Advanced Reactor (STAR) has been defined to investigate design options and physics scenarios that can successfully meet physics performance, engineering requirements and economic conditions of an ST power plant. Following a successful physics/engineering assessment, the STAR Power Plant design will be downsized to meet the specifications established in the design of a near term ST Pilot Plant

FERMI: Fusion Energy Reactor Models Integrator

The Fusion Energy Reactor Models Integrator (FERMI) is an integrated simulation environment under development for the coupled simulation of the plasma, first wall, and blanket of fusion reactor designs. The FERMI goals are to shorten the overall design cycle while guaranteeing unprecedented accuracy, thus integrating fusion design activities, facilitating an optimal reactor design, and reducing development risks. These goals are achieved by coupling single-physics solvers into a multiphysics simulation environment (FERMI). The Integrated Plasma Simulator (IPS)–FASt TRANsport (IPS-FASTRAN) simulation framework is used for the following: plasma physics, MCNP/Shift codes for neutron and photon transport, OpenFoam for computational fluid dynamics and magnetohydrodynamics (MHD), HyPerComp Incompressible MHD solver for Arbitrary Geometry (HIMAG) for dual-coolant lead-lithium (DCLL) blankets, and DIABLO for structural mechanics simulations. These codes are coupled using the open-source library named precise Code Interaction Coupling Environment (preCICE). FERMI’s features are tested with the analysis of the liquid immersion blanket (LIB) [proposed in the Affordable Robust Compact (ARC)–class tokamak design], the DCLL blanket [proposed in the Fusion Pilot Plant (FPP) design], and other benchmark cases. The calculated figures of merit are the tritium breeding ratio, material activation, displacements per atom, shutdown dose rate, heat deposited in the vacuum vessel and blanket, temperature hot spots, and displacements caused by swelling and creep. A critical technical problem is multiphysics code coupling, which is tackled here, and the first three-dimensional (3D) simulations of the DCLL-FPP and LIB-ARC blankets are presented. To the authors’ knowledge, FERMI represents the first effort to perform 3D simulations of nuclear fusion first wall and blankets in a fully coupled multiphysics manner.

A semi-industrial reactor for producing biodiesel from waste cooking oil

This work offers a pilot plant unit designed to produce biodiesel efficiently from waste cooking oil (WCO). The quality of biodiesel from the semi-industrial plant met American Society of Testing and Materials (ASTM) standards with a maximum yield of 71.56%. Many biodiesel samples were tested, but the highest yield was 71.56%, achieved with a mixing speed of 200 rpm, 20% methanol/oil ratio, reaction time of 90 min, reaction temperature of 70 °C, and catalyst concentration of 1%. The fatty acids in WCO were palmitic, oleic, and linoleic, 5.13, 37.22 and 7.66%, but for biodiesel they were 5.1, 26.16 and 49.51%, respectively. Thermal gravimetric analysis and Thin-layer chromatography confirmed the formation of biodiesel. The ester is in the range of 1741:2823 cm−1, which is related to the stretching band of C = O. The physicochemical properties agreed with ASTM standards. The biodiesel yield is significantly affected by the quality of the used WCO. The results indicate the significant effect of purity, quality, cooking temperature and cooking time of the used oil on biodiesel yield. A high yield of 94.5% was obtained for high-quality oil that was slightly heated for no cooking time. The designed pilot plant is efficient and reliable at producing biodiesel from WCO.

Fusion Fuel Cycle Inventory Reduction Studies Using a Processing-Time–Based Discrete-Time Interval Model

Developing a Fusion Pilot Plant (FPP) design that minimizes risks due to tritium in-process inventory (IPI) is an important concern for the operation of commercial devices. This becomes even more of concern since an FPP will be breeding more tritium than is burned in the reactor for sustainability. The IPI is the tritium moving through the system that is not in the storage and delivery subsystem. A process model that solves time-dependent differential equations based on processing times was used to investigate the reduction of the IPI of a potential fuel cycle design. The impact of new and more efficient technologies such as direct internal recycling (DIR), metal foil pumps, continuous pumping, improved isotope separation, and hydrogen separating continuous pumps on IPI was investigated by adjusting subsystem processing times and material flow streams. It was shown that any of the insertions of DIR studied in this paper caused a reduction in the total IPI of the system and proved to be the optimal way to reduce the IPI in the system. Fuel cycle modifications near the torus, such as a coupled DIR and improved pumping systems, produced the largest reductions in tritium inventory.

Heat-activated persulfate for the degradation of micropollutants in water: A comprehensive review and future perspectives.

This work is a critical review of the most important studies that have dealt with heat-activated persulfate to degrade persistent micropollutants in the last six years. The effect of the different operating parameters is discussed, wherein in all cases, the efficiency was favored at higher temperatures and oxidant concentrations. Particular emphasis was given to the effect of the aqueous matrix. Since heat activation is a homogeneous process based on the production of free radicals, in most of the studies presented, the removal of pollutants decreases as the complexity of the aqueous matrix increases except in cases where secondary oxidative species are produced that are selective with specific pollutants. It has also been observed that the change in toxicity usually follows the removal of the parent compound despite the formation of several by-products. Nowadays, combining different processes for the simultaneous activation of persulfate seems to be gaining ground. A hybrid process is an interesting strategy to reduce costs and increase efficiency, especially in real wastewater. In this light, the most interesting studies of hybrid systems for the destruction of micropollutants in recent years based on thermally activated persulfate are also summarized. Finally, some steps are proposed for future research towards the industrial application, including the study of chemical mixtures, the integrated toxicity assessment, the examination of simultaneous disinfection and decomposition of pollutants into real wastewater, the estimation of the required costs, and energy the combination of processes and their coupling with renewable sources, and the design of pilot plants and the scale-up of the hybrid processes.

HTS Cable Conductor for Compact Fusion Tokamak Solenoids

Significant progress has been made recently in the US fusion community to develop a strategic plan to enable engineering design and construction of a fusion pilot plant (FPP). Princeton Plasma Physics Laboratory (PPPL) is working on developing high current density HTS conductors for next fusion experiments. Partnering with the US industry, we are evaluating feasibility and affordability of Conductor on Round Core (CORC <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">${}^\circledR$</tex-math></inline-formula> ) developed by Advanced Conductor Technologies (ACT) for the next compact fusion tokamak facility. High current density achieved by a CORC <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"><tex-math notation="LaTeX">${}^\circledR$</tex-math></inline-formula> cable based on a four-layer model coil recently tested at National High Magnetic Field Laboratory (NHMFL) motivated its consideration for low cost, reduced size fusion magnet application. This is of interest to PPPL because of its scalability to tokamak central solenoid (CS) coils in terms of required flux swings for plasma startup operations. Partnering with ACT, we designed and built a two-layer model coil solenoid directly wound with CORC to demonstrate its applicability for compact solenoids such as that used in the national spherical torus experiment (NSTX), NSTX-upgrade (NSTX-U) and the US sustained high-power density test facility (SHPD). The ∼160 mm diameter solenoid wound by a two-layer CORC is being tested in early 2022 under electromagnetic cyclic loading at NHMFL in a unique 160 mm bore, 14 T background field magnet facility.

Comprehensive optimization of coal chemical looping gasification process for low CO2 emission based on multi-scale simulation coupled experiment

Carbon dioxide (CO2) emission reduction has become an urgent topic to be studied and solved with the in-depth understanding of global warming and frequent occurrence of extreme climate. At present, the application of chemical looping technology in coal gasification to produce high purity synthesis gas is an important way to achieve CO2 emission reduction, ensure energy security, and promote ecological civilization. In this paper, a new fusion research method combining multi-scale modeling and experimental testing is adopted to comprehensively optimize the coal chemical looping gasification (CCLG) process, aiming at ruducing CO2 emissions in the synthesis gas production of CCLG. In order to investigate the effect of main reaction conditions on CCLG process, the pyrolysis and gasification experiments of Meihuajing coal are carried out in a tubular furnace reactor with Fe2O3 and CuO as oxygen carriers respectively. Subsequently, the multi-scale simulation of CCLG process including molecular dynamics (MD) and computational fluid dynamics (CFD) simulations is performed to validate the experimental results and supplement important reaction kinetics data. Both of multi-scale modeling and experimental testing suggest that the optimum pyrolysis temperature range, gasification temperature range, char/oxygen carrier mass ratio (C/O), and steam flow are below 900 ℃, 900–950 ℃, 1:1.5, and 0.15 g/min respectively, providing an effective guidance for the optimal design of practical CCLG pilot plant.

Design of pilot plant for MMA monomers using plant-derived materials has begun

Animal-assisted interventions (AAI) are now being considered an alternative and complimentary treatment modality, supporting the physical, psychosocial, and educational needs of children and adults. AAI is the accepted umbrella term that encompasses various practices including animal-assisted therapy, animal-assisted education, and animal-assisted activities. This article will discuss the foundations of AAI and provide supporting information to conceptualize the value of human–animal interactions. Additionally, attention will be given to provide a possible roadmap for the future of AAI, as well as a discussion on the importance of preserving the welfare of the therapy animals involved.

Using a Virtual Engineering Environment for the Design and Development of a Compact Pilot Plant

This paper introduces a new implementation using virtual engineering approaches in support of the design and development of a compact pilot plant. Developing a compact pilot plant is a costly and high-risk approach. Risk and resource investments can be optimized by using commercially based virtual engineering, integrated simulation, and virtual prototyping environments in the design and development of a compact pilot plant. This paper identifies both the users of the virtual engineering environment as well as where in the system lifecycle it can be implemented. The environment will use and extend existing multiphysics models and simulation of products and characteristics through the development of system-level models and an investigation of virtual prototypes of component elements. The second level involves knowledge sharing across phases of the lifecycle of products, including all contributors and stakeholders in the virtual environment.

Design of a scheelite production pilot plant for the treatment of spent electroless nickel plating solutions in Field Service Solution S.A.S.: an alternative source for tungsten recycling

In this contribution, the design considerations to assemble a pilot-plant for tungsten recovery and further conversion into synthetic scheeliteas raw material, as an eco-friendly improvement for the current electroless nickel process in Field Service Solution (FES) S. A. S., arepresented. This low-cost methodology scale-up aims to provide an alternative treatment for spent electroless nickel solutions (Ni-P-W) asa secondary tungsten source. The plant is projected to treat up to 750 L of industrial waste per week, achieving a maximum scheeliteproduction of 9.1 kg per week. This prototype serves as a model of eco-sustainability in the nickel-plating industry by controlling thedisposal of heavy metals and by facilitating the production of other tungsten derivatives and their feasible reuse in the process.

Design of Bio-Absorbent Systems for the Removal of Hydrocarbons from Industrial Wastewater: Pilot-Plant Scale.

The objective of this study was the development and design of a treatment system at a pilot-plant scale for the remediation of hydrocarbons in industrial wastewater. The treatment consists of a combined approach of absorption and biodegradation to obtain treated water with sufficient quality to be reused in fire defense systems (FDSs). The plant consists of four vertical flow columns (bioreactors) made of stainless steel (ATEX Standard) with dimensions of 1.65 × 0.5 m and water volumes of 192.4 L. Each bioreactor includes a holder to contain the absorbent material (Pad Sentec polypropylene). The effectiveness of the treatment system has been studied in wastewater with high and low pollutant loads (concentrations higher than 60,000 mg L−1 of total petroleum hydrocarbons (TPH) and lower than 500 mg L−1 of TPHs, respectively). The pilot-plant design can function at two different flow rates, Q1 (180 L h−1) and Q2 (780 L h−1), with or without additional aeration. The results obtained for strongly polluted wastewaters showed that, at low flow rates, additional aeration enhanced hydrocarbon removal, while aeration was unnecessary at high flow rates. For wastewater with a low pollutant load, we selected a flow rate of 780 L h−1 without aeration. Different recirculation times were also tested along with the application of a post-treatment lasting 7 days inside the bioreactor without recirculation. The microbial diversity studies showed similar populations of bacteria and fungi in the inlet and outlet wastewater. Likewise, high similarity indices were observed between the adhered and suspended biomass within the bioreactors. The results showed that the setup and optimization of the reactor represent a step forward in the application of bioremediation processes at an industrial/large scale.