Sustainable Industrial Processes Research Articles

Unveiling the effects of nickel loading on methane dry reforming: Perspectives from ni/fibrous Zeolite-Y catalysts

The development of new technologies that employ greenhouse gases, such as CO2 and CH4, is becoming more important in the fight against global warming. Catalytic methane dry reforming (MDR) is one straightforward way to reduce CO2 and CH4. In this study, the influence of nickel (Ni) loading on the catalytic performance of fibrous zeolite-Y catalysts (Ni/FHY) for MDR was explored. The study involved the synthesis and testing of Ni/FHY with varying Ni loadings (1 wt% to 10 wt%). The results demonstrate that the metal loading significantly affects the catalysts' performance through metal-support interaction. The catalytic activity showed that the performance of FHY increased with optimum metal loading of 5 wt% where the CO2 conversion increased to 90.3% from 82.2%, and CH4 conversion to 94.2% from 79.6%. The findings suggest that the 5 wt% optimal Ni loading showed the critical role of the metal-support interaction in shaping catalytic properties. Hence, this work provides insights into catalyst optimization for sustainable industrial processes, highlights the importance of the synergistic metal-support interaction, and provides insights into the relationship between Ni content and catalytic behavior. Thus, it offers a basis for optimizing catalysts in MDR and contributes to the advancement of sustainable industrial processes.

Optimizing light-driven ene-reductase reactions with g-C3N4 and electron mediators

In the realm of green chemistry and sustainable industrial processes, the integration of enzymes with photocatalytic materials offers a promising avenue for achieving efficient, light-driven catalysis while minimizing environmental impact. This study introduces an enzyme-photo-coupled catalytic system (EPCS) using graphitic carbon nitride (g-C3N4) as a photocatalyst and methyl viologen (MV2+) as an electron mediator to drive the reduction of 2-cyclohexen-1-one by the Old Yellow Enzyme (OYE), reducing the reliance on expensive and scarce bioelectronic carriers and demonstrating a sustainable alternative for biocatalytic applications. Furthermore, we explored the incorporation of a Pickering emulsion system to enhance mass transfer, especially in reactions involving highly concentrated substrates. This adaptation not only improves the yield of the EPCS at higher substrate concentrations but also offers a scalable and environmentally benign alternative to traditional photocatalytic systems.

SCADA based common bus regenerative control of PMSM drive for industrial application

AbstractThe emerging trend in sustainable industrial processes focuses on energy‐efficient drives to enhance performance in both intermediate and continuous operating conditions. For decades, researchers have focused on permanent magnet synchronous machines (PMSM) for industrial applications in order to retain consistency in performance and efficiency under wide speed ranges. Common bus regenerative control is an energy‐efficient method used in industrial systems to manage power flow between multiple devices on a shared DC bus. It captures and reuses excess energy generated during braking/deceleration, reducing waste and improving overall system efficiency. The experimental behavior of the drive scheme has been observed as per the standards of the laboratory. In this article, regenerative control of a PMSM drive is using the voltage vector control (VVC+) technique and the SCADA based condition monitoring for the PMSM drive system is integrated to supervise the parameters including current, voltage, power, speed, torque, and temperature under dynamic operating conditions. As a primary step of implementing the drive condition monitoring is carried out through Danfoss's motion control tool software. Further, the SCADA control system is interfaced to FC302 PMSM drive through RS485 Modbus communication to extract the necessary electrical attributes and monitor the same.

Updating the Status quo on the Eco-Friendly Approach for Antioxidants Recovered from Plant Matrices Using Cloud Point Extraction.

The concepts of "green chemistry" are gaining importance in the agri-food sector due to the need to minimize pollution from toxic chemicals, improve the safety and sustainability of industrial processes, and provide "clean-labeled products" required by consumers. The application of the cloud point extraction (CPE) is considered a promising alternative to conventional organic solvents. In the CPE, the separation of compounds from the bulk solution occurs by adding a surfactant (either non-ionic or ionic). When the solution is heated to or above a critical temperature, referred to as the cloud point, two phases are formed-micellar and aqueous. Recently, the horizons of the traditional CPE have been increasingly expanding by improved procedures and integration with other techniques, such as the microwave- and ultrasonic-assisted extraction. This article provides an updated overview of the theory and research articles on the CPE from 2018 to 2023 and critically discusses the issues relevant to the potential applicability of the CPE as a promising and green technique for antioxidants recovered from plant materials. Finally, some future perspectives and research needs for improved CPE are presented.

Sustainable Industrial Management Process: Technology and Management Challenges

Sustainable Industrial Management Process: Technology and Management Challenges

The Pichia pastoris enzyme production platform: From combinatorial library screening to bench-top fermentation on residual cyanobacterial biomass

The demand for industrial enzymes is continually rising, fueled by the growing need to shift towards more sustainable industrial processes. However, making efficient enzyme production strains and identifying optimal enzyme expression conditions remains a challenge. Moreover, the production of the enzymes themselves comes with unavoidable impacts, e.g., the need to utilize secondary feedstocks. Here, we take a more holistic view of bioprocess development and report an integrative approach that allows us to rapidly identify improved enzyme expression and secretion conditions and make use of cyanobacterial waste biomass as feed for supporting Pichia pastoris fermentation. We demonstrate these capabilities by producing a phytase secreted by P. pastoris that is grown on cyanobacterium hydrolysate and buffered glycerol-complex (BMGY) medium, with genetic expression conditions identified by high-throughput screening of a randomized secretion library. When our best-performing strain is grown in a fed-batch fermentation on BMGY, we reach over 7 000 U/mL in three days.

N,O‐Codoped Onion‐like Carbon Catalyzed Selective Oxidation of Methanol to Dimethoxymethane: Structure‐Activity Relationship

AbstractOne‐step synthesis of dimethoxymethane (DMM) via methanol oxidation under the catalysis of nanocarbon is a green and sustainable chemical industrial process. In this work, nitrogen, oxygen codoped onion‐like carbon (NOLC) were prepared via a simple thermal treatment method, which was applied to one‐step synthesis of DMM. The physicochemical characterization results revealed that nitrogen and oxygen elements were successfully introduced into the onion‐like carbon (OLC) catalyst. The proposed NOLC catalysts exhibited DMM selectivity of 75 % at relatively low reaction temperature (150 °C) and long stability over 10 h. In‐situ titration experiments revealed that the carboxylic acid groups on NOLC surface were the main acidic active sites. The Clemmensen reduction control experiment revealed that the carbonyl groups were the active sites for the formation of formaldehyde. The basic reaction kinetics and mechanism such as reaction orders, apparent activation energy and rate determining step etc. for one‐step synthesis of DMM via methanol were studied systematically. The present work shows an important structure‐function relation for designing highly efficient nanocarbon catalyzed methanol conversion reaction system that the appropriate redox/acid intensity on catalyst surface through the modulation of N and O elements would effectively improve the selectivity of DMM.

Monitoring energy consumption of vending machines in university buildings

Vending machines are a convenient source of food and drinks, but they can also be a significant source of energy consumption in public buildings. To reduce energy waste and improve energy efficiency, a low-cost sensor network was used to monitor the energy usage of vending machines. The sensor network consists of small, wireless sensors that are placed inside the vending machines, and a central hub that is connected to the internet via Wi-Fi. The sensors are able to collect data on the energy usage of the vending machines, including when they are idle, in use, or in a standby mode. This data is then transmitted to the central hub, where it is processed and made available to users through a web-based interface or mobile app. With this information, users can identify patterns in energy usage and make changes to reduce overall energy consumption. In a university in southern Spain, 53 vending machines of three types were monitored: snack, cold drinks, and hot drinks. The average monthly consumptions of these types of vending machines were snack (250 kWh), cold drinks (200 kWh), and hot drinks (100 kWh). By using a sensor network to monitor the energy usage of vending machines, it is possible to identify areas where energy is being wasted and make adjustments to reduce this waste. This can help to reduce the environmental impact of the vending machines, by reducing the amount of energy that is consumed and the associated greenhouse gas emissions. Additionally, by making the vending machines more energy efficient, it is possible to improve their overall productivity and cost-effectiveness. Overall, the use of a low-cost sensor network to monitor vending machines energy usage can be seen as a form of cleaner production, because it promotes the use of more sustainable and efficient industrial processes.

Microbial Biofilms: Harnessing the Power of Complex Microbial Communities for Industrial Applications

Microbial biofilms are complex microbial colonies that attach to surfaces and grow inside an extracellular polymeric substance (EPS) matrix. These biofilms have great promise for industrial applications and play crucial roles in several natural and artificial systems. The use of microbial biofilms in industrial settings is examined in this abstract, which also places an emphasis on techniques to improve biofilm development and performance through surface modification and quorum sensing manipulation. Due to their versatility, durability, and cooperative behaviour, biofilms have attracted interest and are useful in a variety of industrial industries. They work in the food business, bioenergy generation, agriculture industry and biosensor, among other fields.Biofilms are more effective in industrial processes because of their intricate interactions, which also lead to higher metabolic capacities, increased stress tolerance, and improved retention of immobilised cells. The production and performance of microbial biofilms need to be improved in order to fully realise their potential. Techniques for surface modification provide a promising way to customise the characteristics of biofilms. It is possible to modify the topography, hydrophobicity, and charge of the substrate to affect how quickly biofilms form after initial microbial attachment. Additionally, functionalization and coatings based on nanomaterials provide novel approaches to improve biofilm adhesion, cohesiveness, and stability. The method of cell-to-cell communication known as quorum sensing (QS) directs the development and behaviour of biofilms. Controlling QS pathways enables fine-grained regulation of biofilm growth. QS may be controlled via genetic engineering and small molecule therapy, which affects the phenotypic and architecture of biofilms. With the use of these techniques, biofilms may be designed with the required properties, including greater thickness, higher resistance to shear pressures, and increased production of desirable chemicals. In conclusion, because of their cooperative nature and adaptable functioning, microbial biofilms show enormous promise for industrial applications. The importance of surface modification and quorum sensing modulation as tactics to improve biofilm performance is highlighted in this abstract. As science advances, a fuller comprehension of the ecology of biofilms, interspecies interactions, and synthetic biology technologies will make it easier to create biofilms that are specifically suited to a given industrial purpose. Understanding the complex principles underlying biofilm production and behaviour will allow for the full realisation of the promise for sustainable and effective industrial processes, ushering in a new age of biofilm-based technology.

Leading Edge Technologies and Perspectives in Industrial Oilseed Extraction.

With the increase in the world's population and per capita wealth, oil producers must not only increase edible oil production but also meet the demand for a higher quality and variety of products. Recently, the focus has shifted from single processing steps to the entire vegetable oil production process, with an emphasis on introducing innovative technologies to improve quality and production efficiency. In this review, conventional methods of oilseed storage, processing and extraction are presented, as well as innovative processing and extraction techniques. Furthermore, the parameters most affecting the products' yields and quality at the industrial level are critically described. The extensive use of hexane for the extraction of most vegetable oils is undoubtedly the main concern of the whole production process in terms of health, safety and environmental issues. Therefore, special attention is paid to environmentally friendly solvents such as ethanol, supercritical CO2, 2-methyloxolane, water enzymatic extraction, etc. The state of the art in the use of green solvents is described and an objective assessment of their potential for more sustainable industrial processes is proposed.

Biochemical and Biotechnological Insights into Fungus-Plant Interactions for Enhanced Sustainable Agricultural and Industrial Processes.

The literature is full of studies reporting environmental and health issues related to using traditional pesticides in food production and storage. Fortunately, alternatives have arisen in the last few decades, showing that organic agriculture is possible and economically feasible. And in this scenario, fungi may be helpful. In the natural environment, when associated with plants, these microorganisms offer plant-growth-promoting molecules, facilitate plant nutrient uptake, and antagonize phytopathogens. It is true that fungi can also be phytopathogenic, but even they can benefit agriculture in some way-since pathogenicity is species-specific, these fungi are shown to be useful against weeds (as bioherbicides). Finally, plant-associated yeasts and molds are natural biofactories, and the metabolites they produce while dwelling in leaves, flowers, roots, or the rhizosphere have the potential to be employed in different industrial activities. By addressing all these subjects, this manuscript comprehensively reviews the biotechnological uses of plant-associated fungi and, in addition, aims to sensitize academics, researchers, and investors to new alternatives for healthier and more environmentally friendly production processes.

Human activity recognition in an end-of-life consumer electronics disassembly task

The production of electronic waste, also known as e-waste, has risen with the growing reliance on electronic products. To reduce negative environmental impact and achieve sustainable industrial processes, recovering and reusing products is crucial. Advances in AI and robotics can help in this effort by reducing workload for human workers and allowing them to stay away from hazardous materials. However, autonomous human motion/intention perception is a primary barrier in e-waste remanufacturing. To address the research gap, this study combined experimental data collection with deep learning models for accurate disassembly task recognition. Over 570,000 frames of motion data were collected from inertial measurement units (IMU) worn by 22 participants. A novel sequence-based correction (SBC) algorithm was also proposed to further improve the accuracy of the overall pipeline. Results showed that models (CNN, LSTM, and GoogLeNet) had an overall accuracy of 88–92%. The proposed SBC algorithm improved accuracy to 95%.

Review of Togolese Policies and Institutional Framework for Industrial and Sustainable Waste Management

Waste and resource management in Togo is expected to become more difficult due to increasing socioeconomic development, industrialization, and renewable energy investments. Although there are numerous elements that affect waste and resource management, legislation and policy frameworks are essential. In response to the growing demands for environmental protection, the legal provisions and regulatory frameworks of waste and resource management, as well as the legal implementation process, must be more and more comprehensive. Some actions have been taken in Togo to improve the incorporation of more sustainable industrial processes, which include restrictions and regulations on MSW generation, decentralization of MSW management, policies and incentive systems that promote waste reduction, reuse, and recycling, improvement of enforcement through investigation and treatment of violations, and encouragement of macro-socio-economies in the management of municipal solid waste. In spite of the presence of these policies, the sector is still plagued with numerous challenges, mostly in terms of implementation and the application of these policies to develop tailor made and locally feasible solutions. This research paper highlights relevant policies relating to MSW management in Togo as well as key international conventions and policies. It also discusses the contribution that “transition management” can make to such processes, emphasizes the role of governance for sustainable development, and it suggests solutions with a long-term transformation impact such as the incorporation of waste to energy systems into industrial processes. The paper further identifies some flaws and challenges with law implementation on MSW management and suggests solutions to improve the effectiveness of law implementation and the conditions and criteria for a safe and secure way to use waste-derived materials and fuels or by-products coming from society or other industries. These policy suggestions may also be applicable globally at an individual industry level to encourage the creation of more Green Industrial Companies (GICs).

Functional fibers from regenerated wood pulp cellulose and a natural‐based phytate with enhanced flame retardancy properties

AbstractThe manufacture of sustainable functional fibers with low environmental footprint and superior properties is a pressing research issue under the auspices of more sustainable industrial textile processes. In the present study, regenerated cellulose fibers (CellReg) with flame retardancy properties are manufactured by functionalizing regenerated wood pulp fibers (obtained through the dissolution of paper‐grade pulp in an ionic liquid followed by regeneration in water) with a natural derived phosphorus compound, namely phytic acid ammonium (PAA). The pale‐yellow modified fibers present a phosphorus content up to 1.80% and a uniform and smooth surface morphology. Furthermore, the functional cellulose fibers exhibit moderate antioxidant activity (ca. 18.4% of maximum radical scavenging), water contact angles below 92°, as well as good thermal‐oxidative stability up to 200°C. The flame‐retardant performance of the CellReg/PAA fibers was investigated by the vertical burning test, and as anticipated, the results show a higher flame retardancy with the increasing content of phosphorus, meaning that the fibers ceased to burn before flaming or glowing, even after several flame applications. The accomplished properties validate the potential of these functional fibers of regenerated wood pulp cellulose and PAA for application as textile fibers with flame retardancy properties.

A Methodological Sustainability Assessment to Process Intensification (MSAtoPI) by reactive-separation systems

To produce clean and cheap power by eliminating the economic and energy penalties, it is necessary to develop new technologies or improve the existing processes based on sustainability criteria and alternative fuels. Integration of sustainability into process design contributes to the achievement of this target by eliminating or minimizing negative effects. However, measuring sustainability performance and decision-making are crucial and challenging steps for the development of sustainable industrial processes. The framework for Methodological Sustainability Assessment to Process Intensification (MSAtoPI) is thus introduced in this study as a methodological approach with appropriate sustainability indicators that ensures the capability of gathering and abstracting the complex process operations (energy, mass, and momentum transport phenomena), and that offers clear analysis and communication. The main concepts are demonstrated in practice by using a biomass-based, highly efficient, and ultra-compact process to produce H2 while simultaneously capturing CO2 in an IGCC (Integrated Gasification Combined Cycle) power plant, which is intensified by reactive-separation systems (a hybrid membrane reactor (MR)/adsorptive reactor (AR) system). MSAtoPI clearly concretizes that the proposed intensified reactive-separation systems have huge potential to produce clean and cheap power by eliminating the economic and energy penalties by having more sustainable natures (minimum: ∼18%, average: ∼75%, maximum: ∼140% improvement in sustainability).

State-of-the-art review of porous polymer membrane formation characterization—How numerical and experimental approaches dovetail to drive innovation

Porous polymer membranes substantially contribute to an acceleration of sustainability transformation based on the energy efficient separation of liquid and gaseous mixtures. This rapid shift toward sustainable industrial processes leads to an increased demand for specifically tailored membranes. In order to predict membrane performance factors like permeability, selectivity and durability, the membrane formation process by film casting and phase inversion needs to be understood further. In recent years, computational models of the membrane formation process have been studied intensely. Their high spatial and temporal resolution allows a detailed quantitative description of phase inversion phenomena. New experimental techniques complement this development, as they provide quantitative data, e.g., on compositional changes of the polymer solution during membrane formation as well as the kinetic progression of the phase separation process. This state-of-the-art review compiles computational and experimental approaches that characterize the phase inversion process. We discuss how this methodological pluralism is necessary for improving the tailoring of membrane parameters, but that it is unlikely to be the way to the ultimate goal of a complete description of the evolution of the membrane structure from the initial demixing to the final solidification. Alternatively, we formulate an approach that includes a database of standardized and harmonized membrane performance data based on previously publicized data, as well as the application of artificial neural networks as a new powerful tool to link membrane production parameters to membrane performance.

Remediation and recycling of inorganic acids and their green alternatives for sustainable industrial chemical processes

Aqueous acidic wastes are generated as a result of various industrial processes, and remediation and recycling of inorganic acids are required to mitigate their negative environmental effects and extending the sustainability of their uses.

Biomaterials and Their Potentialities as Additives in Bitumen Technology: A Review.

The carbon footprint reduction mandate and other eco-friendly policies currently in place are constantly driving the trend of the synthesis and application of sustainable functional materials. The bitumen industry is not an exception to this trend and, every day, new technologies that facilitate safer, cost effective and more sustainable industrial processes and road paving operations are being researched and brought to light. A lot of research is currently ongoing to improve bitumen's properties due to its use as a binder in road paving processes. Over the years, the most common method to improve bitumen's properties has been with the use of additives. The major drawback in the use of these additives is the fact that they are substances of strong chemical nature which are either too acidic, too basic or emit toxic fumes and volatile organic compounds into the environment. In the long run, these chemicals are also toxic to the road pavement personnel that carry out the day to day industrial and paving operations. This led researchers to the initiative of synthesizing and applying biomaterials to be used as additives for bitumen. In this light, several studies have investigated the use of substances such as bio-oils, natural waxes, gum, polysaccharides and natural rubber. This literature review is aimed at classifying the different bio-based materials used to improve bitumen's properties and to provide a deeper knowledge of the application of these biomaterials in bitumen technology. In general, we highlight how the research efforts elaborated herein could potentially foster safer, sustainable, eco-friendly approaches to improving bitumen's properties while also promoting a circular economy.

Regulating monolayer WO4 tetrahedral units to promote a sustainable 4,4-Bisphenol-A industrial process

Catalysts for 4,4-Bisphenol-A (BPA) production have moved from mineral acid (HCl) to bi-functional (-SO3H and -SH) resins, with high performance but limited lifespan while non-regenerable. How to achieve regenerable acidic catalysts with comparable performance as resin catalysts remains a challenge. Here, using a facile and rational approach, we present that the Indium and Titanium dual-doped W-based catalysts give full acetone (ACT) conversion within 2 h at > 96% 4,4-BPA selectivity, being higher than those over commercial resin catalysts. X-ray Absorption Near Edge Structure (XANES) and Extended X-ray Absorption Fine Structure (EXAFS) analysis reveal that the well-organized monolayer WO4 tetrahedral units promoted by In and Ti act as the active species, being highly stable up to 800 °C and regenerable via simple calcination. The performance has been validated via life test (> 8000 h) using crude phenol feedstock. This advance will give strong impacts on sustainable industrial processes beyond 4,4-BPA production, with great potential extending to other acid catalyzed reactions.

Plastid Transformation: New Challenges in the Circular Economy Era

In a circular economy era the transition towards renewable and sustainable materials is very urgent. The development of bio-based solutions, that can ensure technological circularity in many priority areas (e.g., agriculture, biotechnology, ecology, green industry, etc.), is very strategic. The agricultural and fishing industry wastes represent important feedstocks that require the development of sustainable and environmentally-friendly industrial processes to produce and recover biofuels, chemicals and bioactive molecules. In this context, the replacement, in industrial processes, of chemicals with enzyme-based catalysts assures great benefits to humans and the environment. In this review, we describe the potentiality of the plastid transformation technology as a sustainable and cheap platform for the production of recombinant industrial enzymes, summarize the current knowledge on the technology, and display examples of cellulolytic enzymes already produced. Further, we illustrate several types of bacterial auxiliary and chitinases/chitin deacetylases enzymes with high biotechnological value that could be manufactured by plastid transformation.