Journal of Chemical Engineering Research Progress
Journal of Chemical Engineering Research Progress (ISSN BRIN: 3032-7059; ISSN International: 3032-7059; Short Abbreviation Title: J. Chem. Eng. Res. Prog.) is a research journal and invites contributions of the presentation of original fundamental research, interpretative reviews and discussion of new developments in chemical engineering discipline. Papers which describe novel theory and its application to practice are welcome, as are those which illustrate the transfer of techniques from other disciplines, including: fundamentals of chemical engineering; advanced materials related to chemical engineering; applied/industrial chemistry; chemical reaction engineering kinetics; chemical reactor design and optimization; chemical engineering process design and computation; etc. related to chemical engineering discipline. JCERP has been indexed by DOAJ (Directory of Open Access Journal) (URL in DOAJ: https://doaj.org/toc/3032-7059 ). That means all articles published by this journal are indexed in DOAJ database. The Journal of Chemical Engineering Research Progress is published by UPT Laboratorium Terpadu Universitas Diponegoro jointly with Masyarakat Katalis Indonesia - Indonesian Catalyst Society (MKICS) Publisher. The technical management of the JCERP journal is supported by with BCREC Publishing Group. For year 2026, 2 issues are scheduled for publication with 15-20 articles per issue (June and December). Commencement of publication: June 2024. Journal of Chemical Engineering Research Progress is a fully open access international journal. Readers can read and download any full-text articles for free of charge (fully Open Access) in order to enhance the readability and citability of articles. There is no Article Processing Charge (APC) Fee for publishing in this JCERP journal. Editor in Chief: Prof. Dr. I. Istadi. More info about Editorial Team here. International Diversity of Editors/Editorial Board: 12 Editors from 6 Countries/Regions. Time to First Decision = 1 week Review Time = 4-5 weeks Publication Time = 1 weeks Current Acceptance Rate = 90% Time to First Decision is the average number of weeks it takes for an article to go from manuscript submission to the initial decision on the article whether it will be rejected, revised before review, or continued to review process, including standard and desk rejects. Review Time is the average number of weeks it takes for an article (after the first decision) to go through the editorial review process for this journal, including standard and desk rejects. Publication Time is the average number of weeks it takes to reach from manuscript acceptance, layouting process, to the first appearance of the article PDF fulltext online (with DOI). Current Acceptance Rate is percentage of submitted articles accepted during a calendar year; the total number of articles accepted out of the total number of articles submitted in the same year.
UPT Laboratorium Terpadu, Universitas Diponegoro
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Process Intensification of Hydrodealkylation (HDA) for Benzene Production through Heat Integration and Gas Recycle Optimization
In the hydrodealkylation (HDA) process for benzene production, optimization was achieved through the integration of cryogenic distillation and hydrogen recycling techniques. Using Aspen HYSYS, the process was modeled and analyzed to improve energy efficiency by reusing heat from the waste heat boiler (WHB-01) and the partial condenser (PC-01). The energy recovered from these units was used to preheat both fresh and recycled toluene feeds, significantly reducing the consumption of fresh feed and operational costs. By implementing a hydrogen recycle loop, the process decreased the demand for fresh hydrogen, reducing hydrogen and toluene feed consumption from 125 kmol/h and 196 kmol/h to 111 kmol/h for both. This modification resulted in a conversion rate increase from 70% to 88.9% and achieved energy savings of 84%. The integration of cryogenic separation for methane valorization further enhanced the economic feasibility of the process, turning waste methane into a valuable product. These modifications demonstrated a significant improvement in energy efficiency and sustainability, making the modified HDA process more economically viable for large-scale benzene production. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Copyright (c) 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group https://creativecommons.org/licenses/by-sa/4.0
Improving Energy Efficiency by Using Liquid Benzene in Production of Ethylbenzene from Ethylene and Benzene
The production process of ethyl benzene through the alkylation reaction between ethylene and benzene is a crucial stage in the petrochemical industry, especially as the main raw material in the synthesis of styrene. The development and optimization of this process are important to increase reaction efficiency, reduce production costs, and minimize environmental impacts. This study aims to optimize the operating parameters of the alkylation reactor in order to obtain high ethylene conversion and maximum selectivity to ethyl benzene. The methods used include kinetic reaction modeling, process simulation, and sensitivity analysis to variables such as temperature, pressure, and mole ratio of ethylene to benzene. The simulation results show that the optimum conditions are achieved at a temperature of 650°F, a pressure of 300 psig, and a mole ratio of 10:1, with ethylene conversion reaching 97,3% and ethyl benzene selectivity of 99,6%. In conclusion, this optimization approach has succeeded in increasing the efficiency of the ethyl benzene production process and can be applied on an industrial scale to improve profitability and operational sustainability.
Improving Glycerol Conversion by Implementing Recycle Streams and Reducing Distillation Steps in Glycerol Carbonate Production
The rising surplus of glycerol from biodiesel production drives the need for its valorization into high-value compounds such as glycerol carbonate (GC). This study proposes a process intensification strategy to enhance glycerol conversion efficiency through transesterification with dimethyl carbonate (DMC). The modification involves incorporating a recycle stream for unreacted DMC and reducing one distillation column to minimize energy consumption and thermal degradation. Simulations were conducted using Aspen HYSYS® v11, modeling a CSTR operating at 95 °C and 1 atm with a DMC:glycerol molar ratio of 3:1. Process modification resulted in complete DMC utilization and a shift in separation strategy, with simulated glycerol conversion increasing from 91% to 99.98%. These findings demonstrate the trade-offs between energy efficiency and conversion performance in process redesign, offering valuable insights into more sustainable GC production. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Optimization and Modification of the Hydrogen Peroxide to Propylene Oxide (HPPO) Process
The production of Propylene Oxide (PO) through the Hydrogen Peroxide to Propylene Oxide (HPPO) process represents a cleaner and more efficient route compared to conventional methods. This project focuses on the design and feasibility of a chemical plant with an annual capacity of 10,000 tons of PO using propylene and hydrogen peroxide as feedstocks. The HPPO process, catalyzed by a titanium silicate (TS-1) catalyst, offers significant environmental and economic advantages, such as reduced by-products and lower energy consumption. The core reaction occurs in a convergent reactor under mild operating conditions, producing PO with water as the only by-product, thus minimizing environmental impact. This study focuses on process intensification and optimization of the Hydrogen Peroxide to Propylene Oxide (HPPO) process, with the goal of improving energy efficiency, enhancing mass utilization, optimizing reactor operating conditions, and minimizing waste generation through targeted process modifications. The results demonstrate that the HPPO process is a sustainable and economically viable option for small to medium-scale PO production, aligning with green chemistry principles and industrial scalability. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Improving Energy Efficiency in Ammonia Production from Hydrogen and Nitrogen Through Optimizing Operating Condition
As a key raw material in the fertilizer industry, global ammonia consumption showed a steady increase from 2010 to 2020, with an average annual growth rate of approximately 1.81%. The production of ammonia involves four primary stages: feed gas pre-treatment, syngas generation, syngas purification, and ammonia synthesis. The main feedstocks used in this process are natural gas, steam, and air. To accommodate the rising demand for ammonia, it is essential to implement a highly efficient production process that ensures a high conversion rate. One strategy to enhance efficiency involves reducing the operating pressure in the ammonia production process proves to be an effective strategy for enhancing overall energy efficiency. This adjustment lowers the compressor workload, which in turn reduces system temperatures and eases the demand on the cooling system. Importantly, the process maintains a gas-phase reaction environment and high conversion efficiency, indicating that energy savings are achieved without compromising reaction performance. The results confirm that pressure optimization lies within the thermodynamic and kinetic boundaries necessary for effective ammonia synthesis. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Conversion Improvement of Propylene to Acrylic Acid Process
Acrylic acid (C3H4O2) is a chemical compound used widely in industry. This study aims to develop a modifed process for Arcylic Acid production through direct oxidation. The objective is to improve Acrylic Acid conversion over conventional methods. Process modeling and simulation were conducted using Aspen Plus, and the systems were optimized for operating conditions. In conclusion, both proposed methods offer viable and environmentally favorable alternatives for sustainable proyplene production, with the DC2M route offering superior economic performance. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Quality Analysis of Biobriquettes Combination Ratio of Oil palm Frond and Water Hyacinth Waste with Durian Seed Flour Adhesive
This study investigates the production of biobriquettes from a mixture of oil palm frond waste and water hyacinth using durian seed flour as a sustainable adhesive. Biobriquettes were fabricated with varying mass ratios of oil palm frond to water hyacinth (25:75, 50:50, and 75:25) and adhesive concentrations (5%, 10%, 15%, and 20%). Durian seed flour was selected for its starch content, offering an eco-friendly alternative to conventional adhesive like tapioca flour without competing with food resources. Slow primary carbonization (pyrolysis) was employed as the fabrication method. The produced biobriquettes were analyzed for moisture content, ash content, volatile matter, fixed carbon, and calorific value. The optimal formulation was identified at a 75:25 ratio of oil palm frond to water hyacinth with 15% durian seed flour adhesive, yielding a moisture content of 5.91%, volatile matter of 13.97%, ash content of 3.05%, fixed carbon content of 77.07%, and a calorific value of 6,400.78 cal/g. These results demonstrate the potential of durian seed flour as an effective adhesive and highlight the feasibility of utilizing agricultural and invasive biomass wastes to produce high-quality, sustainable biobriquettes. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Hybrid Approaches for Steam Demand Forecasting: Combining First Principles, Box and Jenkins, and Neural Network Models
The pulp and paper industry relies heavily on batch sulphite digesters for chemical cellulose production, where steam is a critical utility – lack of steam prediction results in venting losses, increased costs, and a negative environmental impact. Accurate prediction of steam demand is therefore essential for optimising digester cooking cycles and resource allocation. This study aims to develop and compare predictive models for steam demand in batch pulp digesters using magnesium bisulphite cooking liquor. Three years of production data were pre-processed to extract digester temperature profiles and batch steam demands. Seven modelling approaches were evaluated: a mechanistic first-principles energy balance model, Box–Jenkins ARIMA, two neural network models (LSTM and CNN), and three hybrid models combining first-principles with ARIMA, LSTM, and CNN. The hybrid frameworks employed dimensionless parameters from the mechanistic model as exogenous variables to compensate for unavailable process data. Model accuracy was assessed using RMSE and MAE metrics. The results show that hybrid models consistently outperformed their standalone counterparts. In particular, the hybrid first-principles–CNN model achieved the highest predictive accuracy, demonstrating the CNN’s ability to extract features and capture nonlinear temporal dependencies in steam demand. The hybrid first-principles–ARIMA model also surpassed both the standalone ARIMA and mechanistic models. Integrating mechanistic insights with data-driven methods significantly enhances prediction accuracy in complex batch processes. The findings highlight the value of hybrid modelling strategies for improving steam demand forecasting, with potential benefits for process optimisation, energy efficiency, and batch scheduling in the pulp and paper industry. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Enhance Removal Pollutant from Batik Industrial Wastewater via Photo- Fenton Process: Efficiency and Kinetic Study
The present research evaluates the efficiency of the Photo-Fenton-like process under UV irradiation by varying ratio of hydrogen peroxide (H₂O₂) to Chemical Oxygen Demand (COD) and H₂O₂ to ferrous ion (Fe²⁺) using wastewater from a batik manufacturer in Gresik. Initial experiments demonstrated that varying the ratio of H2O2/COD contributes to Chemical Oxygen Demand (COD) removal, while maintaining a constant H2O2/Fe2+ ratio. The result reveals a significant effect on Chemical Oxygen Demand (COD) removal achieving 64.58% efficiency which indicates that highly reactive OH* radicals successfully generated in photo-Fenton-like process. Further optimization by increasing the ratio H2O2/COD = 15 (g/g) and H2O2/Fe2+ = 20 (g/g) resulting on maximum percentage of Chemical Oxygen Demand (COD) removal of 92.47% proving the massive production of OH* radicals. The kinetics reaction model which describes the Chemical Oxygen Demand (COD) degradation rate showed the BMG kinetic model, with parameters of 1/m = 0.9352, 1/b = 0.7159, and a coefficient of determination (R²) of 0.9986, indicating an excellent fit and high predictive accuracy of the kinetic model for this process. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Comparative Study on the Characteristics and Performance of Ni-Impregnated and Non-Impregnated Natural Zeolite Catalysts in the Hydrocracking of Palm Oil to Biofuels
A catalyst was synthesized from Bayah’s natural zeolite with low crystallinity and uneven pore distribution. To overcome these limitations, the Bayah natural zeolite was subjected to activation and modification processes aimed at increasing its surface area, improving pore structure, and enhancing overall catalytic activity by impregnating with nickel metal which is active catalyst for cracking reaction. Therefore, this study compares the Ni-impregnated Bayah Natural Zeolite (Ni/ZAA) and non-impregnated Bayah Natural Zeolite (Ni/ZAA) with respect to performance of the hydrocracking of palm oil to biofuels (gasoline, kerosene, and diesel). The natural zeolite was pretreated via desilication using NaOH, followed by calcination. Ni was introduced into the zeolite through ultrasonic-assisted impregnation, and the resulting catalysts were characterized using XRD and XRF techniques. Hydrocracking was conducted at 500 °C with a WHSV of 0.1 min⁻¹ using both Ni/ZAA and non-impregnated ZAA catalysts. The liquid products were analyzed by GC-MS to determine selectivity and yield, including coke and gas formation. The desilication process enhanced slightly the Si/Al ratio and catalytic properties of the Bayah zeolite. While Ni impregnation was achieved, suboptimal processing conditions affected the quality of the resulting catalysts. Increasing Ni content improved crystallinity and catalytic activity but also promoted coke formation, which reduced reaction efficiency and liquid product yield. The highest biofuel yield was obtained using the non-impregnated ZAA catalyst, while the 10% Ni/ZAA catalyst showed reduced yield due to excessive coking and pore blockage. These findings suggest that while Ni enhances catalytic activity, excessive loading can lead to overactivity and reduced performance in biofuel production. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Process Intensification of Glucose Hydrogenation Through Excess Hydrogen Feed and Hydrogen Recycle Integration for High Purity Sorbitol Production
High-purity sorbitol is an essential intermediate for food, pharmaceutical, and specialty chemical applications. However, conventional glucose hydrogenation flowsheets often face challenges such as low hydrogen utilization and inadequate product purity. This study introduces a process intensification strategy at the flowsheet level, evaluated using simulation software, which combines excess hydrogen feeding with flash-based hydrogen recovery and a recycle purge loop. The approach enhances both the conversion driving force and downstream separation efficiency. Starting from a once-through base case, the intensified configuration increases the H₂-to-glucose molar feed ratio to 4:1 and incorporates mixers, splitters, and a flash separator to recover unreacted hydrogen for recycle, minimizing hydrogen loss and stabilizing reactor hydrogen availability. Simulation results indicate a significant improvement in product quality, raising sorbitol purity from 74 wt% in the base case to 99.37 wt% in the intensified scheme. Overall, the proposed excess-hydrogen-plus-recycle integration offers a scalable solution for achieving >99 wt% sorbitol while optimizing hydrogen management through an improved separation recycle sequence. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Design Enhancement of Methanol Purification in Syngas-Based Production: The Role of Additional Distillation and Cooling
Methanol is an essential industrial chemical with increasing global demand, yet conventional syngas-based production often encounters challenges related to energy efficiency and separation performance. This study seeks to design and evaluate an improved methanol purification process aimed at maximizing yield and purity through advanced heat management and separation strategies. Employing a rigorous process simulation environment and the Peng–Robinson Equation of State (PR-EOS) for thermodynamic modeling, a comparative analysis was conducted between a conventional base case and a modified process configuration. The base case comprised a single cooling unit, a separator, and one distillation column, whereas the modified design incorporated an additional upstream cooler and a secondary distillation column to enhance phase conditioning and recovery. Simulation results indicate that the proposed modifications substantially outperform the conventional design. The base case achieved a methanol purity of 59.26%, while the modified configuration increased purity to 71.07%. This 11.8% improvement demonstrates that multi-stage distillation combined with enhanced cooling effectively reduces vapor-phase losses and improves separation efficiency, offering a more sustainable pathway for industrial methanol production. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Enhancing Energy Efficiency in Methanol-Based Formaldehyde Production through Heat Recovery Integration
Formaldehyde is a key industrial chemical known for its high reactivity and broad applicability across sectors such as plastics, resins, textiles, and agrochemicals. Its production has evolved from early silver-catalyzed oxidation of methanol to the more efficient Formox process using iron molybdate catalysts. Despite these advancements, conventional production methods remain energy-intensive, prompting the need for sustainable alternatives. This study investigates the impact of process modification through internal heat recovery on the energy efficiency of methanol-based formaldehyde synthesis. By comparing conventional and modified process configurations, the results demonstrate that reusing reactor-generated heat to power auxiliary units significantly reduces external energy demand. The modified system achieved a 30.64% improvement in energy efficiency, underscoring the potential of heat integration strategies to enhance sustainability and reduce operational costs in formaldehyde manufacturing. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Design and Simulation of High-Yield Dimethyl Ether Synthesis Using Series Reactors and Intercooler
Dimethyl ether (DME, CH₃OCH₃), the simplest alkyl ether and a structural isomer of ethanol, has attracted considerable attention as a clean fuel and chemical intermediate. To enhance its production efficiency, process modifications were introduced and rigorously evaluated through simulation modeling. The methodology involved systematic optimization of operating parameters to achieve targeted performance criteria. A key innovation was the adoption of a series-reactor configuration integrated with an intercooler between reactors, designed to improve conversion and yield. The modified process demonstrated a substantial improvement in DME production, with yield increasing from 40.87% to 62.29%. These results confirm that the proposed process modification significantly augments both yield and conversion, thereby offering a more efficient and sustainable route for DME synthesis. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Enhancing Energy Efficiency in Methanol-to-DME Conversion through Process Modification and Heat Integration
Enhancing energy efficiency in dimethyl ether (DME) production is critical for reducing utility consumption and improving process sustainability. This study investigates the impact of targeted modifications to the methanol dehydration system on thermal performance and operational stability. The proposed configuration incorporates an expanded heat-integration network, additional feed-conditioning units, and a split-recycle arrangement to optimize energy recovery and maintain reactor stability. A water knock-out vessel and supplementary exchangers were also integrated to improve separation efficiency and reduce reboiler duty. Comparative process simulations were performed using with the NRTL thermodynamic model to evaluate the baseline and modified flowsheets. Results indicate that the optimized design achieves a 35.55% increase in energy efficiency while preserving the original methanol conversion level of 50.35%, confirming that reduced energy demand does not compromise reaction performance. These findings demonstrate that the proposed modifications provide a more energy-efficient and industrially viable configuration for DME production, offering a strong foundation for future optimization and process intensification strategies. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Enhancing Methanol Production from Syngas through Heat Exchanger Modification and Vapour Distillate Flow Optimization
Methanol production from syngas represents a promising route to strengthen energy independence and reduce reliance on imports. Conventional processes, however, are constrained by low per-pass conversion and unstable reactor inlet conditions, which limit efficiency and accelerate catalyst deactivation. This study investigates process modifications, focusing on two key strategies: the addition of a heat exchanger to stabilize and elevate reactor inlet temperatures, and the optimization of vapor distillate flow in the distillation column to enhance product purity. The modified process achieved a substantial improvement in methanol conversion, rising from 28.34% in the base configuration to 98.70%, while product purity increased from 97.68% to 98.95%. The heat exchanger ensured better thermal conditioning of recycle streams, reducing temperature fluctuations and improving reaction stability, whereas distillate flow optimization enhanced separation efficiency by balancing vapor and liquid reflux. These results demonstrate that targeted retrofitting of existing plants can deliver significant gains in efficiency, stability, and sustainability without the need for new construction. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Integrated Optimization of Cyclohexane Production via Benzene Hydrogenation Incorporating Advanced Separation, Extended Distillation, and Heat Exchanger Integration to Enhance Product Purity and Energy Efficiency
Cyclohexane is an essential intermediate in the production of nylon-based polymers, yet its industrial synthesis via benzene hydrogenation and subsequent purification remains challenged by thermodynamic limitations and the narrow boiling-point gap between benzene and cyclohexane. This study presents an integrated process optimization strategy aimed at enhancing product purity and net energy efficiency without altering the existing operating conditions. Process simulations were performed to evaluate a modified flowsheet incorporating an additional separator, a second distillation column, and heat-exchanger integration for internal heat recovery. The results show that the modified configuration significantly improves separation performance, raising cyclohexane purity from 57.98% in the basic design to 93.40%. Energy integration through strategic heat-exchanger placement also reduced net energy demand from 910,655,219 kJ/h to 37,151,954 kJ/h, demonstrating substantial thermal-efficiency gains. These findings confirm that equipment-level modifications particularly enhanced separation structures and internal heat-recovery mechanisms can effectively intensify cyclohexane production processes, leading to higher product quality and improved energy sustainability. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Enhancing Nitric Acid Production Efficiency Using Tail Gas Recycle
This study simulates and compares the conventional Ostwald process, and a modified full tail-gas recycle configuration to evaluate the enhancement in nitric acid production efficiency. Using simulation software with the Peng–Robinson model, the conventional Ostwald process and a modified recycle configuration were simulated and compared. In the standard process, unabsorbed NO₂ leaves with the tail gas, limiting nitric acid formation. Recycling this tail gas back to the absorber increases NOx contact time and promotes further conversion. Process efficiency, evaluated through production intensity (PI), improved from 0.4702 to 1.0320 kg HNO₃ per kg NH₃, a 119% increase. These results show that tail-gas recycling is an effective and straightforward method to boost nitric acid yield and reduce emissions without significant changes to the existing flowsheet. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Samuel Octavianus Hasiholan Simangunsong
Process Optimization for Enhanced Dimethyl Ether Yield through Methanol Synthesis and Dehydration of Syngas-Derived Methanol
The global energy crisis and continued reliance on fossil fuels highlight the urgent need for sustainable alternatives. Dimethyl ether (DME) has emerged as a promising low carbon fuel owing to its clean combustion properties and versatility as an LPG substitute, diesel replacement, and chemical feedstock. This study focuses on optimizing the design of DME production from syngas derived methanol, with particular emphasis on conversion efficiency and thermal management. Base case simulations revealed that higher methanol dehydration conversion elevated reactor temperatures by nearly 100 °C, thereby disrupting equilibrium and hindering effective separation. To address these challenges, a modified process integrating cooling, heating, and distillation units was developed, achieving an 80% conversion and a DME yield of 97.6%, while simultaneously reducing excessive cooling requirements. These findings demonstrate that improved thermal control and separation strategies can significantly enhance both energy efficiency and environmental performance, reinforcing DME’s potential role in the transition toward cleaner energy systems. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Simulation and Optimization of Ammonia Converter on Increasing the Mole Percent of Ammonia Products in the Ammonia Plant Through Modification Process
Ammonia production efficiency is strongly influenced by temperature management within the multi-bed converter, where deviations from optimal conditions often reduce the final ammonia mole fraction compared to design expectations. To address this challenge, the ammonia synthesis loop was modified by adding a cooler and a heat exchanger between Bed-2A and Bed-2B to achieve more controlled inter-stage temperatures and improve equilibrium conversion. A complete process model was constructed in process simulation software using actual operating data, allowing evaluation of the original thermal profile and ammonia formation across each catalytic bed, followed by simulation of the modified configuration to quantify performance improvements. The optimized arrangement successfully increased the final ammonia mole fraction from 15.97% to 17.74%, approaching the design target of 19.02%, while maintaining temperatures closer to the ideal range for exothermic synthesis reactions. These results highlight that carefully targeted thermal adjustments and strategic heat integration can enhance reaction efficiency, reduce temperature-induced conversion losses, and provide a practical, implementable pathway for improving ammonia yield in existing industrial plants. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Optimizing Energy Efficiency in Acetone Production via Isopropyl Alcohol Dehydrogenation through Feed-Effluent Heat Integration
Acetone production via isopropyl alcohol (IPA) dehydrogenation is an energy‑intensive process due to the endothermic nature of the reaction. This study aims to minimize net energy consumption by simulating a modified process design that incorporates a Feed‑Effluent Heat Exchanger (FEHE) strategy. The simulation results demonstrate that the modified configuration successfully recovers heat from the reactor effluent to preheat the feed stream to 178 °C, thereby reducing the total energy consumption from 4,695.8 kW to 4,532.0 kW. This energy saving of 163.8 kW confirms that the proposed heat integration is technically feasible and significantly enhances the thermodynamic efficiency of the acetone production process. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Heat Integration Strategies for Acetaldehyde Production: Optimizing Ethanol Dehydrogenation and Hydrogen Recovery
Acetaldehyde production via ethanol dehydrogenation is inherently energy-intensive due to its endothermic characteristics, while the hydrogen generated as a co-product must achieve high purity to meet industrial specifications. Enhancing energy efficiency and hydrogen quality is therefore essential to advancing the sustainability and economic feasibility of this process. This study investigates strategies to optimize energy consumption and hydrogen purity in acetaldehyde production through systematic heat integration and absorber operating condition optimization. Process simulations were employed to quantify the influence of internal heat exchanger integration on overall heat demand and to examine the effect of absorbent flow rate variation on hydrogen purification performance. Integration of heat exchangers reduced total energy consumption by "10,148,446.64" kJ/h, corresponding to a 23% improvement in energy efficiency. Moreover, increasing the absorber water flow rate elevated hydrogen purity from 94.6% to 99.5%. The combined optimization decreased specific energy consumption to 34,316,959.07 kJ/h and lowered monthly operating costs by 22.8%. These findings demonstrate that coupling heat integration with absorber flow rate optimization constitutes an effective approach to improving energy efficiency, hydrogen quality, and economic viability in acetaldehyde production via ethanol dehydrogenation. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Improving Heat-Exchange Network Efficiency Through Front-End Process Modification in the Drying Oil Production from Acetylated Castor Oil
Enhancing the energy efficiency of drying oil production is critical for reducing utility consumption and advancing process sustainability. This study explores front end heat integration modifications by replacing the fired heater with a process to process heat exchanger and employing the high-temperature bottom stream of the distillation column as an internal heat source. Comparative simulations using Aspen HYSYS V11 were performed for both the baseline and modified flowsheets. The redesigned system enables internal preheating through mixing and heat recovery, thereby eliminating the fired heater and lowering the cooling demand in downstream units. Consequently, the total net energy requirement decreases from 8.895×10⁶ kJ/h to 7.363×10⁶ kJ/h, corresponding to an efficiency gain of approximately 17.2%, while maintaining product purity at 99.97%. These results highlight the effectiveness of early stage heat integration strategies in reducing external utility demand, improving energy efficiency, and supporting more sustainable drying oil production. Future research may extend to comprehensive heat exchanger network (HEN) optimization and renewable-assisted heat recovery schemes. Copyright © 2025 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).