High Material Costs Research Articles

Ant lion based optimization for performance improvement of methanol production

Abstract Methanol (CH3OH) is a versatile compound used in various industries. Catalytic reactors used in CH3OH production are expensive due to high energy and raw material costs. Multi-objective optimization (MOO) is used to optimize CH3OH production, but it is still lacking. Researchers use alternative strategies or modify existing ones to achieve better results. This study applied model-based optimization using an ASPEN Plus simulator and Multi-objective Ant Lion Optimization (MOALO) to address the issue. The results revealed the highest conversion and product rate, with the lowest energy cost, side product, and bare module cost, CBM. The decision variable plots indicate that the reactor’s pressure significantly affects the optimal solution. This study provides valuable insight into optimizing CH3OH production.

Development and Application of Green Catalysts: Challenges, Optimization, and Future Perspectives

This paper comprehensively reviews the development and application of green catalysts in modern chemical industries, with a focus on analyzing the significant advantages of various types of green catalysts, such as metal-organic frameworks (MOFs) and enzyme catalysts, in improving reaction efficiency, reducing energy consumption, and minimizing by-product generation. The paper delves into the design and synthesis of green catalysts, optimization of reaction conditions, and technologies for catalyst recycling and regeneration, highlighting their key roles in enhancing catalyst performance. Despite challenges such as high material costs, complex synthesis processes, and issues with stability and durability in practical applications, continuous technological innovation and process improvements offer promising solutions. As global attention to sustainable development grows, green catalysts are expected to have broad applications in emerging fields such as carbon capture and utilization, renewable energy conversion, and environmental remediation, thereby driving the green transformation and low-carbon development of the chemical industry and providing strong technical support for achieving global sustainability goals.

Nanostructured Solid Electrolytes for Enhanced Safety and Performance of Battery Materials

Solid-state batteries (SSB) have garnered significant attention by reason of their potential advantages over traditional liquid electrolyte batteries, including higher energy density, enhanced safety, and reduced volume. However, the development and implementation of solid electrolytes confront several challenges, such as lower ionic conductivity, dendrite formation, and interface stability issues. This review explores the current advancements in solid electrolytes (SLs), with a focus on nanostructured materials, including solid polymer electrolytes (SPEs), solid inorganic electrolytes (SIEs), and composite solid electrolytes (CSEs). The review highlights the benefits of nanostructuring in improving mechanical intensity, ionic conductivity and thermostability. Key methods for synthesizing nanostructured solid electrolytes (NSLs), such as the sol-gel method and 3D printing, are discussed. Additionally, the review addresses critical challenges, including the high cost of materials and manufacturing processes, and proposes future research directions to overcome these barriers. The purpose is to comprehensively understand the current status and future potential of NSL in promoting SSB technology.

Nanocomposites in Tire Development – Benefits, Challenges, and the Role of Carbon Nanotubes and Graphene

In the rapidly evolving automotive industry, enhancing vehicle performance and sustainability through innovative materials is paramount. Nanocomposite materials, incorporating nanoparticles such as carbon nanotubes (CNTs), graphene, and silica, have emerged as key enablers in redefining tire technology with improved durability, efficiency, and environmental impact. This review discusses the integration of these nanocomposites into tire manufacturing, emphasizing their role in enhancing mechanical properties, wear resistance, and rolling efficiency while reducing environmental footprints. Challenges such as dispersion uniformity within the rubber matrix and economic considerations due to high material costs are examined, alongside future research directions aimed at scalability and cost reduction. The paper predicts a significant increase in the adoption of nanocomposite tires, driven by technological advances and the shift toward sustainable manufacturing practices. By detailing the synergistic effects of nanocomposites, this review highlights their potential to revolutionize tire performance and contribute to the next generation of green automotive technologies.

Overcoming Challenges in Scented Geranium Cultivation, Processing, and Marketing: Study from Northern Karnataka, India

Medicinal and aromatic crops play a pivotal role in the socio-cultural, economic, spiritual and health dimensions of India's rural population and have become an integral part of our culture and rituals. Karnataka is a major repository of aromatic and medicinal treasures of the country. The demand for aromatic plants in India surpasses the available supply, prompting the widespread commercial cultivation of major aromatic crops in various regions. Among these, scented geranium emerges as a vital perennial aromatic, cultivated for its leaves imbued with a captivating rose fragrance. The aromatic oil of scented geranium is increasingly replacing traditional rose oil and identified as one of the top 20 essential oils traded globally. The present study aims to identify challenges in cultivation, processing and marketing aspects of scented geranium in Northern Karnataka. Considering the area and concentration of scented geranium in the state, Belagavi district is purposively selected for the study. Primary data was collected through personnel interview of randomly selected geranium growers. The major challenges faced by the farmers in the production, processing and marketing aspects of scented geranium were analysed and prioritized through Garett ranking technique. Analysis of the data revealed that in production, high cost of planting material, lack of high yielding varieties and high wage rates, high cost of inputs and sensitivity of crop to heavy rains were identified as top five constraints. Whereas, in processing, significant hurdles were high working capital requirement, high capital investment in installation distillation unit and insufficient knowledge on operation of distillation units, low oil recovery and lack of efficient processing equipment. In marketing aspects, high price fluctuation, lack of marketing information and lack of competition in the market, non-existence of local market and lack of adequate demand in nearby area were identified as major challenges in the study area. Educating farmers in nursery management and implementing mechanization techniques, particularly for harvesting, are crucial for enhancing productivity and profitability. Additionally, training on proper storage and transportation practices is essential to maintain the quality of volatile essential oils. This comprehensive strategy promotes sustainable and economically viable cultivation of scented geraniums in the region.

Investigation of the bond between bamboo and ribbed steel reinforcements and the surrounding concrete by pull-out test

Traditional housing did not use expensive materials like steel reinforcement, yet some have outlived sandcrete or mud-brick housing. One means to build at a low cost is to supplement high-cost materials with low-cost types, which have comparable strength. This study compares the bond between bamboo (Bambusa vulgaris and Bambusa vittata) reinforcement as well as ribbed steel enforcement and the surrounding concrete by pull-out test. Bamboo specimens were split and cut into the dimensions of 600 mm × 20 mm ×10 mm. Sixty (60) samples of each of the two varieties were prepared, thirty (30) were coated with tar oil as waterproof agent to a length of 200 mm and embedded into fresh concrete samples and allowed to cure, while another 30 did not receive any coating. Thirty (30) specimens of 12.5 mm diameter of ribbed steel rods of length 60 mm were used as control Materials for the pull-out test were also embedded in the centre of 150 mm concrete cubes and left to cure for 28 days. The load required to pull the steel rods from concrete (5.49±0.22 kN) was greater than those for both coated Bambusa vulgaris and Bambusa vittata (1.67±0.11 kN – 1.67±0.12 kN) and uncoated Bambusa vulgaris and Bambusa vulgaris vittata (2.04±0.14 kN– 2.14±0.19 kN) bamboo. The differences were significant (p<0.05). The pull-out was also conducted in conformity with the Bureau of Indian Standard (IS) 2770: 1997.

Nano ZnO modified amorphous carbon materials enabling long-cycle performance and high-capacity for lithium/sodium-ion batteries

Zinc-modified carbon materials exhibit high specific capacity, good safety, and low self-discharge, making them promising anode materials for lithium-ion and sodium-ion batteries. However, the high cost of raw materials, complex fabrication processes, and limited cycle life remain significant challenges to their further development. In this study, we elucidated a two-step process, simple in technique and suitable for large-scale production, for in-situ zinc modification of amorphous carbon. The synthesized carbon material exhibited superior reversible specific capacity (maintaining 780.27 mAh·g−1 capacity after 80 cycles at 50 mA·g−1 current density), high cycling stability (maintaining Coulombic efficiency at 100.06 % after 15,000 cycles at 10 A·g−1 current density), and good application value (achieving a capacity of 89.67 mAh·g−1 after 1000 cycles at 200 mA·g−1 current density for the assembled MFAC-Zn||NVP full cell). Through our investigation, we discovered that Nano ZnO not only directly participate in electrochemical reactions but also effectively improve the microstructure of amorphous carbon, increasing its three-dimensional axial stacking and providing more reaction sites. The enrichment of open pores significantly enhances the diffusion efficiency of ions within the carbon-based matrix. The superior diffusion ability of alkali metal-ion in the electrode is the reason for the excellent electrochemical performance of Zinc-modified amorphous carbon. Moreover, the incorporation of Nano ZnO aids in the formation of a robust and thin SEI layer. This significantly enhances the stability of the electrode materials during cycling and improves charge transfer efficiency during the charge-discharge process. Our study provides a new strategy for adjusting the internal microstructure of amorphous carbon materials to achieve high-performance lithium/sodium storage.

ROLE OF COMMUNITY ENGAGEMENT ON IMPLEMENTATION OF INCLUSIVE EDUCATION PRACTICES IN RWANDA, A CASE OF GASABO DISTRICT

This study explored the role of community engagement in implementionof Inclusive Education practices in Gasabo District, Rwanda. The research investigated four key dimensions: community awareness, socio-economic factors, community participation, and social-cultural influences on Inclusive Education implementation. Through qualitative methodology, the study engaged 64 stakeholders, including headteachers, local leaders, and parents of children with and without disabilities, using purposive and convenience sampling methods. Data were analyzed using thematic, narrative, and interpretive approaches. Key findings revealed limited understanding of Inclusive Education concepts and practices among community members, with significant knowledge gaps in supporting children with disabilities. Socio-economic barriers, including resource constraints and high costs of specialized learning materials, created educational exclusion. Community participation was found to be insufficient, lacking structured engagement frameworks. Social-cultural factors showed persistent stigma and misconceptions, though community solidarity and religious values provided some support. The study recommends implementing long-term community awareness campaigns, engaging local and religious leaders to address cultural beliefs about disability, and developing strategies to overcome financial barriers in accessing Inclusive Education. Additionally, it emphasizes the importance of active parent-community engagement through regular communication and workshops. These findings contribute to the development of monitoring and evaluation frameworks for Inclusive Education programs and promote partnerships and help correct misconceptions about disability and highlight the benefits of inclusive education for all children by fostering campaigns among government agencies, educational institutions, civil society organizations, and community stakeholders in implementation of Inclusive Education practices in Rwanda.

Zinc‐Ferricyanide Flow Batteries Operating Stably under −10 °C

AbstractAlkaline ferri/ferro‐cyanide‐based flow batteries are well suited for energy storage because of their features of high electrochemical activity, good kinetics and low material cost. However, they suffer from low energy density and poor temperature adaptability. The ferri/ferro‐cyanide catholyte exhibits low solubility (~0.4 M at 25 °C) in NaOH‐ or KOH‐based supporting electrolyte and can easily form precipitates below room temperature. Here we report a lithium‐based supporting electrolyte that significantly enhances the solubility of ferrocyanide. The use of LiOH intensifies the ion‐dipole interaction between water molecules and solutes and cripples polarization among ferrocyanide ions. Thus, we have achieved a ferrocyanide‐based catholyte of 1.7 M at 25 °C and of 0.8 M at −10 °C. A zinc‐ferricyanide flow battery based on the lithium‐based supporting electrolyte demonstrates a steady charge energy of ~72 Wh L−1catholyte at 25 °C, and maintains stable for ~4200 cycles (~4200 hours). Furthermore, it remains stable for ~800 cycles (~800 hours) at −10 °C.

Mass Transportation Facilitated Porous Fe/Co Dual‐Site Catalytic Cathodes for Ultrahigh‐Power‐Density Al–Air Fuel Cells

AbstractThe development of oxygen‐dependent fuel cells is frequently hindered by the high cost of cathode materials and the sluggish kinetics of the oxygen reduction reaction (ORR). It is thus crucial to explore low‐cost and high‐activity catalysts with accelerated mass transport. Here, a high‐throughput screening method is developed by integrating an explicit solvation model with machine learning potential‐based molecular dynamics simulations, which enables the efficient evaluation of a vast array of diverse diatomic combinations and ultimately identifying Fe–Co dual‐atomic sites as the optimal ORR electrocatalysts. The superior electrocatalytic performance of the diatomic Fe/Co sites loaded on 3D‐interconnected ordered macroporous carbon (FeCo‐3DMNC) is experimentally verified, achieving high ORR activity with half‐wave potentials of 0.806 V in acidic and 0.905 V in alkaline environments. Additionally, innovative hybrid acid/alkali aluminum–air fuel cells (hA/A‐AAFCs) incorporating FeCo‐3DMNC as the cathode catalyst demonstrate a notably high open‐circuit voltage of 2.72 V and a record‐breaking power density of 827 mW cm−2, significantly outperforming conventional alkaline aluminum–air fuel cells. This work marks a significant advancement by combining cutting‐edge computational screening with rigorous experimental validation to develop promising electrocatalysts, potentially paving the way for the advanced energy storage and conversion technologies.

Effect of the infill percentage of 3D printed Polyetheretherketone under the dry sliding condition

Sliding bearings made of advanced polymers like Polyetheretherketone (PEEK) are preferred for medium and heavy-duty applications. The high-temperature additive manufacturing process permits the efficient fabrication of lighter porous parts using high-cost materials like PEEK. Customised geometries and surface features are easily achievable using an additive manufacturing process and facilitate design for the required performance. The 3D-print parameters employed affect the surface characteristics and are investigated. The variation in infill porosity is found to affect the crystallinity, hardness, modulus, and surface roughness of the printed samples. The friction coefficient variation, wear resistance, and temperature rise in the 3D-printed PEEK samples are studied when slid against steel discs under dry sliding conditions. The material transfer between surfaces varies based on the sample's surface properties and porosity, significantly affecting friction and wear behaviour. Accumulation and strong adhesion of wear debris in the groves of PEEK samples contribute to improved wear resistance. The temperature rise in the polymer sample also depends on the infill porosity, and a reduced temperature rise is observed in porous samples, which will improve the life when used in bearings.

Zr4+ and Al3+ coordinated cross-linked conductive collagen fibers/solvent-free polyurethane foam with ultra-low reflective electromagnetic shielding properties

In recent years, electromagnetic shielding materials with low reflectance have developed rapidly. However, high material cost, poor bonding fastness, weak mechanical properties and other problems seriously limit its effect in practical use. In this work, flexible conductive collagen fibers (CLF-Zr4+/Al3+-CNTs) were prepared using chromium tanned waste leather as ingredient, carbon nanotubes (CNTs) as conductive filler and transition metal ions as coordination crosslinking agents, and their molecular dynamics were investigated by quantum chemical simulation software. On this basis, a flexible conductive foam with the double layer and double core-clad structure containing carbon nanotubes was constructed using the solvent-free polyurethane (SFPU) chemical foaming technology, and their electromagnetic shielding properties and reflectance were studied. The experiment results showed that when the ratio of CLF-Zr4+/Al3+-CNTs to SFPU polyol is 1:9 and the impregnation times of CNTs are 2, the loading capacity of CNTs in conductive foam is 0.14 mg/cm3, the electrical conductivity is 57.8 S/m, and the thermal conductivity is 0.061 W/(m·K). Meanwhile, when the thickness is 3 cm, the electromagnetic shielding performance is 42.09 dB, and the reflection efficiency is 0.66 %, the lowest reflection efficiency reaches 0.16 % in the experiment. The mechanism of electromagnetic shielding in conductive foams with the double layer and double core-clad structure has been further explored. The experiment results proved that the flexible conductive foam has excellent mechanical properties, stability, heat insulation and flame retardant properties, and has excellent electromagnetic shielding and low reflection characteristics due to its abundant holes, functional group, interface and hierarchical structure.

Comparative evaluation of adsorptive and repulsive separation using cellulose nanofiber/calcium alginate composite hydrogel filtration membranes with improved degradability

Among several approaches to address hard-to-manage dye wastewater, adsorption is one of the widely used methods, but the usage of these adsorbents can be constrained by their high material and process costs depending on the adsorbent materials as well as handling a large amount of adsorbents in a bulk solution. To overcome the problems, hydrogel membranes have recently attracted much attention because they can provide several strengths such as adsorption removal, confined adsorption sites, and filtration separation. However, to the best of our knowledge, it is still quite rare to find an in-depth comparative evaluation of adsorptive removal and repulsive separation in hydrogel membrane filtration. Herein, this study aims to bridge the gap between existing knowledge and undisclosed phenomena. Through a thorough comparative evaluation of adsorptive removal and repulsive separation in hydrogel membrane filtration, we found that repulsive separation was more suitable and sustainable than adsorptive removal because it was free from internal membrane fouling, adsorption sites’ saturation, and the cake layer formation on the surface. As a result, the hydrogel membranes could maintain excellent real-time separation performance while mitigating severe flux and rejection decline. Furthermore, we significantly improved the degradability of the spent hydrogel membrane under high saline conditions by 6.3 times compared to the control membrane by fine-tuning the structural properties via dual crosslinking, while maintaining the mechanical properties during filtration. It was possible due to the extended distance between polymer chains by dual crosslinking, reducing the burden imposed by plastic waste generated from the spent membrane.

Research on the Rheological Properties and Modification Mechanism of Epoxy Resin/SBS Composite-Modified Asphalt

Both epoxy resin (ER) and SBS are considered effective pavement materials for avoiding ruts. However, epoxy resin asphalt suffers from poor low-temperate performance and a high material cost in practical applications. Aiming to tackle these issues, a new type of composite asphalt modifier (ER-SBS) has been fabricated by combining epoxy resin with SBS. This work prepared modified asphalt with different doping amounts using the above composite asphalt modifier (ER-SBS), intending to explore the properties of composite-modified asphalt and the modification mechanism of the modifier. Furthermore, the effects of the composite modifier at different doping amounts on the viscoelastic property of asphalt were explored through rheological tests, and then the prepared composite-modified asphalt was compared with matrix asphalt and SBS-modified asphalt. In addition, the modification mechanism of the composite modifier was investigated by fluorescence microscopy and infrared spectroscopy. The difference in pavement performance between the composite-modified asphalt and SBS-modified asphalt was compared by a rut test and dynamic modulus test. The research results showed that the composite modifier improved the high- and low-temperature performances and viscoelastic property of matrix asphalt. When the doping amount was raised to 9%, the composite-modified asphalt exhibited better a modification effect than SBS-modified asphalt. The rut test results indicated that composite-modified asphalt demonstrated a stronger deformation resistance than SBS-modified asphalt. The dynamic modulus test showed that the composite-modified asphalt has better viscoelastic properties and temperature sensitivity. Fluorescence microscopy suggested that the crosslinking between the composite modifier and asphalt forms a mesh structure which greatly improves its resistance to deformation. From infrared spectroscopy, the composite modifier clearly functions as a physical modifier.

Chlorinated Polythiophene‐Based Donors with Reduced Energy Loss for Organic Solar Cells

Comprehensive SummaryThe industrialization of organic solar cells (OSCs) faces challenges due to complex synthesis routes and high costs of organic photovoltaic materials. To address this, we designed and synthesized a series of polythiophene‐based donor materials, PTVT‐T‐xCl (20%Cl, 50%Cl and 100%Cl), by introducing different degrees of chlorine substitution within their conjugated skeletons. The incorporation of chlorine atoms does not change the planar conformation of the conjugated main chain of the control polymer, PTVT‐T, but effectively reduces their HOMO energy levels (≤ –5.3 eV) and alters the crystallinity of the polymers. In addition, when preparing OSC by blending with non‐fused electron acceptor A4T‐16, the non‐radiative energy loss of the three photovoltaic devices gradually decreased with the increase of chlorine content (0.343, 0.278 and 0.189 eV, respectively). Notably, PTVT‐T‐20%Cl exhibited a more moderate nanoscale phase separation with the acceptor, leading to efficient exciton dissociation, lower bimolecular recombination, and thus a favorable current in the OSCs. Consequently, the photovoltaic device based on PTVT‐T‐20%Cl:A4T‐16 achieved a remarkable photovoltaic efficiency of 11.8%. In addition, the PTVT‐T‐xCl series polymers show much lower material‐only‐cost (MOC) values than the other reported photoactive material systems. This work provides the way for the development of low‐cost photovoltaic materials and the industrial application of OSC, overcoming previous limitations posed by high energy losses in polythiophene‐based donors.

ECONOMIC AND FINANCIAL SITUATION OF THE FOOD INDUSTRY IN POLAND IN THE YEARS 2019-2023

The aim of the article is to assess the economic and financial situation of the food industry and its main industries in Poland in 2023 compared to 2019. The analysis used the method of synthetic assessment of the financial result developed by Bednarski. A comparative assessment of the dynamics of quantitative and qualitative indicators determining changes in the value of individual production factors and the efficiency of their use was carried out, both for the entire food industry and its main industries. The research was further enhanced by a cause-and-effect analysis of the financial result, which determined the level of influence of individual production factors on the growth of revenues and profit. The study used published and unpublished data from the Central Statistical Office. The synthetic assessment of the financial result of the food industry shows that despite the fact that entities in the audited period faced many challenges, m.in. related to price pressure, their economic and financial situation in 2023 was better than in 2019. In-depth research has shown that the development of the sector took place mainly through the increase in the technical equipment of labor and the improvement of the economic efficiency of the human factor involved in economic activity. Such a situation occurred in most industries (in 13 out of 18 respondents), and only in a few did not improve the net financial result. In the coming years, companies will have to face challenges related to, m.in others, high costs of raw materials and labor, but also the energy transition, which is why achieving sufficiently high processing margins is a priority for enterprises.

Promoting Electricity Production and Cr (VI) Removal Using a Light–Rutile–Biochar Cathode for Microbial Fuel Cells

Microbial fuel cell (MFC) technology holds significant promise for the production of clean energy and treatment of pollutants. Nevertheless, challenges such as low power generation efficiency and the high cost of electrode materials have impeded its widespread adoption. The porous microstructure of biochar and the exceptional photocatalytic properties of rutile endow it with promising catalytic potential. In this investigation, we synthesized a novel Rutile–Biochar (Rut-Bio) composite material using biochar as a carrier and natural rutile, and explored its effectiveness as a cathode catalyst to enhance the power generation efficiency of MFCs, as well as its application in remediating heavy metal pollution. Furthermore, the impact of visible light conditions on its performance enhancement was explored. The X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS) and scanning electron microscopy (SEM) analysis validated the successful fabrication of rutile composites loaded with biochar. The maximum current density and power density achieved by the MFCs were 153.9 mA/m2 and 10.44 mW/m2, respectively, representing a substantial increase of 113.5% and 225% compared to the control group. In addition, biochar-supported rutile MFCs showed excellent degradation performance of heavy metal pollutants under light conditions. Within 7 h, the Cr6+ degradation rate reached 95%. In contrast to the blank control group, the removal efficiency of pollutants exhibited increases of 630.8%. The cyclic degradation experiments also showcased the remarkable stability of the system over multiple cycles. This study successfully integrated natural rutile and biochar to fabricate highly efficient cathode photocatalyst composites, which not only enhanced the power generation performance of MFCs but also presented an environmentally sustainable and economically viable method for addressing heavy metal pollution.

Non-toxic Bi2S3 quantum dot-sensitized TiO2 electrodes for cost-efficient solar power conversion

Inorganic light harvesting materials are revolutionising the current research scope of quantum dot-sensitized solar cells (QDSSCs) day by day. However, it is challenging due to the issues in toxicity and stability of existing light-harvesting materials. Herein, we present highly stable non-toxic bismuth trisulfide (Bi2S3) QDSSCs with iodide/triiodide redox electrolyte. The solar cell is configured as FTO/TiO2 P90/TiO2 P25/Bi2S3/(I-/I-3) electrolyte/Pt. Bi2S3 quantum dots (QDs) were fabricated onto the FTO/TiO2 P90/TiO2 P25 electrode at room temperature using the dip-successive ionic layer adsorption reaction (Dip-SILAR), which is an easy and efficient technique. Electron microscopy confirmed that the quantum dots formed uniformly on the photoanode, with sizes ranging from 50 nm to 80 nm. QDSSCs with an active cell area of 0.16 cm2 were characterized under an illumination of 100 mW cm-2 with AM 1.5 spectral filter and the results depicted that the best cell acquired a power conversion efficiency of 0.26 % with an open circuit voltage (Voc) of 482.9 mV and short circuit current density (Jsc) of 1.05 mA cm-2. To enhance the stability, polyvinylpyrrolidone (PVP) based gel polymer electrolyte has been used. The high cost of conventional light harvesting materials may be significantly reduced by one-step fabrication of Bi2S3 using the SILAR technique.

Equilibrium modelling of steam gasification of PKS system and CO2 sorption using CaO: A digitalized parametric and techno-economic analysis

The conversion of palm oil waste into energy can complement the energy mix with renewable energy and bring economic benefits to the palm oil industry. A process simulation model for palm kernel shell (PKS) steam gasification for H2-enriched syngas with the integration of CO2 capturing using CaO has been investigated using Aspen Plus V10®. Techno-economic and energy analyses have also been conducted to identify energy-saving opportunities for commercialization. The effect of process variables, including reactor temperature (600–800 °C), Steam/PKS ratio (0.5–2 wt/wt), and CaO/PKS ratio (0–1.5 wt/wt), have been determined, with the predicted results compared to the reported experimental data. H2 concentration has been increased with 76–78 vol% with the temperature elevation from 650 to 750 °C. Additionally, a substantial increase in H2 content from 68 to 72vol% was observed when the steam flow rate was increased from 0.5 to 1.5. Conversely, the CO2 concentration decreased from 25 to 8vol% as the adsorbent ratio was raised from 0.5 to 1.5. The techno-economic analysis showed that the capital investment is $4.11 million, and the operating cost is $3.89 million per year, which is also very high due to the high raw material costs. In the case of energy, saving that 3.03 and 1.513 Gcal/hr can be saved in terms of utilities and gas cooling that economized the process which shows that utilization of these in heat exchange networks can significantly reduce costs, with up to 78 % savings in heat exchanger capital and 35 % in total energy consumption. The energy potential could be harnessed through the digitalization of the process.

Application of multi-objective neural network algorithm in industrial polymerization reactors for reducing energy cost and maximising productivity

Optimization on an industrial scale is a complex task that involves fine-tuning the performance of large-scale systems and applications to make them more efficient and effective. This process can be challenging due to the increasing volume of work, growing system complexity, and the need to maintain optimal performance. Due to the significant power required for compression and the high costs of reactant materials, optimizing low-density polyethylene (LDPE) production to provide maximum productivity with a reduction of energy cost is required. However, it is not a simple process because the optimization problem of the LDPE tubular reactor consists of conflicting objective functions. Multi-objective neural network algorithm (MONNA) is a metaheuristic optimization method that provides a versatile and robust approach for solving complex, contradictory targets and diverse optimization problems that do not rely on specific mathematical properties of the problem. It is inspired by the structure and information-processing capabilities of biological neural networks. MONNA iteratively proposes solutions, evaluates its performance, and adjusts its approach based on feedback, which avoids complex mathematical formulations. In this work, we implement Multi-objective optimization neural network algorithm (MONNA) in LDPE tubular reactor for maximising productivity, conversion and minimising energy costs with three scenario of problem optimization, i.e. maximising productivity and reducing energy cost for the first problem (P1); increasing conversion and reducing energy costs for the second problem (P2); and increasing productivity and reducing by-products for the third problem (P3). The results show that the highest productivity, highest conversion, and lowest energy are 545.1 mil. RM/year, 0.314, and 0.672 mil. RM/year. The extreme points in the Pareto Front (PF) for various bi-objective situations provide practitioners with helpful information for selecting the best trade-off for the operational strategy. According to their preferences, decision-makers can use the resulting Pareto to decide on the most acceptable alternative. The decision variable plots show that both initiators in the reacting zone highly affected the optimal solution with the opposite action.