Pilot Plant Scale Research Articles

Enhancement of Corn Flour with Carob Bean for Innovative Gluten-Free Extruded Products.

The aim of this work is to study new, extruded products based on corn flour enriched with carob bean and the evaluation of its functional quality to develop novel gluten-free food products. Five samples based on corn flour with added carob bean flour (5 to 12.5%) were formulated. Extrusion was performed using a single-screw laboratory extruder at pilot plant scale. Extrusion parameters such as color and carbohydrate content (fiber, sucrose, and starch) were evaluated. Carob bean addition led to an increase in starch, soluble fiber, and insoluble fiber. Texture parameters related to hardness (crunchiness) were significantly reduced with the addition of CB (p < 0.05), detectable from a 5% addition of CB and not significant with more CB content. Samples became browner with the addition of CB; however, when the concentrations of CB are high (>5%) no major differences in color were observed. The extrusion process reduced the content of soluble and insoluble fiber, and sucrose in all formulated samples. Extruded samples with 5-7.5% CB seem to be the best formulation in terms of fiber content, color, and texture parameters. These innovative gluten-free foods could be considered as a source of fiber, and a healthier alternative to some commercially available snacks.

Air to liquid heat transfer coefficient experimental comparison between silicon carbide and glass shell and tube heat exchangers in a pilot plant scale

ABSTRACT Instead of the expected 3.8–5.4% increase in the heat transfer coefficient due to the better thermal conductivity of silicon carbide tubes compared to glass tubes, the observed increase was 18–22% for 150–275 kg·h−1 airflow and 6 kg·s−1 propane-1,2-diol coolant in tubes. This additional 15–17% increase is probably due to local flow turbulisation due to the roughness of the sintered carbide of 4–10 µm, which unfortunately also causes a 17–24% higher air pressure drop. The hand calculation model used underestimates the heat transfer coefficient by −2% to 10%, which is better than CHEMCAD 8 modeling results.

Electrochemical removal of ethylene glycol monobutyl ether in aviation industry wastewater using a porous Ti4O7/Ti electrode

Titanium alloy chemical milling wastewater contains a significant amount of ethylene glycol monobutyl ether (EGBE), which is toxic and difficult to be degraded by microorganisms, and the emission will lead to severe environmental pollution. To solve this problem, the electrocatalytic oxidation method was employed to remove EGBE in the wastewater, in which a porous Ti4O7/Ti electrode were prepared and employed as the anode, while stainless steel acted as the cathode. The effects of current density, interelectrode distance, and stirring mode on the COD removal rate were also investigated. Results show that the COD of the wastewater significantly decreases from 12410 to 15 mg L−1 after 16 h of electrolysis at 10 mA cm−2 and electrode spacing of 1.0 cm as well as aeration stirring at 100 mL min−1. Moreover, pilot-plant scale testing reveals that the COD decreasing from 11980 to 183 mg L−1 after 24 h of electrolysis. Consequently, the utilization of porous Ti4O7/Ti electrode as anode in the electrocatalytic oxidation method presents significant potential in removal of EGBE in aviation industry wastewater.

Assessing the aerobic/anoxic enrichment efficiency at different C/N ratios: pilot scale polyhydroxyalkanoates production from waste activated sludge

Polyhydroxyalkanoates (PHA) can be produced using fermentation products of an excess sewage sludge fermentation process. An efficient method to enrich a PHA-producing community is an aerobic-feast/anoxic-famine enrichment strategy. The effect of different carbon to nitrogen (C/N) feed ratios of 1, 2 and 3.5 g COD/g N on the process performance was studied. The study was executed on a pilot plant scale using fermented waste activated sludge as the organic carbon source. The system's performance was monitored in terms of removing contaminants, producing PHA, and reducing N2O emissions. The results indicated that a lower C/N ratio results in lower PHA production, with PHA content in the sludge of 20, 24 and 36 % w/w for C/N ratios of 1, 2 and 3.5 g COD/g N, respectively. At the lowest C/N ratio, the highest nitrite accumulation rate (77%), nitrification efficiency (89%) and denitrification efficiency (89%) were observed, but the N2O production was also the highest (0.77 mg N2O-N/L). The long-term comprehensive monitoring carried out in this study revealed high carbon and ammonia removal efficiencies (never below 80%) despite the C/N shifts and high COD and ammonia concentrations. At the same time, the system showed relatively low PHA production and high environmental impact in terms of high gaseous N2O emission. These findings question the sustainability of the aerobic-feast/anoxic-famine enrichment strategy for PHA production in full-scale plants.

Improved densification of SiCf/SiC composites by microwave-assisted chemical vapor infiltration process based on multifrequency solid-state sources excitation

This paper addresses the possibility of improving and controlling the temperature profile of a Ceramic Matrix Composite preform in a multiport Microwave-assisted Chemical Vapor Infiltration (MW-CVI) pilot-scale plant, based on a multifrequency excitation of the reactor by three solid-state sources. The choice of the most suited excitation frequencies is guided by rigorous numerical modeling of the reactor loaded by the sample, solving the coupled electromagnetic and thermal problems in a self-consistent way. The resulting infiltration front and residual porosity have been evaluated by a pseudo1D model, along the sample thickness, according to the previously computed heating pattern. The practical implementation and validation of the proposed technique are illustrated with MW-CVI trials on 10×10×0.3 cm3 SiCf/(SiC/BN)3/SiC preforms manufactured by Filament Winding method. The obtained results confirm the inside-out densification pattern, expected from the sample volumetric heating, along with an extension of the densification region by a factor of 2–3.

Scaling-up the use of macroscopic photo-CWPO La1-xTixFeO3/SiC alveolar foam catalyst for solar water treatment against micropollutants

Current wastewater treatment plants are not prepared for the removal of micropollutants like phenol, pharmaceuticals and pesticides in water. As their release into the environment has adverse consequences towards the living organisms of ecosystems, the engineering of novel sustainable processes able to ultimately remove the emerging organic contaminants is an objective of paramount importance. Hereby we report for the first time on the successful scale-up of a macroscopic photo-CWPO La1-xTixFeO3/SiC alveolar foam catalyst used at the pilot-plant scale inside a Compound Parabolic Collectors based photoreactor. The removal of a span of organic micropollutants in water matrices of different complexity was efficiently realized under natural solar radiation using H2O2 or persulfates as oxidizing agent. The water matrix composition affected the efficiency of the degradation process. Using H2O2, for a collected energy of ca. 27 KJ/mol, the rate of micropollutant removal ranged from 53 % to 95 % in distilled water depending on the micropollutant in a cocktail configuration. It was lowered to the 17–66 % range in tap water, and to the 8–42 % range in simulated urban wastewater. The results demonstrated the promise of using sodium persulfate as oxidant instead of H2O2, with a better efficiency towards the removal of most of the micropollutants tested. The use of the sodium persulfate oxidant allows for overcoming the drawbacks associated to the treatment of real water matrices observed using H2O2, as better performances were reached when increasing the water matrix complexity. Complete removal of carbamazepine and diclofenac micropollutants was reached in tap water and simulated urban wastewater for ca. 27 KJ/mol of collected energy. The degradation performances combined to the catalyst robustness make this water treatment technology promising for operating in a continuous way under natural solar light.

Statistical modeling and optimization of volatile fatty acids production by anaerobic digestion of municipal wastewater sludge.

Obtaining value-added products from renewable resources is limited by the lack of specific operating conditions optimized for the physico-chemical characteristics of the biomass and the desired end product. A mathematical model and statistical optimization were developed for the production of volatile fatty acids (VFAs) by anaerobic digestion of municipal sewage sludge. The experimental tests were carried out in triplicate and investigated a wide range of conditions: pH 9.5, 10.5, and 11.5; temperatures 25°C, 35°C, 45°C, and 55°C; primary sludge with organic loading (OL) of 10 and 14g VS (volatile solids); and digested sludge with 4 and 6g VS. Subsequently, a statistical search was performed to obtain optimal production conditions, then a statistical model of VFA production was developed and the optimal conditions were validated at pilot plant scale. The maximum VFA concentration predicted was 6975mg COD (chemical oxygen demand)/L using primary sludge at 25°C, initial OL of 14g VS, and pH 10.5. The obtained third-degree model (r2 = 0.83) is a powerful tool for bioprocess scale-up, offering a promising avenue for sustainable waste management and biorefinery development.

(Invited) CO2-Negative Ethylene Via Electrolysis – Greenerene™, a Green Chemistry Start-up

Reduction of greenhouse gases is vital for the long-term environmental health of the planet. While there has been progress in reducing and capturing CO2 emissions, a vast majority of emissions are not captured, and atmospheric CO2 concentration continues to rise. This creates a large and growing market for CO2 sequestration and utilization, which presents an opportunity to rethink how commodity chemicals, which often come with a large carbon footprint, are produced in the US and globally. C2H4 is a key building block in the chemical industry to produce a wide range of plastics, solvents, cosmetics, etc. On average, the production of 1 MMT of C2H4 generates 1.5 MMT of CO2, from fuel combustion, decoking, and utilities. Globally, C2H4 production by steam cracking is ranked as the second-largest contributor of energy consumption (2.8 EJ/year) and greenhouse gas emissions (300 MMT of CO2-e/year) in the chemical industry. Electrochemical CO2 reduction reaction (CO2RR) to produce C2H4 at ambient conditions, when coupled with renewable electricity, could reduce dependence on fossil fuels and decarbonize the chemical sector associated with C2H4 production.At Giner, we are developing technology to improve selectivity, productivity, and durability of the CO2 electrolyzer, enabling commercial deployment. This technology is the basis of a spin-out start-up company called Greenerene™ that is currently seeking investment funding to scale up to the pilot plant scale over the next 3-5 years. Currently, our state-of-the-art electrolyzer has achieved 60% C2H4 selectivity at 500 mA cm-2 and 3 V in a 50 cm2 MEA electrolyzer. We are in the process of translating this performance into multi-cell stacks and larger-area cells to enable 1-ton/day production of ethylene at the pilot scale.We have also developed a detailed Techno-Economic Analysis of our technology, including cost of carbon capture, renewable electricity, and balance of plant including power electronics, recirculation, and purification systems, that demonstrates a pathway to economic competitiveness. With the addition of already implemented and anticipated carbon credits, at scale our technology should be able to produce ethylene at less than current market prices, and with significant environmental and climate benefits compared with current production methods. Acknowledgement: The project is financially supported by the Department of Energy’s Office of EERE under Grants DE-EE000942l and DE-EE0010836.

Learnings from up-scaling CO2 capture: Challenges and experiences with pilot work

Large-scale reduction of greenhouse gasses is necessary to abate the climate crisis, for which technological development will pave the way. Advancing research from academia to industry is crucial for technological progress. Pilot scale studies are the intermediate step from bench to industry. New challenges arise during technology upscaling, many of which have not been previously described in the literature. This article provides a guide of the do's and don'ts to researchers venturing into pilot work. The learnings and experiences gained by working with pilot-scale CO2 capture plant are presented and discussed. This work outlines the process challenges encountered during the commissioning and operation of a CO2 capture pilot using 30 wt% MEA and with a capacity to capture one tonne CO2/day from flue gas. Conducting pilot work in industrial facilities and outside controlled lab environments comes with unexpected problems. The issues faced during our pilot work are presented along with troubleshooting strategies and possible solutions. This work can aid researchers in identifying and rectifying operational challenges and conducting successful pilot campaigns.

Pilot Scale Electrolysis of Peroxodicarbonate as an Oxidizer for Lignin Valorization.

A pilot scale plant at Technology Readiness Level (TRL) 6 comprising an electrochemical ex-cell continuous production of sodium peroxodicarbonate and a thermal depolymerization plug flow reactor for kraft lignin conversion is established. Due to the labile nature of the "green" oxidizer peroxodicarbonate, special attention must be paid to the production parameters in order to optimize its use. A simplified design model describing steady-state and transient operations is formulated and finally validated against experimental data from the electrolysis setup. Design trade-offs are visualized, and their impact on specific energy consumption is evaluated. The pilot plant was operated for a 20-month period for more than 1200 h on-stream. Optimized process conditions result in vanillin yields of 8 wt % and thus prove the successful scale-up.

Carbon capture and utilisation (CCU) solutions: Assessing environmental, economic, and social impacts using a new integrated methodology

Carbon Capture and Utilisation (CCU) technologies play a significant role in climate change mitigation, as these platforms aim to capture and convert CO2 that would be otherwise emitted into the atmosphere. Effective and economically sustainable technologies are crucial to support the transition to renewable and low-carbon energy sources by 2030 and beyond.Currently, studies exploring the financial viability of CCU technologies besides the joint analyses of life-cycle costs and environmental and social impacts are still limited.In this context, the study developed and validated an innovative and integrated methodology, called Life Cycle Cost and Sustainability Assessment (LCC-SA) which allows the joint assessment of (i) project life-cycle costs, (ii) socio-cultural and environmental externalities. This tool was validated with an application to an algal photobioreactors (PBRs) and allowed to assess the economic and environmental sustainability besides identifying the main critical issues to be addressed during the transition from pilot-scale plant to industrial application.The methodology's implementation estimated benefits in two main areas: (i) environmental, including CO2 removal and avoidance through biodiesel production instead of fossil-derived diesel; (ii) socio-cultural, encompassing new patents, knowledge spillovers, human capital formation, and knowledge outputs. The analysis returned as main result that the present value of the social externalities amounts to around EUR 550,000 and the present value of the costs to approximately EUR 60,000. The Economic Net Present Value (ENPV) is EUR 487,394, which shows the significance of the extra-financial effects generated by the research project. At full-scale application, environmental benefits include capturing 187 to 1867 tons of CO2 per year and avoiding 1.7 to 16.7 tons of CO2 annually through biodiesel production instead of fossil-derived diesel.

Influence of Nitrogen Content in Food Waste on Biogas Production

AbstractHigh carbon content and high‐level biodegradability are major constraints of the anaerobic digestion of food waste. In the present study, anaerobic digestion of model food waste was carried out in a fed batch digester. Nitrogen content in model food waste was adjusted by the addition of ammonium chloride at the desired C/N ratio. Biogas production at ammonium chloride percentages of 0, 0.8, 1.5, 2.14, and 3.2 % (weight basis) were carried out under mesophilic conditions in a pilot plant scale floating drum digester. At an ammonium chloride percentage of 1.5 % that balances C/N ratio 25, highest biogas production of 0.42 m3 kg−1 of VS was attained while biogas production from food waste without ammonium chloride of 0.06 m3 kg−1 of VS was obtained. The highest methane yield of 0.323 m3 kg−1 of VS was found at ammonium chloride of 1.5 % while methane yield of 0.042 m3 kg−1 of VS was achieved from food waste without ammonium chloride. The highest percent increase CH4 yield of 669 % was obtained at an ammonium chloride percentage of 1.5 %. Biogas productivity obtained at ammonium chloride percentage of 1.5 % was 0.6 L L−1 d−1. Hence, the optimum ammonium chloride percentage obtained was 1.5 % which balances the C/N ratio at 25.

Evaluating hydrothermal liquefaction hydrochar from sewage sludge as a phosphorus resource through struvite production

Hydrothermal liquefaction (HTL) has attracted considerable attention for valorizing sewage sludge to biofuels while the solid residue, hydrochar, has received little attention for its final application. In the current work hydrochar recovered from hot separation in a pilot-scale HTL plant is evaluated for its nutrient value, in particular as a sustainable Phosphorus (P) resource. Following thorough characterization of the hydrochar, P recovery as struvite (NH4MgPO4·6H2O) is investigated to produce a fertilizer with a lower heavy metal content that could be used in current agricultural practices. P extraction using inorganic (hydrochloric and sulphuric) and organic (citric) acids is evaluated by applying 0.1–1 mol/L of acids for 1–12 h with a liquid/solid ratio of 10 mL/g. A second-order polynomial model was established by response surface methodology (RSM) to predict the P extraction with different acids. The optimum operating conditions for maximum P extraction (94 %) are suggested as 0.7 M of acid strength (H2SO4) and 6.5 h of extraction time. Addition of citric acid (CA) during the struvite precipitation from acid-leached P solution was found to improve the struvite purity from 36.6 % to 54 % with a reduction in heavy metal content. Furthermore, morphological analysis validated the formation of struvite. Upon comparison with the regulations, hydrochar was found to exceed some of the heavy metal limits but was low in polyaromatic hydrocarbons (PAHs), per- and polyfluorinated substances (PFAS) and showed low toxicity to Aliivibrio fischeri. P extraction and struvite precipitation are shown to reduce heavy metal contents below regulatory limits with P recoveries from 40 % to 67 %. Thus, as an alternative to direct land application of hydrochar, harvested struvite from hydrochar could be applied as a fertilizer with no apparent environmental risk.

Enhancing flocculation kinetics assessment: Integrating aggregate size distribution into experimental and modelling frameworks

Flocculation is crucial in drinking water treatment, yet conventional techniques like jar tests may lack precision in capturing particle heterogeneity. To overcome this, a non-intrusive image-based system was employed to directly assess flocculation using aggregate size distribution (ASD). Integrating ASD into a kinetic model with a single parameter (β) allowed for tracking ASD during flocculation. Bench and pilot-plant scale experiments validated our approach. Sensitivity analysis confirmed β's responsiveness to ASD variations (r > 0.92), with modelling indicating errors averaging around 5%, underscoring its efficacy in assessing flocculation efficiency. Linking ASD coefficients from bench to pilot-scale models facilitates predicting flocculation performance.

Techno-economic analysis of biomass value-added processing informed by pilot scale de-ashing of paper sludge feedstock

Paper sludge biomass represents an underutilized feedstock rich in pulped and processed cellulose which is currently a waste stream with significant disposal cost to industry for landfilling services. Effective fractionation of the cellulose from paper sludge presents an opportunity to yield cellulose as feedstock for value-added processes. A novel approach to cellulose fractionation is the sidehill screening system, herein studied at the pilot-plant scale. Composition analysis determined ash removal and carbohydrate retention of both sidehill and high-performance benchtop screening systems. Sidehill screening resulted in greater carbohydrates retention relative to benchtop screening (90% vs 66%) and similar ash removal (95% vs 98%). Techno-economic analysis for production of sugar syrup yielded a minimum selling price of $331/metric ton of sugar syrup including disposal savings, significantly less than a commercial sugar syrup without fractionation. Sensitivity analysis showed that screening conditions played a significant role in economic feasibility for cellulosic yield and downstream processes.

A pilot-scale assessment of five common weeds in the sustainable treatment of sewage utilizing SHEFROL®, with prospects of a closed-loop biorefinery

Relative efficacy of five common weeds—of the kind that are either rooted in soil or which freely float over water—was assessed in rapid, effective and sustainable treatment of sewage at pilot plant scale in the recently developed and patented SHEFROL® bioreactors. The plants were utilized in a unit of capacity 12,000 liters/day (LPD) which, after two years of use, was enlarged to handle 40,000 LPD of sewage. It was then further expanded after an year to treat 57,000 LPD. All the five weeds, of which none has previously been tested in a pilot-scale SHEFROL, were able to foster highly efficient primary treatment (in terms of suspended and total solids) and secondary treatment (in terms of BOD and COD) to levels exceeding 85% in most cases. Additionally, the weeds also helped in achieving significant tertiary treatment. At different hydraulic retention times, and at steady state, the five weeds achieved treatment of BOD, COD, suspended solids, nitrogen, phosphorous, copper, nickel, zinc, and manganese in the ranges, 80–95, 79–91, 82–95, 61–71, 51–73, 37–43, 30–38, 39–47, and 27–35%, respectively. It all occurred in a single process step and without the use of any machine or chemical. This made the system not only simple and inexpensive to install but also to maintain. Over continuous long-term operation for four years, the system was seen to be very robust as it was able to handle wide variations in the volumes and characteristics of sewage, as well as absorb shock loads without compromising the reactor performance. The sustainability of the system can be further enhanced by upgrading it to a circular biorefinery. Energy sources in the form of volatile fatty acids (VFAs) can be extracted from the weeds removed from SHEFROL and then the weeds can be converted into organic fertilizer using high-rate vermireactors recently developed by the authors.

UHPLC-PAD Protocol for the Simultaneous Identification of Polyphenols and Bitter Acids: Organoleptic and Nutraceutical Fingerprinting of Bergamot-Flavored Craft Beer.

In this study, a UHPLC-PDA method for the simultaneous identification of polyphenols and bitter acids (alpha, beta, and isoalpha) in beer was developed. The resulting chemical profiles were leveraged to distinguish the characteristics of four (IPA, Lager, Blanche, ALE) bergamot-flavored beers, produced on a pilot-scale plant. In a streamlined 29 min analysis, thirty polyphenols and fourteen bitter acids were successfully identified under optimized separation conditions. Validation, encompassing parameters such as LOD (from 0.028 ppm for isorhamnetin to 0.106 for narirutin), LOQ (from 0.077 ppm for naringenin to 0.355 for narirutin), R2 (always more than 0.9992), repeatability (from 0.67% for tangeretin to 6.38% for myricetin), and reproducibility (from 0.99% for sinensetin to 6% for naringin), was conducted for polyphenol quantification using constructed calibration curves with seven levels. Exploring polyphenolic components as potential discriminators among different beer styles, a total of thirty-two polyphenolic compounds were identified and quantified, including characteristic bergamot peel polyphenols like neoeriocitrin (from 7.85 ppm for CBS2 to 11.95 ppm in CBS1); naringin (from 4.56 ppm for CBS4 to 10.96 in CBS1), and neohesperidin (from 5.93 in CBS3 to 15.95 for CBS2). The multivariate analysis provided additional insights into variations among specific beer styles, revealing discrepancies in the presence or relative concentrations of specific compounds linked to brewing ingredients and processes. This research enhances the fingerprinting of the chemistry governing beer quality through a straightforward and cost-effective analytical approach.

Pilot-scale CO2 capture demonstration of heat integration through split flow configuration using 30 wt[formula omitted] MEA at a Waste-to-Energy facility

Post-combustion carbon capture is a well-established technology to limit CO2 from industrial emissions. However, challenges such as high energy requirements for solvent regeneration persist. Research is still being conducted to improve the energy efficiency of the process. This study aims to present the results of process intensification in a pilot-scale CO2 capture plant. The pilot-scale investigations were carried out at Amager Bakke, a Waste-to-Energy facility in Copenhagen, Denmark. The tests were conducted by implementing the split flow configuration as a method of process intensification. The CO2 rich stream was split before flowing through the rich/lean heat exchanger. One of the split streams was fed to the stripper top, and the other was sent through the heat exchanger and then fed to the stripper. The cold split stream at the stripper top is heated by the overhead vapours which would otherwise escape the stripper. The current work discusses the split flow configuration results of the pilot plant by employing 30wt% MEA as the solvent and compares it to the base-case performance of the pilot. Experiments were conducted by splitting 22% of the rich solvent and feeding it to the stripper top. The performance of the split flow configuration was analysed at different reboiler duties. A minimum specific reboiler duty of 3.45 GJ/tonne CO2 is obtained for the split flow configuration, which is less than the base case by 7.8%. Additionally, a reduction in the condenser duty by at least 68% was achieved by the implementation of the split flow configuration.

Multivariate evaluation from electrocoalescence to Brazilian crude oils in pilot plant scale

A multivariate evaluation of the electrocoalescence process for crude oil dehydration is presented in this study. The objective is to assess the impact of operational variables and their combined effects on the final water content. To achieve this, a pilot plant unit was constructed for the evaluation of five operational variables in a steady-state regime. The statistical analysis, conducted using results obtained through a factorial experimental design for three types of crude oil, illustrates how the influence of cross-effects impacts dehydration. Different responses from each type of crude oil depend on the combined variables. The findings highlight that a combination of factors, not always immediately apparent, contributes to a reduction in the final water content. Furthermore, the combination of operating factors appears to be more crucial than individual variables. This suggests an opportunity for the optimization of electrocoalescers by simply adjusting field parameters.

Design of carbide free bainitic steels for hot rolling practices

ABSTRACT In this work, we provide with an overview of the main theories, metallurgical and microstructural concepts used for the design of carbide free bainitic steels adapted to industrial hot rolling and coiling practices. The selected alloys were cast and tested at pilot plant scale and the obtained good combinations of properties tend to validate the thorough and careful approach undertaken to predict the microstructures during the alloy design process.