Economical Large-scale Production Research Articles

Unlocking Efficient Hydrogen Production: Nucleophilic Oxidation Reactions Coupled with Water Splitting.

Electrocatalytic water splitting driven by sustainable energy is a clean and promising water-chemical fuel conversion technology for the production of high-purity green hydrogen. However, the sluggish kinetics of anodic oxygen evolution reaction (OER) pose challenges for large-scale hydrogen production, limiting its efficiency and safety. Recently, the anodic OER has been replaced by a nucleophilic oxidation reaction (NOR) with biomass as the substrate and coupled with a hydrogen evolution reaction (HER), which has attracted great interest. Anode NOR offers faster kinetics, generates high-value products, and reduces energy consumption. By coupling NOR with hydrogen evolution reaction, hydrogen production efficiency can be enhanced while yielding high-value oxidation products or degrading pollutants. Therefore, NOR-coupled HER hydrogen production is another new green electrolytic hydrogen production strategy after electrolytic water hydrogen production, which is of great significance for realizing sustainable energy development and global decarbonization. This review explores the potential of nucleophilic oxidation reactions as an alternative to OER and delves into NOR mechanisms, guiding future research in NOR-coupled hydrogen production. It assesses different NOR-coupled production methods, analyzing reaction pathways and catalyst effects. Furthermore, it evaluates the role of electrolyzers in industrialized NOR-coupled hydrogen production and discusses future prospects and challenges. This comprehensive review aims to advance efficient and economical large-scale hydrogen production.

Nickel(BiPhePhos)-Catalyzed Hydrocyanation of Styrene—Highly Increased Catalytic Activity by Optimized Operational Procedures

Nitriles are versatile and highly desired chemical intermediates for a range of products. Their economic large-scale production requires highly efficient and selective synthesis. The nickel-catalyzed hydrocyanation of C=C double bonds provides such selective and 100% atom-economical access to nitriles, but the catalysts hitherto lack activity and longevity. Yet, the literature focusing on increased catalytic activity or optimized operational procedures is scarce, at the least. Here, we present a thorough investigation and optimization of operational procedures using a commercially available diphosphite ligand and styrene as a model substrate. This led us to achieve a TOF20 of more than 300,000 h−1.

Novel drawing technology for high area reduction manufacturing of ultra-thin brass wires

A significant increase in roughness of dieless-drawn wires due to the strain-induced roughness phenomenon has been documented. For small-diameter wires, even a slight surface relief creates stress concentrations that may contribute to the wire breakage during cold drawing. This, in turn, significantly limits the achievable diameter of the product and the efficiency of drawing process. The present study, however, demonstrates that reducing the wire roughness is possible by combining the dieless and conventional drawing methods. Thus, it is possible to improve the process workability threefold when compared to dieless drawing alone, and the product quality is simultaneously improved. In addition, the surface defects typical to the dieless-drawn wires have been significantly reduced, resulting in an increase in the wire strength. This new combined technology enables a significant reduction in the wire diameter and facilitates an economical large-scale production of ultra-thin wires. In addition, based on the classic drawing and dieless drawing process, a brass wire with a diameter of 0.017 mm has been manufactured. Six times thinner than a human hair, it is believed to be the thinnest long brass wire currently manufactured in the world.

Contemporary application of microbubble technology in water treatment.

Microbubble (MB) technology constitutes a suite of promising low-cost technologies with potential applications in various sectors. Microbubbles (MBs) are tiny gas bubbles with diameters in the micrometre range of 10-100 μm. Along with their small size, they share special characteristics like slow buoyancy, large gas-liquid interfacial area and high mass-transfer efficiency. Initially, the review examines the key dissimilarities among the different types of microbubble generators (MBG) towards economic large-scale production of MBs. The applications of MBs to explore their effectiveness at different stages of wastewater treatment extending from aeration, separation/ flotation, ozonation, disinfection and other processes are investigated. A summary of the recent advances of MBs in real and synthetic wastewater treatment, existing research gaps, and limitations in upscaling of the technology, conclusion and future recommendations is detailed. A critical analysis of the energetics and treatment cost of combined approaches of MB technology with other advanced oxidation processes (AOPs) is carried out highlighting the potential applicability of hybrid technology in large-scale wastewater treatment.

Turning bulk V2O5 into an active capacitive material by thermally driven nanostructuring and surface activation

• The technology gap exists between basic science and industrial commercialization. • As a solution to bridge the gap, a new top-down nanostructuring of V 2 O 5 is explored. • Bulk V 2 O 5 is subjected to two thermal treatments under NH 3 and H 2 S. • The resulting nanocomposite is superior when utilized as a supercapacitor electrode. • A synergistic effect induced by the thermal process is the main reason for increment. Despite many new advances in supercapacitor material design, few have been adopted for industrial use because of a lack of consideration for industrial requirements. This fact has long been overlooked in academia, but the potential impact of the technical gap between laboratory-scale demonstrations and large-scale applications is considerable. To this end, we performed a proof-of-concept study using vanadium pentoxide (V 2 O 5 ), one of the most promising supercapacitor electrode materials, to narrow this technical gap. We demonstrated a facile thermal approach in which electrochemically poor bulk V 2 O 5 can be transformed into a highly active electrode material, which can be potentially developed for an economical large-scale production process. Two subsequent thermal treatments of bulk V 2 O 5 under NH 3 and H 2 S gas flow yielded a pseudocapacitive nanocomposite composed of vanadium oxynitride and vanadium sulfide. Superior capacitive performance of the bulk V 2 O 5 in terms of capacitance and stability was achieved by this novel electrode material. In-depth characterization and electrochemical analysis revealed that the underlying reason for this enhancement resulted from a synergistic effect induced by the two-step thermal process. We believe that this successful demonstration of our conceptual approach will be an important stepping stone toward the development of practical material design processes that can meet the rigorous demands of the industry.

Microorganisms-promoted biodiesel production from biomass: A review

Biodiesel is considered as a potential substitute for fossil fuel due to its renewability, sustainability, environmentally friendliness, and biodegradability, especially with comparable fuel properties to diesel. The chemocatalytic production of biodiesel from plant oils is widely used in industrial production due to its low cost and high conversion rate. However, the disadvantages are high energy consumption and environmentally unfriendly processing such as chemical catalysts, downstream technology and simultaneously produced waste. Therefore, in the past decade, enzyme-catalyzed biodiesel has attracted more attentions due to its sustainability and environmental friendliness. High-cost, enzyme stability and reusability are the main obstacles to the large-scale industrial development of microbial biodiesel. This review first showcases the state-of-the-art of microbial biodiesel production, including (1) lipid accumulation of oleaginous microorganisms from pretreated lignocellulose biomass, and (2) production of biodiesel from microbial oils via transesterification by immobilized lipase. Also, the technological challenges and future developmental trends are discussed, with the goal of providing the possibility of more economical large-scale industrial production. This paper provides opportunities for the sustainable and eco-friendly production of enzymatic biodiesel in the future.

Ni2+ enriched carbon nanotubes nanohybrids based non-platinum counter electrodes for dye sensitized solar cells

The development of competent substitutes for Pt counter electrode (CE), possessing excellent electrocatalytic activity, stability, and ready availability, is a key issue to materialize the long-term stability and economical large-scale industrial production of future generation dye sensitized solar cells (DSSCs). In the present work, a cost effective and solution processable hydrothermal technique has been utilized to synthesize Ni2+ enriched nanohybrids of nickel oxide (NiO) and nickel sulfide (Ni3S2) nanoparticles with multi-walled carbon nanotubes (MWCNTs) as CE in DSSCs. NiO/MWCNTs nanohybrids showed superior electrocatalytic behaviour among MWCNTs, NiO, Ni3S2, nanohybrids, and Pt. The nanohybrids containing aligned network MWCNTs exhibited good electrical conductivity, high specific surface area and better stability. These nanohybrids have been further employed as CE in DSSCs and observed higher Power Conversion Efficiency (PCE) for NiO/MWCNTs nanohybrids CE (3.80%) among others and is almost comparable to that of Pt based DSSC (3.90%). It has been explained on the basis of Ni2+content present in the nanohybrids. The higher content of Ni2+species provides a greater number of active sites representing higher electrocatalytic activity that would further productively catalyze the reactions occurring at CE/electrolyte interface in DSSCs.

Recent Advances in Fly-Ash-Based Geopolymers: Potential on the Utilization for Sustainable Environmental Remediation.

This Mini-Review provides the fundamentals and the state-of-the-art overview on geopolymers, novel inorganic polymeric materials (also known as alkali-bounded ceramics), synthesized from aluminosilicate sources and explores their current and potential sustainable environmental applications. It summarizes and examines concisely the recent scientific advances on geopolymers widely synthesized from abundantly available fly-ash-based aluminosilicate materials via alkaline activation at relatively low temperatures. Although geopolymerization is not a new concept and has offered valuable solutions to some environmental challenges as a low-cost and environmentally benign alternative to conventional energy-intensive Portland cement-based construction materials and has also been used as a barrier in immobilizing toxic and radioactive metals, the application of this technology to produce effective adsorptive materials for mitigation of liquid- and gas-phase contaminants is relatively recent. The valorization of the fly-ash waste in the sustainable and cost-effective development of geopolymeric adsorbents and catalysts for the treatment and control of environmental contaminants and energy production and storage could lead to many economic benefits due to the low cost and resource recycling of this globally abundant raw material. Perspectives on the synthesis and utilization of new geopolymer-based adsorbents for environmental and energy applications with insights into future research directions, prospects, and challenges for economic large-scale production are addressed.

2,5-Furandicarboxylic acid production from furfural by sequential biocatalytic reactions

2,5-Furandicarboxylic acid (FDCA) is a valuable compound that can be synthesized from biomass-derived hydroxymethylfurfural (HMF), and holds great potential as a promising replacement for petroleum-based terephthalic acid in the production of polyamides, polyesters, and polyurethanes used universally. However, an economical large-scale production strategy for HMF from lignocellulosic biomass is yet to be established. This study aimed to design a synthetic pathway that can yield FDCA from furfural, whose industrial production from lignocellulosic biomass has already been established. This artificial pathway consists of an oxidase and a prenylated flavin mononucleotide (prFMN)-dependent reversible decarboxylase, catalyzing furfural oxidation and carboxylation of 2-furoic acid, respectively. The prFMN-dependent reversible decarboxylase was identified in an isolated strain, Paraburkholderia fungorum KK1, whereas an HMF oxidase from Methylovorus sp. MP688 exhibited furfural oxidation activity and was used as a furfural oxidase. Using Escherichia coli cells coexpressing these proteins, as well as a flavin prenyltransferase, FDCA could be produced from furfural via 2-furoic acid in one pot.

Atomistic Simulation of Nano-Rolling Process for Nanocrystalline Tungsten

Nanocrystalline tungsten (NC W) sheets and foils have significant high-temperature applications in various technological sectors and hence their economical large-scale production is highly necessary. However, research to help understand the underlying nanoscale deformation mechanisms is limited. Here, we have developed an atomistic model to study the temperature effect on the structural and grain orientation evolution in NC W during nano-rolling. Structural analysis shows that the contribution of dislocation mechanisms decreases and twin mechanisms increases with an increase in temperature. Moreover, atomic strain analysis revealed that cryo-rolling causes formation of a smoother surface, whereas hot-rolling leads to uneven surfaces. A bimodal grain structure is obtained during the cryo-rolling, whereas equiaxed grains are formed at high temperature due to dynamic recrystallization. This work provides insights into comprehending the deformation mechanisms at atomic level, and the compendium of this research will help in studying nano-rolling in other metallic systems.

Facile synthesis of graphene-tin oxide nanocomposite derived from agricultural waste for enhanced antibacterial activity against Pseudomonas aeruginosa

Antibacterial screening of graphene-tin oxide nanocomposites synthesized from carbonized wood and coconut shell is investigated against Pseudomonas aeruginosa for the first time. Efficient and facile one step hydrothermal process adopted in the present work for the synthesis of graphene-tin oxide nanoparticles provides an ideal method for the economic large-scale production of the same. Graphene-tin oxide nanocomposites derived from wood charcoal possess a spherical morphology whereas rod like structures are seen in the case of coconut shell derivatives. An excitation independent fluorescence response is observed in graphene-tin oxide nanohybrids while graphene oxide nanostructures exhibited an excitation dependent behavior. These hydrophilic nanostructures are highly stable and exhibited no sign of luminescence quenching or particle aggregation even after a storage of 30 months. Bactericidal effects of the nanostructures obtained from coconut shell is found to be relatively higher compared to those procured from wood. This variation in antibacterial performance of the samples is directly related to their morphological difference which in turn is heavily influenced by the precursor material used. MIC assay revealed that coconut shell derived graphene-tin oxide composite is able to inhibit the bacterial growth at a lower concentration (250 μg/mL) than the other nanostructures. Nanocomposites synthesized from agro-waste displayed significantly higher antimicrobial activity compared to the precursor and graphene oxide nanostructures thereby making them excellent candidates for various bactericidal applications such as disinfectants, sanitary agents etc.

UV–Vis Absorption and Small Angle X-ray Scattering Spectra of Commercial Polyurethane Coating Filled with Zinc Oxide

Surface-modified hexagonal zinc oxide (ZnO) prisms were incorporated into commercial polyurethane (PU) coating. Dip-coated PU/ZnO composite films on polypropylene sheets exhibited a broad dip in ultraviolet (UV) transmittance corresponding to the ZnO band gap. Compared to 5 and 10 wt% loading, optical properties of PU composites were significantly modified by 20 wt% ZnO fillers in terms of the blue shift and splitting of UV peaks with substantially increased absorption. The morphology effect is demonstrated by replacing the hexagonal ZnO with sword-like ZnO. The sword-like ZnO gave rise to a lower UV absorption and the two slope characteristic in small angle X-ray scattering spectrum corresponding to the thin parts at tapered ends. The proposed procedure and materials used in this work are appropriate for economic large-scale production of composites.

Effect analysis of mineral salt concentrations on nosiheptide production by Streptomyces actuosus Z-10 using response surface methodology.

The objective of this study was to develop an optimal combination of mineral salts in the fermentation medium for nosiheptide (Nsh) production using statistical methodologies. A Plackett-Burman design (PBD) was used to evaluate the impacts of eight mineral salts on Nsh production. The results showed that among the no-significant factors, CaCO3, and K2HPO4·3H2O had positive effects, whereas FeSO4·7H2O, CuSO4·5H2O, and ZnSO4·7H2O had negative effects on Nsh production. The other three significant factors (Na2SO4, MnSO4·H2O, and MgSO4·7H2O) were further optimized by using a five-level three-factor central composite design (CCD). Experimental data were fitted to a quadratic polynomial model, which provided an effective way to determine the interactive effect of metal salts on Nsh production. The optimal values were determined to be 2.63, 0.21, and 3.37 g/L, respectively. The model also ensured a good fitting of scale-up Nsh batch fermentation with a maximum production of 1501 mg/L, representing a 1.56-fold increase compared to the original standard condition. All these results revealed that statistical optimization methodology had the potential to achieve comprehensive optimization in Nsh fermentation behaviors, which indicates a possibility to establish economical large-scale production of Nsh.

Optimizing Ultrasound-Assisted Extraction of Prodigiosin by Response Surface Methodology

Prodigiosin extraction from dried Serratia marcescens jx1 cells using ultrasound-assisted extraction was optimized. The experiment was carried out in accordance with a central composite design (CCD) three-level and single-variable approach. The extraction time, extraction temperature, and solute to solvent ratio with the application of ultrasonication were optimized using response surface methodology (RSM) to maximize the extraction of prodigiosin from dried S. marcescens jx1 cells. The response of prodigiosin was determined using spectrophotometry. A quadratic model was established to predict the prodigiosin extraction yield. The analysis of variance showed that the quadratic model significantly contributed to the response of prodigiosin. The optimal extraction parameters were an extraction time of 17.5 min, an extraction temperature of 23.4°C, and a solvent-to-solute ratio of 1:27.2. Under these optimum conditions, the average prodigiosin yield was 4.3 g ± 0.02 g from 100 g of dried cells, which matches the predicted values. The obtained optimum conditions for prodigiosin extraction provide a scientific basis for the economical large-scale production of prodigiosin.

S‐Fms signalobody enhances myeloid cell growth and migration

Since receptor tyrosine kinases (RTKs) control various cell fates in many types of cells, mimicry of RTK functions is promising for artificial control of cell fates. We have previously developed single-chain Fv (scFv)/receptor chimeras named signalobodies that can mimic receptor signaling in response to a specific antigen. While the RTK-based signalobodies enabled us to control cell growth and migration, further extension of applicability in another cell type would underlie the impact of the RTK-based signalobodies. In this study, we applied the scFv-c-Fms (S-Fms) signalobody in a murine myeloid progenitor cell line, FDC-P1. S-Fms transduced a fluorescein-conjugated BSA (BSA-FL)-dependent growth signal and activated downstream signaling molecules including MEK, ERK, Akt, and STAT3, which are major constituents of Ras/MAPK, PI3K/Akt, and JAK/STAT signaling pathways. In addition, S-Fms transduced a migration signal as demonstrated by the transwell-based migration assay. Direct real-time observation of the cells further confirmed that FDC/S-Fms cells underwent directional cell migration toward a positive gradient of BSA-FL. These results demonstrated the utility of the S-Fms signalobody for controlling growth and migration of myeloid cells. Further extension of our approach includes economical large-scale production of practically relevant blood cells as well as artificial control of cell migration for tissue regeneration and immune response.

Optimization of the production of poly-γ-glutamic acid by Bacillus amyloliquefaciens C1 in solid-state fermentation using dairy manure compost and monosodium glutamate production residues as basic substrates

Poly-γ-glutamic acid (γ-PGA) is a polymer with uses in foods, cosmetics, medicine and agriculture. The medium for the production of γ-PGA by Bacillus amyloliquefaciens C1 was optimized by response surface methodology using agro-industrial wastes in solid-state fermentation (SSF). The optimal SSF medium (20 g substrates with 50% initial moisture) for producing γ-PGA was determined to contain 5.51 g dairy manure compost, 1.91 g soybean cake, 0.57 g corn flour, 2.15 g monosodium glutamate production residues, 1.5 g wheat bran, 0.5 g rapeseed cake, 0.1 g citric acid, 0.05 g MgSO 4·7H 2O and 0.03 g MnSO 4·H 2O. In this medium the strain produced up to 0.0437 g γ-PGA per gram of substrates when cultured for 48 h at 37 °C. SDS–PAGE showed that the molecular weight of the γ-PGA was more than 130 kDa. Due to the high-yields observed and the low-cost nature of the optimal medium, this study indicates a possibility to establish economical large-scale production of γ-PGA.

Production of Carbon Nanotubes by Different Routes-A Review

Carbon Nanotubes are one the most important materials of future. Discovered in 1991, they have reached a stage of attracting the interests of many companies world wide for their large scale production. They possess remarkable electrical, mechanical, optical, thermal and chemical properties, which make them a perfect “fit” for many engineering applications. In this paper various methods of production of carbon nanotubes are discussed outlining their capabilities, efficiencies and possible exploitation as economic large scale production methods. Chemical vapor disposition (CVD) is proposed as a potential method for economic large scale production of carbon nanotubes due to its relative simplicity of operation, process control, energy efficiency, raw materials used, capability to scale up as large unit operation, high yield and purity.

Knocking out of tailoring genes eryK and eryG in an industrial erythromycin-producing strain of Saccharopolyspora erythraea leading to overproduction of erythromycin B, C and D at different conversion ratios

To overproduce erythromycin C, B or D and evaluate the effect of disruption of tailoring genes eryK and eryG in an industrial erythromycin producer. The tailoring genes eryG and eryK were inactivated individually or simultaneously by targeted gene disruption in an industrial strain Saccharopolyspora erythraea HL3168 E3, resulting in the overproduction of erythromycin C (2·48 g l(-1) ), B (1·70 g l(-1) ) or D (2·15 g l(-1) ) in the mutant strain QL-G, QL-K or QL-KG, respectively. Analysis of the erythromycin congeners throughout the fermentation indicated that, at the end of fermentation, comparatively large amount of erythromycin D (0·67 g l(-1) ) was accumulated in QL-G, whereas only small amount of erythromycin D (0·10 g l(-1) ) was produced in QL-K. Inactivation of tailoring genes eryG and eryK in the high producer did not affect the biosynthesis of erythromycin. However, erythromycin D could be more efficiently methylated by EryG than be hydroxylated by EryK. Development of the mutant strains provides a method for the economical large-scale production of potent lead compounds. The information about the accumulation and conversion of erythromycins in the industrial strains may contribute to further improving erythromycin production.

Application and engineering of fatty acid biosynthesis in Escherichia coli for advanced fuels and chemicals

Research towards the commercialization of fungible biofuels has received a great deal of recent interest and investment. To this end the microbial production of fatty acid-derived fuels from sustainable feedstocks is emerging as a viable option with rapid advances from both industry and academia. The manipulation of the fatty acid biosynthesis pathway, especially in Escherichia coli, has been widely studied and several approaches that increase fatty acid production have been identified. However, further advances will be required for the economic large-scale production of fatty acid-derived biofuels. Here we present an overview of fatty acid biosynthesis and its regulation in E. coli from a metabolic engineering viewpoint and offer potential approaches and considerations for the microbial overproduction of custom designed fatty acids for use as biofuels or in the manufacture of oleochemicals.

Large-Scale Production and Characterization of Novel CD4+ Cytotoxic T Cells with Broad Tumor Specificity for Immunotherapy

Immune-cell-based approaches using cytotoxic and dendritic cells are under constant scrutiny to design novel therapies for the treatment of tumors. These strategies are hampered by the lack of efficient and economical large-scale production methods for effector cells. Here we describe the propagation of large amounts of a unique population of CD4(+) cytotoxic T cells, which we termed tumor killer T cells (TKTC), because of their potent and broad antitumor cell activity. With this cultivation strategy, TKTCs from peripheral blood mononuclear cells are generated within a short period of time using a pulse with a stimulating cell line followed by continuous growth in serum-free medium supplemented with a mixture of interleukin-2 and cyclosporin A. Expression and functional profiling did not allow a classification of TKTCs to any thus far defined subtype of T cells. Cytotoxic assays showed that TKTCs kill a panel of tumor targets of diverse tissue origin while leaving normal cells unaffected. Blocking experiments revealed that TKTC killing was, to a significant extent, mediated by tumor necrosis factor-related apoptosis-inducing ligand and was independent of MHC restriction. These results suggest that TKTCs have a high potential as a novel tool in the adoptive immunotherapy of cancer.