Processes, Volume 6, Issue 7 (July 2018) – 24 articles

Tight glutenites are typically composed of heterogeneous sandstone and gravel. Due to low or ultra-low permeability, it is difficult to achieve commercial production in tight glutenites without hydraulic fracturing. Efficient exploitation requires an in-depth understanding of the fracturing behavior of these reservoirs. This paper provides a numerical method that integrates the digital image processing (DIP) technique into a numerical code rock failure process analysis (RFPA). This method could consider the glutenite heterogeneities, including intrarock and interrock heterogeneities, and the practicability is verified through two numerical tests. Two-dimensional (2D) simulations show hydraulic fractures (HFs) can penetrate or deflect to propagate along the gravels, depending on the magnitude of stress anisotropy and gravel strength. Three-dimensional (3D) simulations with the consideration of gravel distribution orientation, gravel size and axial ratio show HFs could propagate past the gravel with no deflection, forming a bypass fracture that is not easy to observe in common laboratory experiments. HFs could also deflect to propagate along the gravels. The impacts of the gravel distribution orientation, gravel size and axial ratio are discussed in detail. The main propagation modes of HFs intersecting the gravels are summarized as: (1) penetrating directly; (2) deflecting to propagate along the gravels to form distorted HFs; (3) propagating to bypass the gravels; (4) a combination of (1) and (2), or (2) and (3). Full article

In this experiment, a variety of inorganic materials were simply compounded with Polysilicate Aluminum Ferric Sulfate (PSAFS) to treat emulsified oil-contaminated water. Manganese sulfate (MnSO₄), magnesium sulfate (MgSO₄), and zinc sulfate (ZnSO₄) were selected as the materials to modify PSAFS in order to obtain a coagulant with good flocculation performance. During the preparation of modified PSAFS, metal manganese, magnesium, and zinc were introduced for modification, and four factors were used to optimize the best proportion of modifiers and PSAFS. The results showed that the order of demulsification and oil-removal ability is as follows: Mn-PSAFS (Mn-modified PSAFS) > Zn-PSAFS (Zn-modified PSAFS) > Mg-PSAFS (Mg-modified PSAFS) > PSAFS. Modified PSAFS was characterized by infrared spectroscopy (IR) and a Scanning Electron Microscope (SEM). In the range of 604 cm⁻¹ to 1200 cm⁻¹, due to the complexation reaction between metal ions and polysilicic acid, the absorption peaks of the modified PSAFS and PSAFS were significantly different. SEM results revealed that the particles of the spatial network structure were fibrous and arranged more closely (0.5 mm × 50.0 mm) than others. This study provided that the modified PSAFS had good potential application in treating emulsified oily wastewater in the future. Full article

The nonlinear flow regimes of a crossed fracture model consisting of two fractures have been investigated, in which the influences of hydraulic gradient, surface roughness, intersecting angle, and scale effect have been taken into account. However, in these attempts, the aperture of the two crossed fractures is the same and effects of aperture ratio have not been considered. This study aims to extend their works, characterizing nonlinear flow through a system of two intersecting fractures with different apertures. First, three experiment models with two fractures having different apertures were established and flow tests were carried out. Then, numerical simulations by solving the Navier-Stokes equations were performed and the results compared with the experiment results. Finally, the effects of fracture aperture on the critical pressure difference and the ratio of hydraulic aperture to mechanical aperture were systematically analyzed. The results show that the numerical simulation results agree well with those of the fluid flow tests, which indicates that the visualization techniques and the numerical simulation code are reliable. With the increment of flow rate, the pressure difference increases first linearly and then nonlinearly, which can be best fitted using Forchheimer’s law. The two coefficients in Forchheimer’s law decrease with the increasing number of outlets. When increasing fracture aperture from 3 mm to 5 mm, the critical pressure difference increases significantly. However, when continuously increasing fracture aperture from 5 mm to 7 mm, the critical pressure difference changes are negligibly small. The ratio of hydraulic aperture to mechanical aperture decreases more significantly for a fracture that has a larger aperture. Increasing fracture aperture from 5 mm to 7 mm, that has a negligibly small effect on the critical pressure difference will however significantly influence the ratio of hydraulic aperture to mechanical aperture. Full article

The Pseudo Steady-State (PSS) constant b_Dpss is defined as the difference between the dimensionless wellbore pressure and dimensionless average pressure of a reservoir with a PSS flow regime. As an important parameter, b_Dpss has been widely used for decline curve analysis with Type Curves. For a well with a finite-conductivity fracture, b_Dpss is independent of time and is a function of the penetration ratio of facture and fracture conductivity. In this study, we develop a new semi-analytical solution for b_Dpss calculations using the PSS function of a circular reservoir. Based on the semi-analytical solution, a new conductivity-influence function (CIF) representing the additional pressure drop caused by the effect of fracture conductivity is presented. A normalized conductivity-influence function (NCIF) is also developed to calculate the CIF. Finally, a new approximate solution is proposed to obtain the b_Dpss value. This approximate solution is a fast, accurate, and time-saving calculation. Full article

Internal erosion at soil–structure interfaces is a dangerous failure pattern in earth-fill water-retaining structures. However, existing studies concentrate on the investigations of internal erosion by assuming homogeneous materials, while ignoring the vulnerable soil–structure-interface internal erosion in realistic cases. Therefore, orthogonal and single-factor tests are carried out with a newly designed apparatus to investigate the critical hydraulic gradient of internal erosion on soil–structure interfaces. The main conclusions can be draw as follows: (1) the impact order of the three factors is: degree of compaction > roughness > clay content; (2) the critical hydraulic gradient increases as the degree of compaction and clay content increases. This effect is found to be more obvious in the higher range of the degree of soil compaction and clay content. However, there exists an optimum interface roughness making the antiseepage strength at the interface reach a maximum; (3) the evolution of the interface internal erosion develops from inside to outside along the interface, and the soil particles at the interface flow as a whole; and (4) the critical hydraulic gradient of interface internal erosion is related to the shear strength at the interface and the severity and porosity of the soil. Full article

Synthetic ammonia produced from fossil fuels is essential for agriculture. However, the emissions-intensive nature of the Haber–Bosch process, as well as a depleting supply of these fossil fuels have motivated the production of ammonia using renewable sources of energy. Small-scale, distributed processes may better enable the use of renewables, but also result in a loss of economies of scale, so the high capital cost of the Haber–Bosch process may inhibit this paradigm shift. A process that operates at lower pressure and uses absorption rather than condensation to remove ammonia from unreacted nitrogen and hydrogen has been proposed as an alternative. In this work, a dynamic model of this absorbent-enhanced process is proposed and implemented in gPROMS ModelBuilder. This dynamic model is used to determine optimal designs of this process that minimize the 20-year net present cost at small scales of 100 kg/h to 10,000 kg/h when powered by wind energy. The capital cost of this process scales with a 0.77 capacity exponent, and at production scales below 6075 kg/h, it is less expensive than the conventional Haber–Bosch process. Full article

Embedded devices are gaining popularity day by day due to the expanded use of Internet of Things applications. However, these embedded devices have limited capabilities concerning power and memory. Thus, the applications need to be tailored in such a way to perform the specified tasks within the constrained resources with the same accuracy. In Real-Time task scheduling, one of the challenging factors is the intelligent modelling of input tasks in such a way that it produces not only logically correct output within the deadline but also consumes minimum CPU power. Algorithms like Rate Monotonic and Earliest Deadline First compute hyper-period of input tasks for periodic repetition of the same set of tasks on CPU. However, at times when the tasks are not adequately modelled, they lead to an enormously high value of hyper-period which result in more CPU cycles and power consumption. Many state-of-the-art solutions are presented in this regard, but the main problem is that they limit tasks from having all possible period values; however, with the vision of Industry 4.0, where most of the tasks will be doing some critical manufacturing activities, it is highly discouraged to prevent them of a certain period. In this paper, we present a resource-aware approach to minimise the hyper-period of input tasks based on device profiles and allows tasks of every possible period value to admit. The proposed work is compared with similar existing techniques, and results indicate significant improvements regarding power consumptions. Full article

The myogenic response is a key autoregulatory mechanism in the mammalian kidney. Triggered by blood pressure perturbations, it is well established that the myogenic response is initiated in the renal afferent arteriole and mediated by alterations in muscle tone and vascular diameter that counterbalance hemodynamic perturbations. The entire process involves several subcellular, cellular, and vascular mechanisms whose interactions remain poorly understood. Here, we model and investigate the myogenic response of a multicellular segment of an afferent arteriole. Extending existing work, we focus on providing an accurate—but still computationally tractable—representation of the coupling among the involved levels. For individual muscle cells, we include detailed Ca${}^{2+}$ signaling, transmembrane transport of ions, kinetics of myosin light chain phosphorylation, and contraction mechanics. Intercellular interactions are mediated by gap junctions between muscle or endothelial cells. Additional interactions are mediated by hemodynamics. Simulations of time-independent pressure changes reveal regular vasoresponses throughout the model segment and stabilization of a physiological range of blood pressures (80–180 mmHg) in agreement with other modeling and experimental studies that assess steady autoregulation. Simulations of time-dependent perturbations reveal irregular vasoresponses and complex dynamics that may contribute to the complexity of dynamic autoregulation observed in vivo. The ability of the developed model to represent the myogenic response in a multiscale and realistic fashion, under feasible computational load, suggests that it can be incorporated as a key component into larger models of integrated renal hemodynamic regulation. Full article

A new direction of the 4th industrial revolution in manufacturing and IT industries is presented in this study, wherein the manufacturing sector will be able to survive in this period by achieving rapid and flexible change through effective convergence between both industries. Under such an environment, manufacturing IT requires speedy development and a new distribution form, as well as a new method of IT project development which is adequate for that form. Thus, this study compares and analyzes the waterfall method which is being used in general manufacturing System Integration (SI) projects and the proposed DevOps method, which requires faster distribution and improvement. This study confirms that the required human resources are less than the existing SI projects when system improvement is made using the DevOps method. At the same time, this method provides much-improved quality for the same price. Therefore, future manufacturing IT projects would achieve a faster and more efficient development and operation form by adopting the DevOps method to perform continuous and repetitive improvement and operation through the convergence of manufacturing and IT. Also, some of the current smart factory models can be found in several ICT (Information & Communication Technology) advanced countries, and they have actually increased the efficiency in their factories and generated much value-added business. As with the production facilities, materials, and methods, human resource management occupies an important role in the smart factory system to increase efficiency. This study aims to validate such logic by proving the effectiveness of a Bluetooth beacon-based worker positioning system by which workers’ safety can be secured along with the security of the factory itself. This system can be foundational to establishing a safer working environment by controlling accesses to the critical production facilities and determining their whereabouts in case of an accident. Full article

The issue of “safe working” has received increasing concern in recent years worldwide, especially in Europe. Several European countries developed specific strategies to ensure the safety of operators and the awareness on the potential risks that can emerge from a vast set of activities, including field activity in agriculture. Earlier investigations have lately investigated this topic, proposing quali-quantitative analysis applied to specific economic sectors. The present study focused on the working accidents occurred in agriculture over the last 6 years (2012–2017) in Italy. By exploring where and when injuries occurred, the socio-demographic profile of involved persons (including age, gender, nationality) and correlating these episodes to agricultural practices, the present paper reveals intrinsic patterns of safe (or unsafe) working conditions at a quite detailed spatial scale (administrative provinces) in Italy. Based on these results, training/educational programs should be planned to increase awareness of risks involving workers in agriculture. Future scenarios can be explored based on specific information dealing with risk factors and operating conditions at various working sites with the final objective to establish suitable technical, legislative and operational measures to reduce job accidents. Full article

This work presents a mathematical model for the simultaneous optimisation of water and energy usage in hydraulic fracturing using a continuous time scheduling formulation. The recycling/reuse of fracturing water is achieved through the purification of flowback wastewater using thermally driven membrane distillation (MD). A detailed design model for this technology is incorporated within the water network superstructure in order to allow for the simultaneous optimisation of water, operation, capital cost, and energy used. The study also examines the feasibility of utilising the co-produced gas that is traditionally flared as a potential source of energy for MD. The application of the model results in a 22.42% reduction in freshwater consumption and 23.24% savings in the total cost of freshwater. The membrane thermal energy consumption is in the order of 244 × 10³ kJ/m³ of water, which is found to be less than the range of thermal consumption values reported for membrane distillation in the literature. Although the obtained results are not generally applicable to all shale gas plays, the proposed framework and supporting models aid in understanding the potential impact of using scheduling and optimisation techniques to address flowback wastewater management. Full article

Recently, the energy demand and supply situation in the Republic of Korea (ROK) has been largely affected by the fluctuations in the energy markets around the world. Such a situation has provided a basis for requiring improvements to power plant facilities. The automatic generator voltage control systems in large-scale power plants are adopting a rapid-response static excitation method to improve the transient stability. A domestic commercially developed large-scale triple-redundant excitation system is currently operated by the 1000 MW-class nuclear power plant and its efficiency has been verified at the same site. However, such a system is too costly for smaller power plants so that a reliable and low-cost redundant digital excitation control system was developed and introduced in this study to resolve the cost problem. The system has improved its stability and reliability at the same time through double (redundant) configuration. Additionally, the system’s performance was put to the test by conducting a series of control function tests after applying it to the gas turbine used in a thermal power station. This study includes the development of system hardware, simulations as well as on-site experiments and each element was validated as a result. Also, the study discusses and validates the method used for replacing the protective relays at the Kanudi power plant operating in Papua New Guinea. The replacement of 27 and 81 protective relays at the existing power plant was carried out as they did not function properly. New relays were installed after removing the power supply in the existing panel. The individual power output sections of new relays were connected in parallel with the existing properly functioning relays, as previous protective relays had only allowed monitoring without outputting the contents. Thus, the new protective system was designed to enable both existing and new relays to carry out the detection function. It was validated that the replacement was successful. The new system with the new relays is performing properly by protecting its power generator and preventing further accidents. Full article

Biofilms have a profound impact on the environment, human health and industrial systems. In order to manage and control them, it is important to measure their mechanical properties intact. Therefore, it has been proposed to grow the biofilms on the atomic force microscope prior to nanoindentation tests with the same probe. However, for nanoindentation of biofilm grown on spherical indenter itself, the existing nanoindentation models become invalid. Therefore, modified models have been proposed to describe the nanoindentation response of biofilm grown on a sphere based on finite element modelling. It was found that the applicability of the models depends on the biofilm thickness and constitutive mechanical models adopted for biofilms. The models developed here would enable more reliable determination of viscoelastic properties of biofilms that grow intact on the indenter itself. Full article

This paper addresses the issues related to the favorable operating conditions for the small-scale production of synthesis gas from the catalytic partial oxidation of methane over rhodium. Numerical simulations were performed by means of computational fluid dynamics to explore the key factors influencing the yield of synthesis gas. The effect of mixture composition, pressure, preheating temperature, and reactor dimension was evaluated to identify conditions that favor a high yield of synthesis gas. The relative importance of heterogeneous and homogenous reaction pathways in determining the distribution of reaction products was investigated. The results indicated that there is competition between the partial and total oxidation reactions occurring in the system, which is responsible for the distribution of reaction products. The contribution of heterogeneous and homogeneous reaction pathways depends upon process conditions. The temperature and pressure play an important role in determining the fuel conversion and the synthesis gas yield. Undesired homogeneous reactions are favored in large reactors, and at high temperatures and pressures, whereas desired heterogeneous reactions are favored in small reactors, and at low temperatures and pressures. At atmospheric pressure, the selectivity to synthesis gas is higher than 98% at preheating temperatures above 900 K when oxygen is used as the oxidant. At pressures below 1.0 MPa, alteration of the dimension in the range of 0.3 and 1.5 mm does not result in significant difference in reactor performance, if made at constant inlet flow velocities. Air shows great promise as the oxidant, especially at industrially relevant pressure 3.0 MPa, thereby effectively inhibiting the initiation of undesired homogeneous reactions. Full article

Industrialization of bioreactors has been achieved by applying several core concepts of science and engineering. Modeling has deepened the understanding of biological and physical phenomena. In this paper, the state of existing cell culture models is summarized. A framework for development of dynamic and computationally feasible models that capture the interactions of hydrodynamics and cellular activities is proposed. Operating conditions are described by impeller rotation speed, gas sparging flowrate, and liquid fill level. A set of admissible operating states is defined over discretized process parameters. The burden on a dynamic solver is reduced by assuming hydrodynamics at its fully developed state and implementation of compartmental modeling. A change in the conditions of operation is followed by hydrodynamics switching instantaneously to the steady state that would be reached under new conditions. Finally, coupling the model with optimization solvers leads to improvements in operation. Full article

A plasma-induced ozone colour-fading treatment was used for treating a blue sulphur-dyed knitted cotton fabric. Since the process parameters of plasma-induced ozone colour-fading treatment are inter-related with one other, the final colour-fading results are affected. An orthogonal array testing strategy (OATS) method was used for determining the optimum conditions of the plasma-induced ozone colour-fading treatment in this study. Three process parameters used in the plasma-induced ozone colour-fading treatment, i.e., oxygen gas concentration (%), water content in fabric (%), and treatment time (minutes), were used in the optimization process. Experimental results reveal the optimum conditions for fading the colour by plasma-induced ozone colour-fading treatment are: (1) oxygen gas concentration = 70%; (2) water content in fabric = 35%; and (3) treatment time = 30 min. The order of importance of these parameters is: oxygen gas concentration > water content in fabric > treatment time. In addition, the plasma-induced ozone colour-fading treatment can effectively remove the colour from the dyed fabric and the colour-fading effect is uniform and even. Full article

Fluid catalytic cracking (FCC) processes have been used widely in petroleum refineries. FCC regenerators play important roles for maintaining catalyst activity and supply the reaction heat. The regenerator efficiency is mainly connected to the hydrodynamics of the fluidized bed, because the gas and solid behaviors are very important factors in mass and heat transfer. The void properties, such as chord length, rising velocity, frequency, and fraction, have been determined in a large cold flow model (0.48 m-ID × 6.4 m-high) of the FCC regenerator, which was geometrically scaled down from a commercial FCC unit. The local void chord length, rising velocity, frequency, and fraction exhibit their maximum value along the radial direction of the bed. The cross-sectional mean void chord length, rising velocity, and fraction increase and the cross-sectional mean void frequency decreases with height in the bed. The variation of void properties in the FCC regenerator with turbulent fluidized bed exhibit similar trends to those in a bubbling fluidized bed. The void properties in the FCC regenerator have been correlated with the experimental parameter on the basis of bubbling bed concept. The predicted void velocities based on the correlations agreed well with the experimental data from present and previous studies. A modified bubbling fluidized bed model could describe the void properties in the regenerator operated in turbulent fluidized bed regime. Full article

Materials processing is challenging because the final structure and properties often depend on the process conditions as well as the composition. Past research reported in the archival literature provides a valuable source of information for designing a process to optimize material properties. Typically, the issue is not having too much data (i.e., big data), but rather having a limited amount of data that is sparse, relative to a large number of design variables. The full utilization of this information via a structured database can be challenging, because of inconsistent and incorrect reporting of information. Here, we present a classification approach specifically tailored to the task of identifying a promising design region from a literature database. This design region includes all high performing points, as well as some points having poor performance, for the purpose of focusing future experiments. The classification method is demonstrated on two case studies in polymeric materials, namely: poly(3-hexylthiophene) for flexible electronic devices and polypropylene–talc composite materials for structural applications. Full article

Pervious concrete is a kind of porous and permeable material for pavements and slope protection projects, etc. In this paper, a kind of pervious concrete was prepared with Portland cement, silica fume (SF), polycarboxylate superplasticizer (SP), and limestone aggregates. The performance of concrete, such as its porosity, pore distribution, permeability coefficients, and mechanical properties, were studied through laboratory tests. The volumetric porosity was measured by the water displacement method, and the planar porosity and pore size distribution were determined using image processing technology. A permeameter with a transparent sidewall and an exact sidewall sealing method were used to measure the permeability coefficients accurately. The results show that the segregation index and flow values of pastes increased with the increase of SP and water cement ratio (W/C). The measured porosity (volumetric porosity and planar porosity) of pervious concrete with a single-size aggregate was closer to the design porosity than that with the blended aggregate. Compared with the design porosity selected in this study, aggregate size was the main factor influencing the pore distribution of pervious concrete. The standard deviation of the permeability coefficient was less than 0.03 under different hydraulic gradients. It was found that the relationships between the permeability coefficient and volumetric porosity (or effective pore size d₅₀) approximately obey polynomial function. Based on the test results, the optimized parameters were suggested for practical engineering: W/C of 0.26–0.30; 0.5% SP content; 5% SF content; 15–21% design porosity; and aggregate sizes of 4.75–9.5 mm and 9.5–16 mm. Full article

To solve the technical problem of supporting a water-dripping roadway below contiguous seams at the Tuanbai coal mine, the deformation law of surrounding rocks for the roadway was studied using Fast Lagrangian Analysis of Continua in Three Dimensions (FLAC3D) numerical simulation. Then, a mechanical model of water-dripping rock using a bolt support was established, and further, technical countermeasures to control the deformation of the roadway with a bolt and cable support are proposed. The results show that the erosion of the water dripping on the roadway was substantial and showed notable changes over time during roadway excavation and mining work. These effects caused the road to heave slightly, but it tended to be stable during roadway excavation. Moreover, the erosion of the roof and two ribs increased exponentially, and the floor heave increased with significant displacement oscillation during mining. The anchoring length of bolts and the rock weakening from water dripping had noticeable effects on the surrounding rocks of the roadway. The logical parameters of the bolt spacing and tightening force (the bolt line spacing was 0.7–0.9 m and the tightening force exceeded 40 kN) of the bolt supports were studied and optimized. Finally, a support scheme for water dripping on the roadway at the Tuanbai coal mine is proposed. The observation data regarding the deformation of the surrounding rocks, monitoring of bolt and cable stress, endoscopy results of roof failure, and roof bed separation monitoring were used to verify the reasonableness of the scheme and ensure the requirements for support were met. The study results can serve as a reference regarding the support for water dripping on a roadway under similar conditions. Full article

A dynamic model of a concentrating solar thermal array and thermal energy storage system is presented that is differentiable in the design decision variables: solar aperture area and thermal energy storage capacity. The model takes as input the geographic location of the system of interest and the corresponding discrete hourly solar insolation data, and calculates the annual thermal and economic performance of a particular design. The model is formulated for use in determining optimal hybridization strategies for industrial process heat applications using deterministic gradient-based optimization algorithms. Both convex and nonconvex problem formulations are presented. To demonstrate the practicability of the models, they were applied to four different case studies for three disparate geographic locations in the US. The corresponding optimal design problems were solved to global optimality using deterministic gradient-based optimization algorithms. The model and optimization-based analysis provide a rigorous quantitative design and investment decision-making framework for engineering design and project investment workflows. Full article

Fracture grouting has been a mitigation measure widely used against seepage in the Yellow River Embankment. However, there is currently a lack of systematic investigations studying the anti-seepage effect of the fracture grouting employed in this longest river embankment in China. Therefore, in this work, laboratory and in situ experiments are carried out to investigate the reinforcement effect of fracture grouting in the Jinan section of the Yellow River Embankment. In particular, laboratory tests concentrate on studying the optimum strength improvement for cement–silicate grout by varying the content of backfilled fly ash and bentonite as admixtures. Mechanical strength and Scanning Electron Microscope photographs are investigated for assessing the strength and compactness improvement. Subsequently, based on the obtained optimum admixtures content, in situ grouting tests are carried out in the Jinan section of the Yellow River Embankment to evaluate the reinforcement and lapping effect of fracture grouting veins, where geophysical prospecting and pit prospecting methods are employed. Laboratory results show that, compared with pure cement–silicate grouts, the gelation time of the improved slurry is longer and gelation time increases as fly ash content increases. The optimum mixing proportion of the compound cement–silicate grout is 70% cement, 25% fly ash, and 5% bentonite, and the best volume ratio is 2 for the investigated cases. Geophysical prospecting including the ground penetrating radar and high-density resistivity method can reflect the lapping effect of fracture grouting veins on site. It shows that the grouting material mainly flows along the axial direction of the embankment. The treatment used to generate directional fracture is proved to be effective. The injection hole interval distance is suggested to be 1.2 m, where the lapping effect of the grouting veins is relatively significant. For the investigated cases, the average thickness of the grouting veins is approximately 6.0 cm and the corresponding permeability coefficient is averagely 1.6 × 10⁻⁶ cm/s, which meets the anti-seepage criterion in practice. Full article

The naphtha recovery unit (NRU) is an integral part of the processes used in the oil sands industry for bitumen extraction. The principle role of the NRU is to recover naphtha from the tailings for reuse in this process. This process is energy-intensive, and environmental guidelines for naphtha recovery must be met. Steady-state models for the NRU system are developed in this paper using two different approaches. The first approach is a statistical, data-based modelling approach where linear regression models have been developed using Minitab^® from plant data collected during a performance test. The second approach involves the development of a first-principles model in Aspen Plus^® based on the NRU process flow diagram. A novel refinement to this latter model, called “withdraw and remix”, is proposed based on comparing actual plant data to model predictions around the two units used to separate water and naphtha. The models developed in this paper suggest some interesting ideas for the further optimization of the process, in that it may be possible to achieve the required naphtha recovery using less energy. More plant tests are required to validate these ideas. Full article

Traditionally used herbal medicines are deep in the consciousness of patients for the treatment of only minor diseases by self-medication. However, manufacturers of herbal medicinal products suffer from major problems such as increasing market pressure by e.g., the food supplement sector, increasing regulations, and costs of production. Moreover, due to more stringent regulation and approval processes, innovation is hardly observed, and the methods used in process development are outdated. Therefore, this study aims to provide an approach based on modern process engineering concepts and including predictive process modelling and simulation for the extraction of traditional herbal medicines as complex extracts. The commonly used solvent-based percolation is critically assessed and compared to the so-called pressurized hot water extraction (PHWE) as a new possible alternative to replace organic solvents. In the study a systematic process design for the extraction of hawthorn (Crataegus monogyna JACQ.) is shown. While for traditional percolation the solvent is optimized to a mixture of ethanol and water (70/30 v/v), the PHWE is run at a temperature of 90 °C. The extracts of various harvest batches are compared to a commercially available product based on a chromatographic fingerprint. For the first time, natural batch variability was successfully incorporated into the physico-chemical process modelling concept. An economic feasibility study reveals that the PHWE is the best choice not only from a technical point of view but also from economic aspects. Full article