Industrial Processes Research Articles

Production, purification, characterization, and safety evaluation of constructed recombinant D-psicose 3-epimerase

BackgroundD-psicose 3-epimerase (DPEase) is a potential catalytic enzyme for D-psicose production. D-psicose, also known as D-allulose, is a low-calorie sweetener that has gained considerable attention as a healthy alternative sweetener due to its notable physicochemical properties. This research focused on an in-depth investigation of the expression of the constructed DPEase gene from Agrobacterium tumefaciens in Escherichia coli for D-psicose synthesis. Experimentally, this research created the recombinant enzyme, explored the optimization of gene expression systems and protein purification strategies, investigated the enzymatic characterization, and then optimized the D-psicose production. Finally, the produced D-psicose syrup underwent acute toxicity evaluation to provide scientific evidence supporting its safety.ResultsThe optimization of DPEase expression involved the utilization of Mn2+ as a cofactor, fine-tuning isopropyl β-D-1-thiogalactopyranoside induction, and controlling the induction temperature. The purification process was strategically designed by a nickel column and an elution buffer containing 200 mM imidazole, resulting in purified DPEase with a notable 21.03-fold increase in specific activity compared to the crude extract. The optimum D-psicose conversion conditions were at pH 7.5 and 55 °C with a final concentration of 10 mM Mn2+ addition using purified DPEase to achieve the highest D-psicose concentration of 5.60% (w/v) using 25% (w/v) of fructose concentration with a conversion rate of 22.42%. Kinetic parameters of the purified DPEase were Vmax and Km values of 28.01 mM/min and 110 mM, respectively, which demonstrated the high substrate affinity and efficiency of DPEase conversion by the binding site of the fructose-DPEase-Mn2+ structure. Strategies for maintaining stability of DPEase activity were glycerol addition and storage at -20 °C. Based on the results from the acute toxicity study, there was no toxicity to rats, supporting the safety of the mixed D-fructose–D-psicose syrup produced using recombinant DPEase.ConclusionsThese findings have direct and practical implications for the industrial-scale production of D-psicose, a valuable rare sugar with a broad range of applications in the food and pharmaceutical industries. This research should advance the understanding of DPEase biocatalysis and offers a roadmap for the successful scale-up production of rare sugars, opening new avenues for their utilization in various industrial processes.

Enhanced catalytic performance for gas phase epoxidation of propylene with H2 and O2 by multiple pretreated Au/TS-1 catalysts

Direct epoxidation of propylene (C3H6) with hydrogen (H2) and oxygen (O2) over Au/TS-1 catalyst was promising way for the synthesis of propylene oxide (PO). However, high selectivity of PO (>95 %) and conversion of C3H6 (>5 %) cannot be achieved at the same time. The industrialization process was severely restricted. In this paper, Au/TS-1 catalysts were synthesized by deposition precipitation method with alkali metal promoter. And alkaline gases and silane coupling post-treatment were performed to promote the catalytic activity. The prepared samples exhibited a much better C3H6 conversion (6.5 %) and PO selectivity (95.1 %) compared with general catalyst using normal synthetic technology. Cs2CO3 was beneficial to increasing Au nanoparticles uptake efficiency. Both NH3 and triethoxyvinylsilane post-treatment were good for smaller and more uniform loading of Au nanoparticles. The decreasing in surface hydroxyl density effectively alleviated the occurrence of PO ring opening isomerization. The increased hydrophobicity of TS-1 surface was conducive to the rapid desorption of generated PO and significantly increased PO selectivity. Multiple pretreatment was also favorable for extending the lifetime of Au/TS-1 catalyst.

Numerical simulation of a partially ionized Oldroyd-B nanofluid flow driven by two homocentric rotating disks with motile microorganisms

Nanofluids are assumed to be an excellent source of enhanced heat transfer with advanced thermophysical characteristics. Nanofluids are the backbone of the heating and cooling in the industrial processes. This research delves into the dynamics of a partially ionized Oldroyd-B nanofluid flowing between stretchable rotating disks. The study investigates heat transfer mechanisms incorporating a modified Fourier law and convective heat conditions. The viscoelastic fluid model presented here allows for the examination of relaxation and retardation times. Furthermore, the heat and mass transport of the Oldroyd-B nanofluid is characterized using a Buongiorno model, which considers thermophoresis and Brownian diffusion effects. Additionally, the study explores the impact of gyrotactic microorganisms in nanofluids, potentially enhancing environmental management strategies. The governing equations transform into dimensionless forms using Von Karman similarity variables. Numerical investigation of the anticipated model is conducted using the bvp4c scheme in MATLAB. The variation of different parameters in the dimensionless equations is illustrated through graphs and in tabulated format. The results indicate that increasing thermophoresis and Lewis numbers lead to a decrease in fluid concentration. Moreover, the temperature of the fluid rises at the lower disk and declines at the upper disk relative to the Biot number. The proposed model is validated through comparison with closely related published work.

Design of a Shell and Tube Heat Exchanger for Methyl Chloride Production

This paper presents the design and analysis of a shell and tube heat exchanger specifically tailored for the efficient handling of methyl chloride. The utilization of heat exchangers in industrial processes is well-established, yet the unique properties and requirements of methyl chloride demand a specialized approach to design. Through a comprehensive literature review and an in-depth exploration of previous designs, this study outlines the key considerations and challenges in creating an effective heat exchanger for this application. The Tubular Exchanger Manufacturers Association (TEMA) standard guides the design process for the heat exchanger, providing the necessary dimensional specifications. Alongside these, specific details regarding the working fluid are meticulously defined. The evaluation of these parameters involves manual calculations using the Microsoft Excel application to assess the performance of the designed heat exchanger. Findings from the study suggest that the designed heat exchanger meets established standards. With 85 tubes and an effective value surpassing 75%, it demonstrates strong performance. A high tool effectiveness value signifies the heat exchanger's commendable operational capability.

Enhancement of DDST-MFAC for tracking performance by using dynamic data reconciliation

Abstract Model-free adaptive control (MFAC) stands out as an effective data-driven method for addressing nonlinear problems in industrial processes. To maintain good control performance, a data-driven set-point tuning (DDST) method is used to update the virtual set-point of the MFAC system. The DDST-based MFAC (i.e. DDST-MFAC) constantly approaches the target of the process through the nonlinear set-point tuning method. However, due to equipment errors and external interference, industrial sensors often suffer from measurement noise, which can have adverse effects on the control performance. In this article, an available dynamic data reconciliation (DDR) technique is adopted to improve the tracking performance of the DDST-MFAC, which suppresses the impact of process noise by using predicted information and measured data to achieve high-precision requirements for controlling nonlinear processes. Finally, considering both Gaussian and non-Gaussian distribution of measurement noise, the effectiveness of the proposed method was verified through the simulation of a nonlinear nonaffine plant. It is also applied to the steam-water heat exchange process, the control result is improved ultimately.

Low-dose hexavalent chromium induces mitophagy in rat liver via the AMPK-related PINK1/Parkin signaling pathway.

Hexavalent chromium (Cr(VI)) is a hazardous metallic compound commonly used in industrial processes. The liver, responsible for metabolism and detoxification, is the main target organ of Cr(VI). Toxicity experiments were performed to investigate the impacts of low-dose exposure to Cr(VI) on rat livers. It was revealed that exposure of 0.05 mg/kg potassium dichromate (K2Cr2O7) and 0.25 mg/kg K2Cr2O7 notably increased malondialdehyde (MDA) levels and the expressions of P-AMPK, P-ULK, PINK1, P-Parkin, and LC3II/LC3I, and significantly reduced SOD activity and P-mTOR and P62 expression levels in liver. Electron microscopy showed that CR(VI) exposure significantly increased mitophagy and the destruction of mitochondrial structure. This study simulates the respiratory exposure mode of CR(VI) workers through intratracheal instillation of CR(VI) in rats. It confirms that autophagy in hepatocytes is induced by low concentrations of CR(VI) and suggest that the liver damage caused by CR(VI) may be associated with the AMPK-related PINK/Parkin signaling pathway.

The Still Elusive Role of Lightweight Doping in Carbon-Based Electrocatalysts for the Selective Oxygen Reduction Reaction to Hydrogen Peroxide.

The two-electron electrocatalytic oxygen reduction reaction (ORR) to hydrogen peroxide (H2O2) is a valuable alternative to the more conventional and energy-intensive anthraquinone process. From a circularity viewpoint, metal-free catalysts constitute a sustainable alternative for the process. In particular, lightweight hetero-doped C-materials are cost-effective and easily scalable samples that replace - more and more frequently - the use of critical raw elements in the preparation of highly performing (electro)catalysts. Anyhow, their large-scale exploitation in industrial processes still suffers from technical limits of samples upscale and reproducibility other than a still moderate comprehension of their action mechanism in the process. This concept article offers a comprehensive and exhaustive "journey" through the most representative lightweight hetero-doped C-based electrocatalysts and their performance in the 2e- ORR process. It provides an interpretation of phenomena at the triple-phase interface of solid catalyst, liquid electrolyte and gaseous oxygen based on the doping-driven generation of ideal electronic microenvironments at the catalyst surface.

The Influence of Acetone on the Kinetics of Water Electrolysis Examined at Polycrystalline Pt Electrode in Alkaline Solution

This study investigated the impact of acetone on the electrochemical behavior of polycrystalline platinum electrodes in 0.1 M NaOH solution, with respect to the kinetics of hydrogen and oxygen evolution reactions (HER and OER) and indirectly to the underpotential deposition of hydrogen (UPDH). Cyclic voltammetry (CV) and electrochemical impedance spectroscopy (EIS) techniques were employed to analyze these processes for acetone concentrations ranging from 1.0 × 10−6 to 1.0 × 10−3 M. The addition of (CH3)2C=O enhanced the catalytic efficiency of alkaline water splitting, which was believed to be a result of a significant reduction in the surface tension phenomenon (due to mutual interaction of acetone and water molecules), thus considerably facilitating hydrogen bubble detachment from the Pt electrode. Key findings in this work are described with respect to facilitation of both the HER and the OER reactions’ kinetics by the presence of acetone (also undergoing Pt electroreduction over the potential range for UPDH) in the working solution, without an electrode surface poisoning effect. The latter implies significant opportunities for traces of organic additives into alkaline electrolyte to improve the industrial alkaline water electrolysis process.

Optimizing vertical pump reliability: Investigating main shaft challenges through integrated design and testing strategies

ABSTRACT Vertical pump systems are vital in industries like water treatment, power generation, and oil and gas production. Their efficiency depends on well-designed components, especially the main shaft connecting the motor to the pump impeller. Changes in shaft length greatly impact vibration, structure, and overall performance. Therefore, thorough evaluation of shaft length modifications is crucial for ensuring equipment suitability and long-term reliability. This study examines how changing shaft length in a vertical pump system, from 70 cm to 170 cm due to construction constraints, affects its performance. Using Finite Element Analysis (FEA), the study evaluates both shaft designs’ natural frequencies, critical speeds, and maximum stresses. Results reveal that the 170 cm shaft design is unsuitable, leading to increased stresses and a higher risk of vibration-induced failures compared to the original design. These findings stress the importance of controlling design parameters and conducting thorough analyses before implementing modifications to ensure reliability and operational stability. Unplanned design changes like shaft length modifications can severely impact pumping equipment performance, emphasizing the need for careful consideration and analysis prior to implementation. This research emphasizes the importance of considering shaft length in the design of vertical pump systems to ensure reliability. The findings offer valuable insights for engineers and designers to maintain long-term operational stability and performance. Ultimately, this improves safety and efficiency in industrial and municipal processes reliant on these pump systems.

Coordination Environment and Distance Optimization of Dual Single Atoms on Fluorine-Doped Carbon Nanotubes for Chlorine Evolution Reaction.

The chlorine evolution reaction (CER) is a crucial anode reaction in the chlor-alkali industrial process. Precious metal-based dimensionally stable anodes (DSAs) are commonly used as catalysts for CER but are constrained by their high cost and low selectivity. Herein, a Pt dual singe-atom catalyst (DSAC) dispersed on fluorine-doped carbon nanotubes (F-CNTs) is designed for an efficient and robust CER process. The prepared Pt DSAC demonstrates excellent CER activity with a low overpotential of 21 mV to achieve a current density of 10 mA cm-2 and a remarkable mass activity of 3802.6 A gpt-1 at an overpotential around 30 mV, outperforming those of commercial DSA and Pt single-atom catalysts. The excellent CER performance of Pt DSAC is attributed to the high atomic utilization and improved intrinsic activity. Notably, introducing fluorine atoms on CNTs increases the oxidation and chlorination resistance of Pt DSAC, and reduces the demetalization ratio of Pt atoms, resulting in excellent long-term CER stability. Theoretical calculations reveal that several Pt DSAC configurations with optimized first-shell ligands and interatomic distance display lower energy barriers for Cl intermediates generation and weaker ionic Pt-Cl bond interaction, which are favorable for the CER process.

Fractional Numerical Analysis of γ-Al2O3 Nanofluid Flows with Effective Prandtl Number for Enhanced Heat Transfer

Abstract Nanoparticles have gained recognition for significantly improving convective heat transfer efficiency near boundary layer flows. The characteristics of both momentum and thermal boundary layers are significantly influenced by the Prandtl number, which holds a crucial role. In this vein, the current study conducted a detailed computational analysis of the mixed convection flow of γAl2O3-H2O and γAl2O3-C2H6O2 nanofluids over a stretching surface. This research integrates an effective Prandtl number, utilizing viscosity and thermal conductivity models based on empirical findings. Additionally, a unique double-fractional constitutive model is debuted to accurately evaluate the effective Prandtl number’s function in the boundary layer. The equations were solved using a numerical technique that combined the finite-difference method with the L1 algorithm. This investigation presents numerical findings related to the velocity, temperature distributions, wall shear stress coefficient, and heat transfer coefficient, contrasting scenarios with and without the effective Prandtl number. The research shows that integrating nanoparticles into the base fluids reduces the temperature of the nanofluid with an effective Prandtl number while enhancing the heat transfer rate irrespective of its presence. Nonetheless, the introduction of a fractional parameter reduced the heat transfer efficiency within the system. Notably, the γAl2O3-C2H6O2 nanofluid demonstrates superior heat transfer enhancement capabilities compared to its γAl2O3-H2O counterpart but also exacerbates the drag coefficient more significantly. Many practical applications of this study include electronics cooling, industrial process heat exchangers, and rotating and stationary gas turbines in power plants, and efficient heat exchangers in aircraft.

Forming limit diagram of annealed copper OFE thick sheets for optimized hydroforming of superconducting RF cavities

Coated superconducting radio-frequency (SRF) cavities are planned to be implemented in the Future Circular Collider (FCC) at the European Organization for Nuclear Research (CERN). The interest in industrialized and high-performance processes for fabrication of the corresponding copper substrates has thus risen. Tubular hydroforming is a well-known industrial process, but has not been thoroughly applied for ultra-pure oxygen-free electronic copper (Cu-OFE) thick products. To provide a feasibility analysis for the optimized fabrication process of copper substrate seamless cavities, a Forming Limit Diagram (FLD) of the material of interest was studied. In this paper, the methodology, test results and initial benchmark of the material model is presented, for 4 mm and 2 mm thick sheets.

A review on development of enzymatic biosensors for industrial applications

Enzymatic biosensors are vital tools across various industries due to their high specificity, sensitivity, and rapid response times. They are extensively used in medical diagnostics for monitoring biomarkers like glucose and lactate, environmental monitoring to detect pollutants, food safety and quality assurance, bioprocess control in industrial fermentation, pharmaceutical drug development and quality control, soil health and agrochemical detection in agriculture, and for identifying biological warfare agents. However, several challenges limit their broader adoption and effectiveness in industrial settings. Key challenges include enzyme stability, as enzymes can denature under extreme environmental conditions, reducing sensor lifespan and performance. Variability in enzyme activity and immobilization techniques also leads to inconsistencies, affecting sensor reproducibility and reliability. Complex sample matrices, such as those in environmental and food samples, introduce interference that can affect sensor accuracy. Integrating biosensors into existing industrial processes is another significant challenge, requiring compatibility with automated systems and real-time data processing capabilities. Additionally, high production costs and scalability issues hinder widespread adoption. Regulatory and standardization barriers further complicate the development and deployment of enzymatic biosensors. Despite these limitations, advancements in materials science, nanotechnology, and bioengineering are paving the way for more robust and reliable biosensors. Innovations such as nanomaterial-based enzyme immobilization, synthetic biology for enzyme engineering, and advanced data analytics integration hold promise for overcoming current limitations. Collaborative efforts among researchers, industry stakeholders, and regulatory bodies are essential to accelerate the development and application of enzymatic biosensors in industrial settings. While enzymatic biosensors offer significant potential, addressing these challenges through ongoing research and technological advancements is crucial for their widespread implementation and optimization.

Multimodal Hard X‐ray Nanotomography Probes Pore Accessibility of Technical Catalysts after Coking

Coking is a common catalyst deactivation route in industrial processes involving carbonaceous species. While coking is easy to diagnose, this is often performed by bulk analysis. Understanding specific symptoms such as pore blockage and obstruction of active sites is especially challenging for technical catalysts and requires a spatially‐resolved approach. Here a combination of ptychographic X‐ray computed tomography (PXCT) and X‐ray fluorescence nanotomography (XRF‐CT) could identify and allocate regions of coke deposition within a technical zeolite‐based propane dehydrogenation catalyst. PXCT is sensitive to the quantitative electron density of the sample, therefore indirectly visualising coke deposition in meso‐ and macropores with 56‐61 nm 3D spatial resolution. For more direct visualisation the catalysts were treated with Cu solution as fluorescent marker, whereby complementary XRF‐CT analysis could distinguish accessible and blocked pores based on the presence or absence of adsorbed Cu. This strategy was used to assess coking as a function of time on stream, to evaluate coke removal by oxidative regeneration, and to distinguish the presence of coke deposits separately within the zeolite and binder components. This strategy is applicable to virtually any porous solid catalyst and can deliver previously unknown insights into the common phenomenon of coke deposition particularly in technical catalysts.

Fabrication, Modeling, and Testing of a Prototype Thermal Energy Storage Containment

Abstract Increasing penetration of variable renewable energy resources requires the deployment of energy storage at a range of durations. Long-duration energy storage (LDES) technologies will fulfill the need to firm variable renewable energy resource output year round; lithium-ion batteries are uneconomical at these durations. Thermal energy storage (TES) is one promising technology for LDES applications because of its siting flexibility and ease of scaling. Particle-based TES systems use low-cost solid particles that have higher temperature limits than the molten salts used in traditional concentrated solar power systems. A key component in particle-based TES systems is the containment silo for the high-temperature (>1100 ∘C) particles. This study combined experimental testing and computational modeling methods to design and characterize the performance of a particle containment silo for LDES applications. A laboratory-scale silo prototype was built and validated the congruent transient finite element analysis (FEA) model. The performance of a commercial-scale silo was then characterized using the validated model. The commercial-scale model predicted a storage efficiency above 95% after 5 days of storage with a design storage temperature of 1200 ∘C. Insulation material and concrete temperature limits were considered as well. The validation of the methodology means the FEA model can simulate a range of scenarios for future applications. This work supports the development of a promising LDES technology with implications for grid-scale electrical energy storage, but also for thermal energy storage for industrial process heating applications.

Comparative Evaluation of Fenton and Persulfate Processes with UV/H2O2 for Batik Wastewater Treatment: Optimizing Fe2+ and S2O8 2- Ratio by H2O2 for Enhanced Pollutant Degradation

Wastewater generated from industrial processes including the batik industry in Indonesia contains high organic pollutants and dyes. In this study, the advanced oxidation process that will produce hydroxyl radicals was used to degrade pollutants in this batik industry wastewater. This study aims to compare the Fenton and Persulfate processes with the influence of variations in the concentration of Fe2+ and S2O8 2- added. This method is carried out by adding H2O2 as an oxidant which is added to each catalyst, namely Fe2+ and S2O8 2- in the presence of a combination of UV light. Fenton process was carried out in 60 minutes and Persulfate process was carried out in 45 minutes. In this study, there was a tendency to increase the efficiency of COD and color removal along with the increasing concentration of each catalyst added. The highest COD and color removal efficiency occurred at a ratio of H2O2:Fe2+ and H2O2: S2O8 2- of 1: 0.08.

Droplet–droplet vapor-mediated interactions in confined environments

The evaporation of multiple droplets ensues ubiquitously in nature and industry. Vapor mediation caused by evaporating neighboring droplets is a demonstrated phenomenon that shows that droplets can interact with each other via the vapor in both open and confined configurations, i.e., the “shielding effect.” However, interactions between paired droplets in confined environments, more common in industrial processes, remain unexplored. In this Letter, we experimentally investigate the evaporation of water based paired sessile droplets on hydrophilic glass slides at different spacings in the absence and presence of an enclosed chamber. The results demonstrate that a confined environment significantly attenuates droplet evaporation, which intensifies with decreasing spacing between droplets. A 30%–82% increase in the droplet lifetime is found for the shortest distance studied in a confined environment, while results in an open environment are provided as a control. Both the local shielding effect and the global vapor accumulation due to confinement collaboratively induce such strong evaporation suppression. In addition, two well differentiated evaporation regimes ensue in a confined environment where the shielding effect initially dominates the evaporation suppression, whereas confinement governs the later evaporation stage. The later stage accounts for over 60% of the droplet lifetime. Such transition and further evaporation suppression, when compared to the classical shielding effect, highlights the importance of a confined environment in multiple droplet evaporation.

Heteroatoms-Stabilized Single PalladiumAtoms on Amorphous Zeolites: Breaking the Tradeoff between Catalytic Activity and Selectivity for Alkyne Semihydrogenation.

As a fundamental industrial catalytic process, the semihydrogenation of alkynes presents a challenge in striking a balance between activity and selectivity due to the issue of over-hydrogenation. Herein, we develop an efficient catalytic system based on single-atom Pd catalysts supported on boron-containing amorphous zeolites (Pd/AZ-B), achieving the tradeoff breaking between the activity and selectivity for the selective hydrogenation of alkynes. Advanced characterizations and theoretical density functional theory calculations confirm that the incorporated B atoms in the Pd/AZ-B can not only alter the geometric and electronic properties of Pd atoms by controlling the electron migration from Pd but also mitigate the interaction between alkene and the catalyst supports. This boosts the exceptional catalytic efficacy in the semihydrogenation of phenylacetylene to styrene under mild conditions (298 K, 2 bar H2), achieving a recorded turnover frequency (TOF) value of 24198 h-1 and demonstrating 95% selectivity to styrene at full conversion of phenylacetylene. By comparison, the heteroatom-free amorphous zeolite-anchored Pd nanoparticles and the commercial Lindlar catalyst have styrene selectivities of 73% and 15%, respectively, under identical reaction conditions. This work establishes a solid foundation for developing highly active and selective hydrogenation catalysts by controllably optimizing their electronic and steric properties.

Advances in Aureobasidium research: Paving the path to industrial utilization.

We here explore the potential of the fungal genus Aureobasidium as a prototype for a microbial chassis for industrial biotechnology in the context of a developing circular bioeconomy. The study emphasizes the physiological advantages of Aureobasidium, including its polyextremotolerance, broad substrate spectrum, and diverse product range, making it a promising candidate for cost-effective and sustainable industrial processes. In the second part, recent advances in genetic tool development, as well as approaches for up-scaled fermentation, are described. This review adds to the growing body of scientific literature on this remarkable fungus and reveals its potential for future use in the biotechnological industry.

Energy-efficient production of sustainable industrial process heat with a parabolic dish-conical cavity solar collector

Industrial decarbonization in response to global carbon neutrality requires vast process heat to be supplied in a low-carbon manner. Solar energy is regarded as one of the most promising alternatives to fossil fuel applied for heat-driven industrial processes, however, lack of effective approaches to improve the solar-thermal conversion efficiency is a longstanding issue. Here, we propose an efficient approach to produce industrial process heat based on a novel concentrated solar collector, mainly consisting of a parabolic dish concentrator and a conical cavity receiver. Results showed that the collector was competent to supply the process heat meeting various low-temperature industrial occasions, and there was an optimum flow rate to achieve a trade-off between the outlet temperature of working fluid and thermal efficiency of the solar collector. The thermal efficiency of the proposed solar collector was 2.7%–27.5% higher than that of most other existing collectors used for production of low-temperature process heat, and such a superior solar-thermal conversion efficiency was a consequence of the reduction in energy losses between the solar receiver and surroundings as confirmed by the comprehensive energy analysis performed in this study.