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DOE OSTI2022

Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy (Workshop Report)

The US Department of Energy’s (DOE’s) Advanced Manufacturing Office held the virtual workshop entitled “Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy” in November and December 2020. The workshop brought together participants from universities/laboratories, industries, equipment manufacturers, technology vendors, nongovernmental organizations, and subject-matter experts to discuss transformative technologies and strategies to substantially improve the performance (e.g., energy productivity, thermal efficiency, reduced greenhouse gas [GHG] emissions, reduced number of process steps) of thermal processing systems in the industrial sector. The US industrial sector accounts for 32% of the nation’s primary energy use (including feedstocks), and refining, chemicals, pulp and paper, iron and steel, and food products represent the top energy-consuming sectors. Thermal processing or process heating represents the largest energy use category; it accounts for 63% of all energy use in manufacturing. Additionally, thermal processing is the largest contributor of carbon dioxide (CO2) generation, resulting from combustion of fuels and process related chemical reactions, such as in the case of cement and lime production. The challenge of achieving net-zero industrial GHG emissions is colossal considering the established industrial base that depends mainly on carbon-based processes and energy sources; the time frame and cost to replace carbon-based energy sources and feedstocks; and the long-term outlook for development with large-scale adaptation of alternative non carbon–based technologies. The goals of the DOE Advanced Manufacturing Office Thermal Process Intensification Workshop were as follows: (1) Identify R&D gaps and opportunities to facilitate transformative improvement in industrial thermal processes beyond current technologies and allow for entirely new methods for processing materials; (2) Gain insight into new and innovative approaches to thermally intensify processes, reduce heat demand, harness waste heat, and use fuels and hydrocarbon feedstocks more efficiently; (3) Identify the R&D pathways to thermal process intensification (TPI) with the highest potential for impact and adoption by the industrial sector; (4) Define areas of research, development, and demonstration (RD&D) activities to accelerate development and application of emerging and transformative technologies to intensify thermal processes in industry. The scope and focus of the workshop were defined to meet these goals. Based on the available data for energy use and GHG emissions, the industries that collectively use more than 80% of the total process heating energy consumption were selected as primary focus areas. The chosen industries were combined into the following four groups based on similarities in their thermal processes: high-temperature metal processing (iron and steel industry, alumina-aluminum industry); high-temperature nonmetal and mineral processing (cement and glass industry); medium- to low-temperature thermal processing (food processing and pulp and paper industry as part of forest products sector); and hydrocarbon processing (petroleum refining and chemical industry). Furthermore, all potential TPI technologies associated with the processes defined were considered as part of the workshop. Different types of TPI technologies possible in industrial in the document.

42 ENGINEERING↗

DOE OSTI2022

Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Smart Manufacturing Pathways for Industrial Decarbonization and Thermal Process Intensification

Rapid decarbonization is fast becoming the primary environmental and sustainability initiative for many economic sectors. Industry consumes more than 30 % of all primary energy in the United States and accounts for nearly 25 % of all greenhouse gas (GHG) emissions. More than 70 % of energy consumed by the industrial sector is related to thermal processes, which are also the largest contributors of carbon emissions, overwhelmingly due to the combustion of fossil fuels. Thermal process intensification (TPI) seeks to dramatically improve the energy performance of thermal systems through technology pillars focusing on alternative energy sources and processes, supplemental technologies, and waste heat management. The impacts of TPI have significant overlap with the goals of industrial decarbonization (ID) that seeks to phase out all GHG emissions from industrial activities. Emerging supplemental technologies such as smart manufacturing (SM) and the industrial internet of things (IoT) enable significant opportunities for the optimization of manufacturing processes. Combining strategies for TPI and ID with SM and IoT can open and enhance existing opportunities for saving time and energy via approaches such as tighter control of temperature zones, better adjustment of thermal systems for variations in production levels and feedstock properties, and increased process throughput. Data collected by smart processes will also enable new advanced solutions such as digital twins and machine learning algorithms to further improve thermal system savings. Herein, this paper examines the individual pathways of TPI, ID, and SM and how the combination of all three can accelerate energy and GHG reductions.

42 ENGINEERING↗

DOE OSTI2021

Intensification of Biomass Thermal Deoxygenation via a Two-Stage Process

Not provided.

Engineering↗

DOE OSTI2023

Temporal performance indicators for an integrated pilot-scale membrane distillation-concentrated solar power/photovoltaic system

Management of concentrate streams in inland applications has uncertain long-term environmental impacts. This study investigates an intensified solar-energy capture desalination system that integrates membrane distillation (MD) with a hybrid concentrated solar power (CSP)/photovoltaic (PV) collector to realize self-sustained zero-waste discharge for effective management of concentrate streams in inland and off-grid applications. The demonstration-scale CSP/PV system can produce up to 178 kWh of thermal energy and 4 kWh of electrical energy per day. The thermal and electrical energy from the CSP/PV system is directly supplied to the air gap MD (AGMD) pilot-scale system producing up to 288 L of distilled water per day. Experiments were performed on the hybrid AGMD-CSP/PV system to evaluate system performance under various operating conditions including AGMD and CSP flow rates, CSP system pre-heating, and AGMD vacuum pressure. Experimental results indicate that doubling the AGMD flow rate results in a 119% increase in thermal energy utilization and a 71% increase in distillate production. Compared to the winter months, operating the system in summer months when direct normal irradiance (DNI) is highest results in nearly double the distillate production (88 L in winter and 168 L in summer) and nearly three times the amount of thermal energy consumption (15 kWh in winter and 43 kWh in summer). Operating with vacuum resulted in a 34% increase in distillate production and allowing the thermal storage reservoir to preheat in the winter resulted in a 61% increase in distillate production. Altogether, experimental results highlight the tradeoff between distillate production and thermal and electrical energy production and consumption under various environmental conditions and the potential for AGMD-CSP/PV to be a stand-alone desalination system.

14 SOLAR ENERGY↗

DOE OSTI2025

Cobalt promotion of the InO x –TiO 2 heterojunction for dual photothermal reduction of CO 2

A series of cobalt-promoted indium–titanium composite oxides was synthesized using a microemulsion method. Their functional properties were investigated for the photothermal reduction of carbon dioxide. In this series, the indium content varied between 2.5 and 20%, while the cobalt percentage was kept constant at 4% throughout the series. In all cases, carbon monoxide formation occurred selectively through the reverse water gas shift reaction. The sample with 2.5% In maximized the synergistic use of the two energy sources, while the sample with 10% In showed the highest catalytic activity under both thermal and dual photo-thermo conditions. A physicochemical characterization was performed for all samples. The use of microscopy and X-ray absorption spectroscopy demonstrated that sub-nanometric indium entities, in combination with atomically dispersed cobalt oxide entities, achieved a balance between high thermal activity and significant synergy between light and heat in a catalytic process. The system with 10% indium is thus able to improve the thermal catalytic process through the use of light, providing an intensification procedure for the classic process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Process intensification approach to enhancing heat and mass transfer during drying: Ultrasonic (US) assisted drying of paper and board

Drying of paper and board is conventionally achieved through alternating conduction (steam-heated cylinders) and pocket convection (heated air over the paper web surface). These conventional drying systems rely heavily on steam from fossil fuels, resulting in inefficiencies, high energy usage, and thermal losses due to surface-driven mechanisms. Here, to address these challenges, an experimental system, with in-situ drying characteristics measurements, was developed to investigate process intensification using ultrasonic-based dewatering—a volumetric, pressure-driven acoustic energy system—integrated with conventional drying. The objectives of this study are to assess the impact of ultrasonics (US) on dewatering; compare performances to conventional drying systems; identify improvements in drying rate and energy use as a function of moisture content; and gain potential insights on heat and mass transfer mechanisms during US-assisted drying. US performance was evaluated across frequencies, power levels, pulp types, and basis weights. Results show that improvements to ultrasonic applications in conjunction with convection were 30-43% in drying rate and 20-35% in drying time over continuous and intermittent applications. When combined with conduction and convection, ultrasonics yielded up to 20% improvement in both rate and time and up to 20% reduction in energy consumption. Observations support a hypothesis of extension of the constant rate period due to improved capillary flow at higher moisture content and enhancing vapor diffusion and boundary layer disruption at lower moisture contents during falling rate period. These findings will inform future modeling, simulation, design and optimization of advanced drying systems.

42 ENGINEERING↗

DOE OSTI2025

Integrated Radio Frequency and Ultrasonics with Conventional Processes for Efficient Water Removal in Pulp and Paper and Other Biomaterial Applications

Conventional drying processes used in the pulp and paper industry primarily involve lengthy, surface based, multi-cylinder conductive and convective drying with low thermal efficiencies and often use some fossil-based energy. Integration of cross cutting, electrically-powered, volumetric drying process intensification technologies based on Radio Frequency (RF) and acoustics (Ultrasonics) (US) will directly impart energy into the biomaterials resulting in improved energy efficiency and throughput. Integration of RFUS-based drying technology is expected to enable U.S. manufacturing industry to reduce capital and operating costs, energy consumption, and carbon emissions while increasing energy efficiency and throughput, improving product quality and sustainability, and helping preserve U.S. manufacturing jobs. The hybrid drying approach incorporates directed radio frequency (RF) and ultrasonic (US) energy with conventional conduction, diffusion and convective heat and mass transfer overcoming the limitations of the conventional drying processes and that meets/exceeds the minimum goals. We have shown the effective removal of free and bound water in the biomaterials by leveraging the synergies of RF and US technologies integrated with conventional manufacturing processes.

42 ENGINEERING↗

DOE OSTI2024

Fiber Sorbents – A Versatile Platform for Sorption-Based Gas Separations

Increasing demand for high-purity fine chemicals and a drive for process intensification of large-scale separations have driven significant work on the development of highly engineered porous materials with promise for sorption-based separations. While sorptive separations in porous materials offer energy-efficient alternatives to longstanding thermal-based methods, the particulate nature of many of these sorbents has sometimes limited their large-scale deployment in high-throughput applications such as gas separations, for which the necessary high feed flow rates and gas velocities accrue prohibitive operational costs. These processability limitations have been historically addressed through powder shaping methods aimed at the fabrication of structured sorbent contactors based on pellets, beads or monoliths, commonly obtained as extrudates. These structures overcome limitations such as elevated pressure drops commonly recorded across powder adsorption beds but often accrue thermal limitations arising from elevated particle density and aggregation, which ultimately cap their maximum separation performance. Furthermore, the harsh mechanical strain to which powder particles are subjected during contactor fabrication, in the form of extrusion/compression forces, can result in partial pore occlusion and framework degradation, further limiting their performance. Here, we present the development of porous fiber sorbents as an alternative sorbent contactor design capable of addressing sorbent processability limitations while enabling an array of performance-maximizing heat integration capabilities. This new sorbent form factor leverages pre-existing know-how from hollow fiber spinning to produce fiber-shaped sorbent contactors through the phase inversion of known polymers in a process known as dry-jet/wet quenching. The process of phase inversion allows microporous sorbent particles to be latched onto a macroporous polymer matrix under mild processing conditions, thus making it compatible with soft porous materials prone to amorphization under traditional pelletization conditions. Sorbent fibers can be created with different geometries through control of the spinning apparatus and process, offering the possibility to produce monolithic and hollow fibers alike, the latter of which can be integrated with thermalization fluid flows. In this Account, we summarize our progress in the field of fiber sorbents from both design and application standpoints. We further guide the reader through the evolution of this field from the early inceptive work on zeolite hollow fibers to recent developments on MOF fibers. We highlight the versatile nature of fiber sorbents, both from the composition, fabrication and structure points of view, and further demonstrate how fiber sorbents offer alternative paths in tackling new and challenging chemical separation challenges like direct air capture (DAC), with a final perspective on the future of the field.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Process intensification of CO 2 capture by low-aqueous solvent

Low-energy solvent-based CO 2 absorption processes have drawn attention as a next-generation post-combustion CO 2 capture technology to reduce CO2 emissions from fossil fuel– or biomass-fired power generation and industrial flue gas streams. A low-aqueous (or water-lean) solvent process may substantially reduce the thermal energy consumption for solvent regeneration. Low-aqueous solvent–based processes are thermally sensitive, requiring a delicate temperature control within the absorber because of the fast exothermic amine-CO 2 reaction and low heat capacity organic diluent. This reaction may result in heat accumulation in a packed absorption column and undesirable CO 2 desorption occurring as the solvent moves through the column, reducing the solvent’s CO 2 capture efficiency if its temperature is not controlled. Using a 3D printed intensified packing device, enhanced heat and mass transfer were demonstrated in an amine-CO 2 scrubbing process using low-aqueous solvent. The multifunctional intensified device facilitates contact of the reactive solvent and gas phases in a single stage and heat removal by a cooling fluid flowing through channels in the interior of the corrugated plates of the device. These functionalities led to effective thermal management along the column via intrastage cooling and significant improvement in CO 2 uptake under a wide range of operating conditions. Intrastage cooling effectively reduced the solvent average temperature along the column by ~10 °C and, as a result, the solvent’s capture efficiency improved by up to 25%.

42 ENGINEERING↗

DOE OSTI2022

Enhanced Pool Boiling of Low-Pressure Refrigerants on Round Tubes- An Experimental Evaluation

Pool boiling heat transfer is one of the most effective heat transfer methos and crucial for several energy conversion processes such as electronic cooling, steam generation, water purification and thermal management. Enhancing boiling heat transfer around the tubes enables higher heat flux, which can improve the efficiency and lead to compact heat exchangers. Delaying the onset of critical heat flux (CHF) allows for higher CHFs and protects equipment during anomalous transient conditions. Growing interest in process intensification and delayed CHF has motivated the current study. An experimental approach has been deployed to investigate a potential technique to enhance the pool boiling performance around small diameter tubes by open cell metal foams. The findings for nucleate pool boiling of Novec HFE 7000 on the externally enhanced and smooth tubes are reported. The enhanced tube comprised of compressed aluminum foam brazed around. All the samples were horizontally oriented, and the experiments were performed under ambient pressure conditions. The heat transfer measurements for the smooth tubes were compared with several existing correlations and established the baseline. The preliminary results showed that the aluminum foam effectively enhanced the heat transfer coefficient and delayed the onset of critical heat flux. In addition, the pool boiling process around the round tube sample was visualized from both side and front views to comprehend the heat transfer mechanisms underlying substantial enhancement observed during experiments.

Yang, Cheng-Min↗

DOE OSTI2026

PERFORMANCE ANALYSIS OF AN ENGINEERING SCALE HYDROTHERMAL LIQUEFACTION SYSTEM

This work evaluates the Modular Hydrothermal Liquefaction System (MHTLS), an engineering-scale, integrated continuous HTL plant operated at the Pacific Northwest National Laboratory (PNNL), for converting realistic wet wastes into energy-dense biocrudes. The production campaigns discussed here processed algae, sewage sludges, lignocellulosic blends, Industrial food waste, and engineered food-waste slurries at 350?°C and around 200?bar, with nominal feed rates of ~12?L?h?¹. We report biocrude yields and composition, establish mass and elemental (C, N) balances, and quantify energy performance via heater duties, heat-exchanger behavior, and system-level efficiencies. Biocrudes contained 76–80?wt?% C (dry, ash-free) with HHVs of 38-41?MJ?kg?¹, substantially higher than feed materials HHVs of 16.6–26.1?MJ?kg?¹ and approaching petroleum fuels. Dry, ash-free biocrude yields of 32–53?wt?% corresponded to 43–71?wt?% carbon yields, with 18–40?wt?% of feed carbon routed to the aqueous phase. Thermal efficiencies were 50-65%, and total energy efficiencies, including reactor heat input, were 35-55%. A counter-current tube-in-tube heat exchanger delivered U values of 200–450?W?m?²?K?¹, with fouling-induced declines impacting heat recovery and heater duty. The analysis highlights three priorities for the process intensification of HTL: robust, fouling-resistant heat recovery, hydrodynamically suitable reactor and heat-exchanger designs, simplified and predictable solids management, and biocrude-water separation.

Biocrude production↗

DOE OSTI2022

Comparative Study of Flash and Acid Hydrolysis of Microalgae (Scenedesmus sp.) for the Recovery of Biochemicals and Production of Porous Biocarbon Nanosheets

An integrated biorefinery concept is a novel and economical process intensification methodology for efficient utilization of biomass components. In this research, microalgae (Scenedesmus sp.) slurry with biomass concentration of 8.5 wt.% was parallelly fractionated using two techniques: 'flash hydrolysis (FH)' and 'acid hydrolysis (AH)'. FH was performed at 240 degrees C with a residence time of 10 +/- 2 s in a continuous flow reactor, whereas AH was performed at 155 degrees C and reaction time of 15 min in a batch reactor. About 63% of microalgal biomass was solubilized in liquid hydrolysate through both FH and AH. However, AH had an advantage over FH in recovering microalgae proteins and carbohydrates. FAME recovery through solvent extraction from FH and AH derived wet solids (insoluble microalgae) was 40 and 63%, respectively. Finally, the FH- and AH-derived post extraction solid residue was thermally activated using K2CO3 to produce highly microporous biocarbon nanosheets with BET surface areas of 712 and 1289 m2 g-1, respectively. Overall, an integrated process was developed using two potential hydrolysis techniques to maximize utilization of microalgae components.

BASIC BIOLOGICAL SCIENCES,BIOMASS FUELS↗

DOE OSTI2020

Thermal / structural analysis of the HB 650 thermal shield

Fermilab’s PIP-II project’s superconducting linear accelerator will drive the next generation of particle accelerators through a revolution in beam intensity. Key to beam intensification are the high efficiencies of niobium-tin superconducting radiofrequency (SRF) cavities operating at cryogenic temperatures near 5 Kelvin. A multifaceted approach is employed to achieve and maintain the extreme temperature. Vacuum provides the first barrier to thermal convection. Physical thermal intercept zones further isolate the exterior shell vacuum vessel at 300 Kelvin from the supercooled beamline. The first thermal intercept lies just inside the exterior vacuum vessel forming the 40 Kelvin zone. This 40K thermal shield is the focus of this investigation. In preparation for operation, the thermal shield is cooled from 300K to 40K in a slow process over 2-1/2 days. The factors limiting the cooling rate are a high thermal gradient which produces thermal strain and high mechanical stress. D ecreasing the time required to reach operational temperatures is the desired research goal. Physical testing data and finite element method (FEM) computer models from the Single Spoke Resonator – 1 (SSR1) and Linac Coherent Light Source (LCLS-II) cryomodules will be evaluated to determine needed design changes. The thermal shield design for the High Beta 650 MHz (HB650) will be modified and analyzed using FEM computer models to determine maximum cooling rate with a target of 50 thermal cycles of life. Maximum allowable stress will be determined through low cycle fatigue calculations.

43 PARTICLE ACCELERATORS↗

DOE OSTI2020

10 MWE CDCL Large Pilot Plant – pre-FEED Study

Coal Direct Chemical Looping (CDCL) is an advanced oxy-combustion technology that has the potential to substantially reduce the energy penalty and the cost of electricity (COE) for coal-fired power generation with CO₂ capture. The Babcock & Wilcox Company (B&W) and The Ohio State University (OSU) have been collaborating on the development of an iron oxide oxygen-carrier based chemical looping technology for clean power generation with inherent carbon capture. In this process, coal is dried and pulverized prior to being transported into a moving-bed reducer. In the reducer, coal reacts with the oxygen-carrier particles, forming combustion byproducts, predominantly CO₂ and H₂O, while reducing the iron oxide oxidation state from Fe₂O₃ to a mixture of FeO and Fe. The reduced state particles are then transported to a combustor reactor and re-oxidized with air. Following the oxidation, the oxygen-carrier particles are regenerated, and a large amount of heat is released for steam production. The produced steam is sent to a turbine for electricity generation. Meanwhile, the CO₂–rich stream leaving the reducer is cooled, cleaned, and compressed for subsequent pipeline transportation and sequestration. By combining air separation and fuel conversion into a single system, the CDCL technology enables the intensification of oxy-combustion processes by eliminating the energy and cost intensive cryogenic air separation unit and thereby results in higher overall plant efficiencies and lower COE’s. The use of a moving-bed reducer results in high conversions of volatile hydrocarbons and high CO₂ purity, which reduces the cost of downstream CO₂ purification for sequestration or utilization. The Babcock & Wilcox Company in collaboration with The Ohio State University, Johnson & Matthey, The Electric Power Research Institute, and Dover Light & Power completed a Preliminary Front-End Engineering and Design (Pre-FEED) study of a 10 MWe coal-direct chemical looping (CDCL) pilot plant. The planned system is a modular 10 MWe CDCL large pilot facility consisting in 4 modules of 2.5 MWe each, working in parallel and to be hosted within the current structure at the City of Dover’s Municipal Power Plant. The CDCL system can achieve auto-thermal operation and includes a sub-critical steam cycle for power generation. The pilot system was designed to demonstrate full commercial operation at a reduced scale. The coal distribution per plan area is a representative slice of larger commercial arrangements. The system includes a CO₂ recycle system, but it does not include a compression system. The large pilot includes all the environmental control equipment and oxygen carrier and ash handling systems. As part of the project, the Team performed laboratory testing and carried out multiple pilot test campaigns to obtain design and performance information at the 250 kWth CDCL pilot facility at the Babcock & Wilcox Company’s Research Center. The Team demonstrated sustained operations at designed coal inputs, high coal conversion, high CO₂ purity, heat generation on the combustor, low carbon carryover between reactors and low particle attrition. Emissions generated in the reducer reactor were identified as SO₂ and NO x . The commercial manufacturing cost of oxygen carrier particle was evaluated by JM. A particle manufacturing report was generated and submitted to the DOE. Based on the results from the pilot tests and the pre-FEED design efforts, a techno-economic analysis was performed. The study shows that the CDCL process is a promising carbon-friendly technology capable of producing electricity with high efficiency. The estimated COE of the supercritical CDCL plant is $83.3 / MWh, which meets DOE’s target of less than 30% increase in COE when compared to a supercritical PC plant without CO₂ capture. This is the lowest among the existing carbon capture technologies (post-combustion and oxy-combustion) for fossil fuel power plant. CDCL is evaluated to be the most promising technology for carbon capture from the economic aspect.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

Process intensification for generating and decomposing formic acid, a liquid hydrogen carrier

We preview two processes that facilitate using formic acid (HCOOH) as a liquid hydrogen carrier to store renewably-generated electrical energy and then release it to generate electrical power cleanly for backup or emergency applications. First, we show that simultaneously oxidizing an organic solute (typically a waste stream) can assist the electrochemical synthesis of formic acid by lowering the cell potential. The electrolyser comprises a hybrid 3-chamber PEM stack that reduces CO₂ via a gas-diffusion cathode boosted by the oxidation of aqueous methanol. However, the extent of the boosting needs to be optimized across the whole operation of the cell. Next, we present results from an intensified reactor for decomposing formic acid back into H₂ and CO₂ at elevated pressure so that the H₂ can be used in a fuel cell. The reactor combines three operations: Vaporization of the formic acid, its decomposition, and separation of the product stream. Their close coupling affords energy savings and a compact design that could be mounted on a mobile skid. We briefly discuss the electrode catalyst that facilitates the first process and two thermally activated catalysts (Ir supported on covalent triazine framework and Pd supported on carbon) that enable the second process.

25 ENERGY STORAGE↗

DOE OSTI2020

Solvent selection for biphasic extraction of 5-hydroxymethylfurfural via multiscale modeling and experiments

We introduce a comprehensive conceptual framework for selecting solvents for reactive extraction in biphasic organic-water systems and demonstrate it for the separation of HMF (5-hydroxylmethylfurfural), a platform chemical produced in the acid-catalyzed dehydration of hexoses. We first perform in silico screening of ~2500 solvents, from the ADFCRS-2018 database using the ADF COSMO-RS implementation, and classification, based on the solvent partition coefficient. We then determine experimentally the partition coefficients for HMF, fructose, and products of HMF rehydration (levulinic acid (LA), and formic acid (FA)), the mutual water-organic solvent solubilities, and the separation factors in >50 select solvents spanning multiple homologous series at room temperature and a typical reaction temperature with in situ sampling. We find that COSMO-RS is excellent for screening purposes (typical error in most cases within a factor of ~2). Increased temperatures lead to significant reduction in partitioning, and room temperature measurements are clearly inadequate for solvent selection. Upon down selecting classes of solvents based on separation performance, we perform experimental thermal stability and reaction compatibility studies of a small set of solvents at relevant reactive-extraction temperatures. We discover that many substituted phenols exhibit an order-of-magnitude increase in partitioning compared to conventional solvents due chiefly to hydrogen bond interactions and show the necessary stability but retain a significant fraction of water and LA, factors that need to be considered in technoeconomic analysis. In contrast, anilines, aldehydes, and acids are good to excellent regarding separation but incompatible with this specific reaction medium. Furthermore, this multifaceted framework can be extended to other biomass-derived products and processes.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Alternating conduction and convection drying of paper – an experimental analysis with a continuous data acquisition approach

In conventional multi-cylinder drying of paper and board, both conductive drying from steam-heated dryer cylinders and convective drying by flowing air over the paper surface in the pockets are used. Conductive drying from steam-heated drying cylinders is a critical component in providing the necessary thermal energy to paper and board as they dry. Steam temperature and internal and external resistances at the contacting surface are critical process parameters influencing the conductive drying process. An experimental setup was developed to study the alternating conductive and convective drying of paper and board. Paper sheet moisture, temperature, and temperature distribution within the heated platen and the instantaneous heat flux as the sheet was being dried were measured. The instantaneous heat flux, contact heat transfer coefficient, and drying rates were determined as drying proceeds. Experimental results, as well as comparisons to literature and commercial data, are presented. The conductive heat transfer coefficients determined were compared to traditional correlations normally used in the modeling of paper drying. Similarly, the convective heat and mass transfer coefficients are also determined and compared to literature data. In addition to the evaluation of alternating conductive and convective drying characteristics of paper and board, the potential inclusion of auxiliary energy components will also be included. Experimental results from the conduction and convection drying system are presented. Furthermore, this data will be useful in process development, intensification of manufacturing processes, and modeling and simulation of paper drying processes.

42 ENGINEERING↗