Process intensification connects scales and disciplines towards sustainability

Emerging Technologies Supporting the Transition to a Circular Economy in the Plastic Materials Value Chain

Plastic waste has come to the forefront of academic and political debates as a global problem that demands an urgent solution. Promoted by policymakers, academia, and corporations alike, the circular economy model presents a viable path to reach more sustainable levels of development. Emerging and disruptive technologies can catalyse the transition to a circular economy, but their application to the transition of the plastic materials realm is not fully understood. Based on a systematic review of the literature, this paper aims to understand the role of key emerging technologies in the transition towards a circular economy in the plastic materials value chain, their potential impact, as well as the barriers of adoption and diffusion. Employing the ReSOLVE framework, the analysis reveals that rather than individual technologies, four technology sets associated with Industry 4.0, distributed economies, bio-based systems, and chemical recycling stand as major enablers of this transition. The complementarity of technologies and the change needed from a systemic perspective are discussed along with a proposal for governance and practical implementation pathway to overcome barriers and resistance to the transition.

Electron paramagnetic resonance of sonicated powder suspensions in organic solvents

The chemical effects of the acoustic cavitation generated by ultrasound translates into the production of highly reactive radicals. Acoustic cavitation is widely explored in aqueous solutions but it remains poorly studied in organic liquids and in particular in liquid/solid media. However, several heterogeneous catalysis reactions take place in organic solvents. Thus, we sonicated trimethylene glycol and propylene glycol in the presence of silica particles (SiO₂) of different sizes (5-15 nm, 0.2-0.3 µm, 12-26 µm) and amounts (0.5 wt% and 3 wt%) at an ultrasound frequency of 20 kHz to quantify the radicals generated. The spin trap 5,5-dimethyl-1-pyrrolin-N-oxide (DMPO) was used to trap the generated radicals for study by electron paramagnetic resonance (EPR) spectroscopy. We identified the trapped radical as the hydroxyalkyl radical adduct of DMPO, and we quantified it using stable radical 2,2,6,6-tetramethyl-1-piperidinyloxy (TEMPO) as a quantitation standard. The concentration of DMPO spin adducts in solutions containing silica size 12-26 µm was higher than the solution without particles. The presence of these particles increased the concentration of the acoustically generated radicals by a factor of 1.5 (29 µM for 0.5 wt% of SiO₂ size 12-26 µm vs 19 µM for 0 wt%, after 60 min of sonication). Ultrasound produced fewest radicals in solutions with the smallest particles; the concentration of radical adducts was highest for SiO₂ particle size 12-26 µm at 0.5 wt% loading, reaching 29 µM after 60 min sonication. Ultrasound power of 50.6 W produced more radicals than 24.7 W (23 µM and 18 µM, respectively, at 30 min sonication). Increased temperature during sonication generated more radical adducts in the medium (26 µM at 75 °C and 18 µM at 61 °C after 30 min sonication). Acoustic cavitation, in the presence of silica, increased the production of radical species in the studied organic medium.

Two-stage continuous production process for fatty acid methyl ester from high FFA crude palm oil using rotor-stator hydrocavitation

Two-stage continuous production process for fatty acid methyl ester (FAME) from crude palm oil was performed using the rotor-stator hydrocavitation reactor. The novel ABS filament printed rotor having spherical holes on the surface of the rotor which is an efficient, fast and cost-effective procedure, was installed in the stainless steel stator of hydrosonic reactor. The 3D printed hydrosonic reactor was used to treat the FFA-rich in MCPO by esterification and followed by transesterification to produce the methyl ester. The optimum conditions of both esterification and transesterification processes were determined using the response surface methodology (RSM). For the 1st step esterification, the conditions of methanol 17.7 vol%, sulfuric acid 2.9 vol%, 3000 rpm rotor speed, hole's diameter and depth 4 and 6 mm, and 25 L/h MCPO, were used for decreasing the FFA from 11.456 to 1.028 wt%. For the 2nd step, transesterification was employed with the optimal condition of 28.6 vol% methanol, 6.2 g/L of potassium hydroxide, 3000 rpm rotor speed, the dimension of the spherical holes on the rotor's surface having diameter of 6.4 mm and 6.2 mm in depth, and esterified oil flow rate 25 L/h, for producing the methyl ester to over 99.163 wt%. Moreover, the purified biodiesel yields and the average energy consumption for the entire two-stage continuous process between hydrosonic and ultrasonic clamp reactors were compared. The results of purified methyl ester clearly indicate that the methyl esters of 99.163 wt% and 97.814 wt% were achieved from hydrosonic and ultrasonic clamp reactors, respectively, under the same optimized conditions. The maximum yields of purified biodiesel were 97.51 vol% and 88.69 vol% using hydrosonic and ultrasonic clamp reactors, respectively. The average energy consumption for the entire continuous two-stage process for both hydrosonic and ultrasonic clamp reactors were 0.049 and 0.056 kW h/L, respectively. For practical industrial processes, stainless steel rotors inside the stator was manufactured by CNC machine, which was also verified under the optimum conditions. The results showed that 1.07 wt% FFA and 99.221 wt% methyl ester of were obtained from first step and second step, respectively.

Continuous and pulsed ultrasound pectin extraction from navel orange peels

Pectin is a valuable product (up to 30 $kg^-1) that makes-up 20-30% of an orange's peel. The commercial extraction is lengthy (up to 6h) and energy intensive as it requires heating aqueous solutions (60-100 °C). Ultrasound speeds up the extraction process reducing processing time by macroscopic and microscopic mixing by acoustic cavitation. We adopted an ultrasonic horn to deliver a rated power of 500W at amplitudes of 20%, 40%, and 60% with and without pulsation to extract pectin from waste orange peels. These correspond to power densities of 0.08Wml^-1, 0.16Wml^-1 and 0.24Wml^-1, respectively. The extractions operated at a pH of either 2 or 3. The experimental data agree with the fitted values from the statistical model (R²=95.5%). The model confirms our predictions that yield increases with amplitude/power density and decreasing pH. The highest yield was (11%) at a pH of 2 and with continuous ultrasonic irradiation at a power density of 0.24Wml^-1. There is only a 1.3% difference between this datum and pulse ultrasound mode (1 s on/1 s off) at the same conditions - a Student's t test confirmed that there was no significant difference in yield between continuous and pulse mode. However, pulsing is more efficient in that it consumes less than half the energy of continuous operation (80kJ vs. 190kJ).

Numerical Investigation of Process Enhancement Using a Bifunctional Catalyst in a Dual Fluidized-Bed Reactor

The paper outlines the concept of process intensification and integration, with a particular focus on sorption-enhanced, solid-catalyzed chemical processes. An alternative and attractive solution to a system of parallel fixed-bed apparatuses is evaluated, which utilizes the solids’ circulation in a dual fluidized-bed reactor–regenerator system. This allows for continuous mode operation and greatly simplifies the control procedures. To illustrate some aspects related to the steady-state operation of such a dual system, a simplified mathematical model of two interconnected fluidized beds operating in the bubbling regime was developed. A generic reversible chemical reaction of the overall second-order, catalyzed by bifunctional pellets, integrating catalytic active sites and adsorption sites, was considered as a test case. The model was used to study the effects of the bed hydrodynamics, as well as of the chemical reaction and physical adsorption equilibrium constants. It was shown how the superposition of various chemical, physical and hydrodynamical phenomena affects the performance of the system.