Platinum-catalysed cinnamaldehyde hydrogenation in continuous flow

Platinum is one of the most widely used hydrogenation catalysts. Here we describe the translation of batch reactions to continuous flow, affording tunable C=O versus C=C hydrogenation over a Pt/SiO2 catalyst, resulting in high steady state activity and single-pass yields in the selective hydrogenation of cinnamaldehyde to cinnamyl alcohol under mild conditions. Negligible catalyst deactivation occurs under extended flow operation due to removal of reactively-formed poisons from the reaction zone. Process intensification imparts a four-fold enhancement in cinnamyl alcohol productivity.

A solar-powered reverse osmosis system for high recovery of freshwater from saline groundwater

Desalination of groundwater is essential in arid regions that are remote from both seawater and freshwater resources. Desirable features of a groundwater desalination system include a high recovery ratio, operation from a sustainable energy source such as solar, and high water output per unit of energy and land. Here we propose a new system that uses a solar-Rankine cycle to drive reverse osmosis (RO). The working fluid such as steam is expanded against a power piston that actuates a pump piston which in turn pressurises the saline water thus passing it through RO membranes. A reciprocating crank mechanism is used to equalise the forces between the two pistons. The choice of batch mode in preference to continuous flow permits maximum energy recovery and minimal concentration polarisation in the vicinity of the RO membrane. This study analyses the sizing and efficiency of the crank mechanism, quantifies energy losses in the RO separation and predicts the overall performance. For example, a system using a field of linear Fresnel collectors occupying 1000 m2 of land and raising steam at 200 °C and 15.5 bar could desalinate 350 m3/day from saline water containing 5000 ppm of sodium chloride with a recovery ratio of 0.7.

A desalination system with efficiency approaching the theoretical limits

The objective of this project is to design a new desalination system with energy efficiency approaching the theoretical thermodynamic limit—even at high recovery ratio. The system uses reverse osmosis (RO) and a batch principle of operation to overcome the problem of concentration factor which prevents continuous-flow RO systems from ever reaching this limit and thus achieving the minimum possible specific energy consumption, SEC. Batch operation comprises a cycle in three phases: pressurisation, purge, and refill. Energy recovery is inherent to the design. Unlike in closed-circuit desalination (CCD), no feedwater is added to the pressure circuit during the pressurisation phase. The batch configuration is compared to standard configurations such as continuous single-stage RO (with energy recovery) and CCD. Theoretical analysis has shown that the new system is able to use 33% less energy than CCD at a recovery ratio of 80%. A prototype has been constructed using readily available parts and tested with feedwater salinities and recovery ratios ranging from 2,000 to 5,000 ppm and 17.2–70.6%, respectively. Results compare very well against the standard configurations. For example, with feedwater containing 5,000 ppm NaCl and recovery ratio of 69%, a hydraulic SEC of 0.31 kWh/m3 was obtained—better than the minimum theoretically possible with a single-stage continuous flow system with energy recovery device.

The flow behaviour of shallow fluidised beds

The flow behaviour of shallow gas-fluidised beds was studied. experimentally using a rotational viscometer, and an inclined open channel. Initially, tests were carried out with the viscometer in order to establish qualitative trends in the flow properties of a variety of materials over a wide range of fluidising conditions. Also, a technique was developed which enabled quantitative viscosity data to be extracted from the experimental results. The flow properties were found to be sensitive to the size, size-range and density of the fluidised material, the type of distributor used, and the moisture content of the fluidising gas. Tests in beds up to 120 mm deep showed that the fluidity of the bed improves with reduction in depth; and indicated a range of flow behaviour from shear-thinning to Newtonian, depending chiefly on fluidising velocity .. Later, an apparatus was built which provided for a steady, continuous flow of fluidised material down an inclined open channel of 3m length x 0.15m square, up to a mass flowrate of 10 kg/s (35 ton/hr). This facility has enabled data to be obtained that is of practical value in industrial applications; which is otherwise difficult in view of the present limited understanding of the true mechanism of fluidised flow. A correlation has been devised, based on analogy with laminar liquid flow, which describes the channel flow behaviour with reasonable accuracy over the whole range of shear-rates used. 1he channeI results indicated that at low fluidiising velocities the flow was adversely affected by settlement of a stagnant layer of particles on to the distributor, which gave rise to increased flow resistance. Conversely, at higher fluidising velocities the resistance at the distributor appeared to be less than at the walls. In view of this, and also because of the disparity in shear-rates between the two types of apparatus, it is not possible as yet to predict exactly the flow behaviour in an open channel from small-scale viscometer tests.

The application of computerised modelling techniques in manufacturing system design

The absence of a definitive approach to the design of manufacturing systems signifies the importance of a control mechanism to ensure the timely application of relevant design techniques. To provide effective control, design development needs to be continually assessed in relation to the required system performance, which can only be achieved analytically through computer simulation. The technique providing the only method of accurately replicating the highly complex and dynamic interrelationships inherent within manufacturing facilities and realistically predicting system behaviour. Owing to the unique capabilities of computer simulation, its application should support and encourage a thorough investigation of all alternative designs. Allowing attention to focus specifically on critical design areas and enabling continuous assessment of system evolution. To achieve this system analysis needs to efficient, in terms of data requirements and both speed and accuracy of evaluation. To provide an effective control mechanism a hierarchical or multi-level modelling procedure has therefore been developed, specifying the appropriate degree of evaluation support necessary at each phase of design. An underlying assumption of the proposal being that evaluation is quick, easy and allows models to expand in line with design developments. However, current approaches to computer simulation are totally inappropriate to support the hierarchical evaluation. Implementation of computer simulation through traditional approaches is typically characterized by a requirement for very specialist expertise, a lengthy model development phase, and a correspondingly high expenditure. Resulting in very little and rather inappropriate use of the technique. Simulation, when used, is generally only applied to check or verify a final design proposal. Rarely is the full potential of computer simulation utilized to aid, support or complement the manufacturing system design procedure. To implement the proposed modelling procedure therefore the concept of a generic simulator was adopted, as such systems require no specialist expertise, instead facilitating quick and easy model creation, execution and modification, through simple data inputs. Previously generic simulators have tended to be too restricted, lacking the necessary flexibility to be generally applicable to manufacturing systems. Development of the ATOMS manufacturing simulator, however, has proven that such systems can be relevant to a wide range of applications, besides verifying the benefits of multi-level modelling.