Pilot-scale Prototype Research Articles

Pilot-scale study of methane-assisted catalytic bitumen partial upgrading

The direct utilization of heavy and extra-heavy crude oils presents a formidable challenge due to their inherent physical and chemical properties such as high C/H ratio, extremely high viscosity and density, low APIo, super low mobility, high asphaltene and impurity (Fe, Ni, Co, S, N, etc.) contents. To tackle these problems cost-effectively, we have proposed and established a novel technique, distinct from conventional hydrotreating, for catalytic partial upgrading of extra heavy crudes with co-fed methane and a multi-functional catalyst. This technique has been further optimized using lab-scale batch reactors (100 mL, 300 mL), bench-scale and pilot-scale fixed bed reactors with their processing capacity of 250 mL/day and 20 L/day, respectively. The feasibility, stability, and profitability of this technique have been successfully verified using all these facilities and a wide variety of feedstock. Yet, further scale-up is necessary to advance this technique towards commercialization in industry. In this study, a pilot-scale prototype unit (processing capacity of 1 barrel/day) was designed and manufactured based upon the previous achievements, and a bitumen sample recovered from the Steam Assisted Gravity Drainage (SAGD) process was chosen as a typical extra heavy crude for the upgrading. A 30-day upgrading has been conducted smoothly without clogging and a liquid yield of 96.7 % was observed with remarkable enhancements in product quality. The notable decreases in density, viscosity, TAN, asphaltene content, and sulfur content were confirmed and consistent with previous results. A low olefin content implies excellent stability and compatibility of the liquid product. Additionally, a preliminary TEA (Techno-Economic Assessment) and LCA (Life-Cycle Analysis) have been conducted and the beneficial features of this novel technique have been confirmed with higher profitability, lower cost, and lower carbon footprint. This study further consolidates the advantages of this promising technique as a cost-effective and environmentally friendly alternative to hydrotreating for processing extra heavy crudes.

Winter Season Outdoor Cultivation of an Autochthonous Chlorella-Strain in a Pilot-Scale Prototype for Urban Wastewater Treatment

The global population increase during the last century has significantly amplified freshwater demand, leading to higher wastewater (WW) production. European regulations necessitate treating WW before environmental. Microalgae have gained attention for wastewater treatment (WWT) due to their efficiency in remediating nutrients and pollutants, alongside producing valuable biomass. This study investigates the phycoremediation potential of a Chlorella-like strain isolated from urban WW in a 600L-scale system under winter conditions. Experiments in December 2021 and February 2022 tested the strain’s adaptability to varying environmental conditions, particularly temperatures (min-max temperature range: from −3.69 to 10.61 °C in December and −3.96 to 17.61 °C in February), and its ability to meet legal discharge limits. In December, low temperatures algal growth. Nitrates showed an RE of about 92%, while ammonia slightly decreased (RE, about 32%), and phosphorous remained unchanged. In February, mild temperatures increased algal density (33.3 × 106 cell mL−1) and, at the end of experiment, all nutrients were below legal limits with very high RE % (NH4+, 91.43; PO43− 97.32). Both trials showed an E. coli RE, % = 99%. The study highlights the potential of microalgae for WWT and the importance of considering seasonal variations when implementing these systems.

Performances and control aspects of steam storage systems with PCM: Key learnings from a pilot-scale prototype

Medium and High temperature steam is used as Heat Transfer Fluid in a wide range of industrial processes. Steam storage is required when steam production or consumption is variable in time, like in solar thermal facilities or batch industrial processes. In introduction, this paper gives an extensive review of the PCM storage prototypes that were operated worldwide for steam applications between 120 and 400 °C. At CEA Grenoble, a PCM steam storage prototype was operated during >300 days during three tests campaigns from 2013 to 2019. 78 charge–discharge cycles were performed with the same PCM volume under a wide range of operating conditions. This paper aims at reporting some significant experimental results obtained from this prototype. Thermal performance indicators (storage capacity, utilization rate, storage efficiency, and exergy efficiency) are evaluated in detail for the first time for a pilot scale PCM steam storage. For a complete charging-discharging cycle at sliding pressure, constant mass flow, and from homogeneous temperatures in initial conditions, utilization rate is estimated at 81.9%, storage efficiency at 79.3%, and storage exergy efficiency at 76.2%. From 2013 to 2019, thermal testing of the storage prototype showed very repeatable results: in this paper, the authors demonstrate that heat transfers were not altered between 2013 and 2019. Beyond most commonly used operating modes for PCM steam storage (fixed pressure and sliding pressure), advanced control strategies are proposed. Two examples of advanced controls are described in this paper, showing an insight of the valuable services that a PCM storage system can provide to an industrial steam user (power cycle, industrial steam network,…).

Power Grid Integration and Use-Case Study of Acid-Base Flow Battery Technology

There are many different types of energy storage systems (ESS) available and the functionality that they can provide is extensive. However, each of these solutions come with their own set of drawbacks. The acid-base flow battery (ABFB) technology aims to provide a route to a cheap, clean and safe ESS by means of providing a new kind of energy storage technology based on reversible dissociation of water via bipolar electrodialysis. First, the main characteristics of the ABFB technology are described briefly to highlight its main advantages and drawbacks and define the most-competitive use-case scenarios in which the technology could be applied, as well as analyze the particular characteristics which must be considered in the process of designing the power converter to be used for the interface with the electrical network. As a result, based on the use-cases defined, the ESS main specifications are going to be identified, pointing out the best power converter configuration alternatives. Finally, an application example is presented, showing an installation in the electrical network of Pantelleria (Italy) where a real pilot-scale prototype has been installed.

Exploitation of sea fennel (Crithmum maritimum L.) for manufacturing of novel high-value fermented preserves

Sea fennel (Crithmum maritimum L.) contains several bioactive compounds like vitamin C, polyphenols, essential oils, and fatty acids. The present study was aimed at exploring the lactic acid fermentation of sea fennel sprouts by the selection and inoculation of multiple strain starters to produce laboratory-scale prototypes and, subsequently, a pilot-scale prototype. A rapid pH reduction was seen in the laboratory-scale prototypes, mainly due to lactic acid production. Linoleic and α-linolenic acids were the most abundant detected fatty acids, while among volatile compounds monoterpene hydrocarbons prevailed. Fruity, pungent and yogurt notes emerged from the sensory analysis. The analysis of the pilot-scale prototype confirmed the physico-chemical data collected from the laboratory scale prototypes, except for a slower acidification. In addition, a decrease in antioxidant activity and content of vitamin C, fiber and total polyphenols was seen during fermentation, whereas sensory analysis revealed a kerosene-like note, a salty flavor, and a crunchy consistency. No coagulase positive staphylococci and botulinum toxin-producing clostridia were detected. The results overall collected highlighted the great potential of sea fennel and selected lactic acid bacteria starters to produce high value, safe and microbiologically stable preserves.

Novel separator skimmer for oil spill cleanup and oily wastewater treatment: From conceptual system design to the first pilot-scale prototype development

Abstract Frequent oil spill accidents, oily industrial wastewater and organic solvents discharge have caused alarming and serious environmental, health and economic issues. Therefore, the development of an environmentally friendly, cost-effective and efficient oil–water separation (OWS) technology is highly urgent. Although traditional methods have been demonstrated to be effective, they still suffer from numerous drawbacks. Herein, we report the concept, design, assembly, and testing of novel and advanced proof-of-concept pilot-scale OWSS prototype module for OWS. This system is built around a unique and innovative combination of hydrophobic–hydrophilic porous sorbent materials-based OWS bed and a vacuum-assisted oil collection system, which allows continuous and efficient removal of highly pure oily contaminants from water surface. The main goals of the present work are the development of a prototype design for a pilot-scale system and the fabrication of the prototype module. A detailed description of the design development, main system components, assembly and construction steps is reported herein, focusing predominantly on the main design choices adopted to comply with the challenging technical requirements. System specifications have been defined to obtain optimum prototype performance with simultaneous oil sorption and recovery as well as a high oil uptake rate and selectivity, which will provide a sustainable solution for industry with robust instrumentation. Initial economic analysis including the technical and economic feasibility of the prototype manufacturing and implementation has also been discussed. The first prototype is being manufactured in our facilities, and the operating tests during and after assembly showed excellent OWS performance, which demonstrates that the developed prototype has been constructed successfully. We believe that this simplified separation–collection system design allows its straightforward implementation for large-area oil spill cleanup and in industrial wastewater treatment plants.

Energy recovery in pilot scale membrane CDI treatment of brackish waters

An energy recovery technique using a high-current bi-directional dc-dc converter for membrane capacitive de-ionization (mCDI) of brackish waters is described and it’s performance assessed in a pilot-scale prototype. The energy recovery system is shown to reduce the energy consumption of the pilot-scale mCDI unit, powered by photovoltaics and with battery storage, by between 30 and 40%. Use of a stopped flow process also enables water recovery of up to 87%.The contributions to energy consumption in the system are quantified with the insights gained from this analysis enabling the selection of an optimum voltage range for desorption termination that maximizes the daily recovered energy. The experimental results demonstrate that energy usage by the mCDI process of lower than 0.4 kWh/m3 is achievable with almost 40% of the energy supplied by the batteries recovered.

Assessment of the Li-air Battery Technology for Automotive Applications through the Development of a Multi-Electrode Solid-State Prototype

This report highlights the results of a project carried out at the National Research Council of Canada (NRC), with the overall objective to address the major issues of the Li-air battery technology and assemble a multi-electrode pilot-scale prototype. Several innovative ideas and technologies were investigated along the core concept of a polymer-based solid-state technology. The assessment of the Li-air technology is discussed through the results of the project as well as other sources, especially concerning its readiness and perspectives for automotive applications.

BUBBLE-NET - System to catch fish and the respective method of use

Event Abstract Back to Event BUBBLE-NET - System to catch fish and the respective method of use Cláudia S. Correia1, Carlos M. Matos1 and Teresa M. Mouga1* 1 Polytechnic Institute of Leiria, GIRM - Marine Resources Research Group, Portugal Fishing is a socio-economic activity of great relevance worldwide. However the environmental sustainability of the fishing arts is far from being effective. It is necessary to find more selective types of fishing to ensure sustainable catches of target species and also to protect other organisms accidentally caught with no commercial value. The answer to these problems arise, often, from the nature itself, as is the case of bubble net feeding, the feeding behavior of the humpback whale (Megaptera novaengliae). We tried to mimic the hunting behavior of these whales through the production of a continuous network of bubbles, therefore replacing traditional fishing nets used to catch pelagic fish (sardines, mackerel, horse mackerel ...). We believe that this device presents large environmental benefits such as the reduction of bycatch, the absence of ghost fishing, clean capture, that is, the absence of human handling, and sustainable yield by allowing the capture of the legal quantities and sizes. Additionally, it also lets the remaining fish to be returned alive to the ocean, either in excess on small in size. There are also obvious economic advantages, such as the reduction of cost of the fishing gear, increased lifetime of the device and also the reduction of cost associated with maintenance. Tests carried out under controlled conditions in aquaculture show success indicators regarding the behavior of the bubbles relatively shoal. Pilot scale prototype is currently being developed to validate the results obtained in real sea conditions. The device includes a compressor, an air-lung, two sets of hoses, floaters and ballast. Finally, further tests are required for the implementation and optimization of this new gear on commercial vessels. Acknowledgements The authors wish to thank all the colleagues from ESTM who assisted in field and laboratory work as well as the technical support in some steps of this work. This project is being financed by PROMAR 2007-2013, Eixo III, Ações Coletivas. Keywords: Bubble net feeding, Humpback Whale, purse seine fishing, fisheries sustainability, selective fishing Conference: IMMR | International Meeting on Marine Research 2014, Peniche, Portugal, 10 Jul - 11 Jul, 2014. Presentation Type: Poster Presentation Topic: FISHERIES AND MANAGEMENT Citation: Correia CS, Matos CM and Mouga TM (2014). BUBBLE-NET - System to catch fish and the respective method of use. Front. Mar. Sci. Conference Abstract: IMMR | International Meeting on Marine Research 2014. doi: 10.3389/conf.fmars.2014.02.00147 Copyright: The abstracts in this collection have not been subject to any Frontiers peer review or checks, and are not endorsed by Frontiers. They are made available through the Frontiers publishing platform as a service to conference organizers and presenters. The copyright in the individual abstracts is owned by the author of each abstract or his/her employer unless otherwise stated. Each abstract, as well as the collection of abstracts, are published under a Creative Commons CC-BY 4.0 (attribution) licence (https://creativecommons.org/licenses/by/4.0/) and may thus be reproduced, translated, adapted and be the subject of derivative works provided the authors and Frontiers are attributed. For Frontiers’ terms and conditions please see https://www.frontiersin.org/legal/terms-and-conditions. Received: 09 May 2014; Published Online: 18 Jul 2014. * Correspondence: Prof. Teresa M Mouga, Polytechnic Institute of Leiria, GIRM - Marine Resources Research Group, Peniche, 2520-641, Portugal, mougat@ipleiria.pt Login Required This action requires you to be registered with Frontiers and logged in. To register or login click here. Abstract Info Abstract The Authors in Frontiers Cláudia S Correia Carlos M Matos Teresa M Mouga Google Cláudia S Correia Carlos M Matos Teresa M Mouga Google Scholar Cláudia S Correia Carlos M Matos Teresa M Mouga PubMed Cláudia S Correia Carlos M Matos Teresa M Mouga Related Article in Frontiers Google Scholar PubMed Abstract Close Back to top Javascript is disabled. Please enable Javascript in your browser settings in order to see all the content on this page.

Recovery of ammonia from poultry litter using flat gas permeable membranes

The use of flat gas-permeable membranes was investigated as components of a new process to capture and recover ammonia (NH3) in poultry houses. This process includes the passage of gaseous NH3 through a microporous hydrophobic membrane, capture with a circulating dilute acid on the other side of the membrane, and production of a concentrated ammonium (NH4) salt. Bench- and pilot-scale prototype systems using flat expanded polytetrafluoroethylene (ePTFE) membranes and a sulfuric acid solution consistently reduced headspace NH3 concentrations from 70% to 97% and recovered 88% to 100% of the NH3 volatilized from poultry litter. The potential benefits of this technology include cleaner air inside poultry houses, reduced ventilation costs, and a concentrated liquid ammonium salt that can be used as a plant nutrient solution.

A modified UCT method for biological nutrient removal: Configuration and performance

A pilot-scale prototype activated sludge system is presented, which combines both, the idea of University of Cape Town (UCT) concept and the step denitrification cascade for removal of carbon, nitrogen and phosphorus. The experimental set-up consists of an anaerobic selector and stepwise feeding in subsequent three identical pairs of anoxic and oxic tanks. Raw wastewater with influent flow rates ranging between 48 and 168 l d −1 was fed to the unit at hydraulic residence times (HRTs) of 5–18 h and was distributed at percentages of 60/25/15%, 40/30/30% and 25/40/35% to the anaerobic selector, 2nd and 3rd anoxic tanks, respectively (influent flow distribution before the anaerobic selector). The results for the entire experimental period showed high removal efficiencies of organic matter of 89% as total chemical oxygen demand removal and 95% removal for biochemical oxygen demand, 90% removal of total Kjeldahl nitrogen and total nitrogen removal through denitrification of 73%, mean phosphorus removal of 67%, as well as excellent settleability. The highest removal efficiency and the optimum performance were recorded at an HRT of about 9 h and influent flow rate of 96 l d −1, in which 60% is distributed to the anaerobic selector, 25% to the second anoxic tank and 15% to the last anoxic tank. Consequently, the plant configuration enhanced removal efficiency, optimized performance, saved energy, formed good settling sludge and provided operational assurance.