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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Improving Product Purity of Ethylene Glycol Production from Ethylene Oxide by Modify Process Using Multi-stage Distillation
Ethylene glycol (EG) is an important industrial chemical widely used in the manufacture of polyester fibers, antifreeze formulations, and heat-transfer fluids. Industrially, EG is produced through the hydration of ethylene oxide; however, achieving high product purity remains a significant challenge due to the presence of water and higher glycols in the reaction mixture. This study proposes a process modification aimed at improving ethylene glycol purity through the implementation of a multi-stage distillation system. The conventional single-stage distillation configuration was evaluated and compared with a modified two-stage distillation scheme. Simulation results indicate that the proposed modification significantly enhances separation performance, increasing ethylene glycol mole fraction from 0.8991 in the unmodified process to 0.9990 in the modified configuration. The improvement is attributed to better distribution of separation duties and enhanced control of vapor–liquid equilibrium across multiple distillation stages. These findings demonstrate that multi-stage distillation, supported by rigorous process simulation, is an effective strategy for producing high-purity ethylene glycol and offers valuable insights for industrial process optimization and design. Copyright © 2026 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) 2026 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group https://creativecommons.org/licenses/by-sa/4.0
Minimizing Net Energy Consumption in Vinyl Chloride Monomer (VCM) Production using Heat-Integrated Process Design
Vinyl chloride monomer (VCM) is a key intermediate in polyvinyl chloride (PVC) production, and its manufacture via thermal cracking of 1,2-dichloroethane (EDC) is highly energy intensive. This study aims to reduce the net energy demand of the EDC–VCM section through a heat-integrated process design. A steady-state simulation of the conventional EDC cracking and distillation train was developed as an industrial benchmark. Based on this model, a modified configuration was introduced by adding a feed–effluent heat exchanger to recover heat from the hot reactor effluent and preheat the combined fresh and recycled EDC feed, while maintaining reactor operating conditions and product specifications. Energy performance was evaluated by comparing heating and cooling duties of major equipment. The heat-integrated design lowered the total utility requirement from 9.39 × 10⁷ to 7.93 × 10⁷ kJ/h, equivalent to a 15.5% reduction in external energy demand and reducing total energy cost by 4.3%. These results demonstrate that a simple heat-exchanger retrofit can significantly improve energy efficiency in VCM production, providing a practical route to reduce utility consumption and operational costs. Copyright © 2026 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 Process Design for n-Octane Production Enhancing Yield and Energy Saving via Recycle, Heat Integration, and Purge-gas Utilization
n-octane is an essential hydrocarbon in fuels and petrochemicals, yet conventional production suffers from high energy demand and material losses. This study develops an integrated process design combining recycle systems, heat integration, and purge-gas utilization for n-octane production. Results show that recycle integration raises yield from 92.81% to 97.46%, heat integration achieves 36.38% energy savings, and purge-gas valorization sustains high yield (97.41%) while delivering the greatest energy reduction (62.30%). The findings demonstrate that synergistic process intensification enhances efficiency and sustainability, offering a transferable framework for hydrocarbon production optimization. Copyright © 2026 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).
Improved Conversion Performance in Methyl Chloride Production from Methanol and Hydrogen Chloride Through Heat Exchanger Based Waste Heat Recovery and Process Modification
Methyl chloride (CH₃Cl) is an essential intermediate in the manufacture of silicones, agrochemicals, amines, refrigerants, and synthetic rubber; however, conventional production routes are constrained by substantial energy inefficiencies and exergy destruction. This study seeks to enhance the hydrochlorination of methanol to methyl chloride by integrating heat exchangers (HE) as a waste‑heat recovery strategy. Simulation software was used to simulate both the baseline and heat‑integrated process configurations, employing the Peng–Robinson EOS to represent thermodynamic behavior. In the baseline system, the process required 12,302.48 kW of energy input and produced 9,028.60 kW of useful output, achieving a conversion of 73.4%, with unrecovered hot streams contributing significantly to entropy generation. The modified configuration introduced three heat exchangers (E‑100, E‑101, E‑102) to recover reaction and condensation heat, enabling feed preheating and reducing external utility demand. This integration increased conversion from 73.4% to 95%, raised energy output to 11,912 kW, and reduced both energy losses and exergy destruction. The resulting dataset from the optimized system was subsequently evaluated using machine learning models, among which Bayesian Ridge Regression (BRR) demonstrated the highest accuracy and stability, exhibiting superior MSE, MAE, and R² performance. Overall, the findings show that coupling heat‑integration strategies with machine‑learning analysis provides a robust pathway for improving energy efficiency, product quality, and predictive reliability in methyl chloride production. Copyright © 2026 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).
Purity Enhancement of Vinyl Chloride Monomer from Ethylene Dichloride Using Distillation Column Optimization and Recycle Integration
Vinyl Chloride Monomer (VCM) is a key precursor in the manufacture of polyvinyl chloride (PVC), a polymer of considerable industrial significance. A major synthetic route to VCM involves the reaction of ethylene dichloride (EDC), producing VCM and hydrogen chloride as the principal products. This study aims to enhance the purity of VCM by implementing process improvements through the integration of distillation columns and recycling systems. The optimized configuration achieved an outstanding VCM purity of 99.97%, while simultaneously increasing energy efficiency and minimizing the formation of undesirable by-products. These results underscore the critical importance of advanced reactor design and purification technologies in elevating VCM quality, thereby contributing to more sustainable PVC production within the chemical industry. Copyright © 2026 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).
Recovery and Utilization of Waste Heat from Cooler Effluent for Preheating Applications
Maleic anhydride (MA) is an important intermediate for polymers, coatings, and fine chemicals, yet its production through n-butane oxidation remains energy-intensive due to the highly exothermic nature of the reaction. Inefficient heat management leads to excessive utility demand and reduced process performance. This study aims to improve energy efficiency by recovering and reusing waste heat from the cooler effluent for preheating applications. The process is simulated using Aspen HYSYS to compare the basic configuration with a modified design that integrates a recycle stream from the cooler outlet to the heater. The modified configuration demonstrates a significant reduction in external energy consumption, achieving a 43% energy saving compared to the basic process. Net energy decreases markedly, while overall energy efficiency increases to 86%. The recycle stream stabilizes temperature profiles, reduces utility demand, and enhances process reliability. These improvements confirm that waste heat recovery through heat integration provides a practical and effective approach to optimize maleic anhydride production. In conclusion, the modification advances the current state of process design by demonstrating that simple operational changes can deliver substantial energy savings and support sustainable chemical manufacturing. The findings highlight the potential application of waste heat recovery strategies in other exothermic oxidation systems and provide a foundation for future studies on coupling heat integration with advanced separation schemes. Copyright © 2026 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 Optimization of Hydrogen Production via the Water–Gas Shift Reaction Using CO Recycle and Exothermic Reactor Operation
Hydrogen production via the Water–Gas Shift Reaction (WGSR) is limited by thermodynamic equilibrium, restricting carbon monoxide (CO) conversion and process efficiency. The baseline process achieved 80.07% CO conversion, while the modified design incorporated CO recycle and controlled exothermic operation at 200 ° C. These changes significantly improved CO conversion to approximately 98%, reducing raw material losses and enhancing hydrogen yield. The results demonstrate that integrating recycle streams and thermal management strategies effectively overcomes equilibrium constraints for sustainable hydrogen production. Copyright © 202 6 by Authors, Published by Universitas Diponegoro and BCRE Publishing Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).
Process Optimization of Cumene Production: Energy Efficiency Optimization and Conversion Enhancement through Heat Integration and Recycle Strategies
Cumene production via benzene–propylene alkylation is a highly exothermic process that requires effective thermal management. This study aims to optimize energy efficiency and enhance conversion performance in cumene production through the integration of reactor heat recovery and recycle strategies. To improve heat utilization efficiency, the process was modified by integrating a circulating heat transfer fluid system that captures reactor heat and reuses it for feed preheating, thereby reducing external utility demand. Additional heat released during effluent cooling is recovered to supply the mechanical energy required for pumping. The modified and baseline configurations were modeled using chemical process simulator and evaluated using a net energy (NE) framework. Results show that the basic process yields an NE of 3,119,682.58 kJ/h, while the modified process achieves 2,055,114.79 kJ/h, with 21,294,605.8 kJ/h of internal energy successfully recovered and reused. This demonstrates a substantial improvement in thermal integration and reduced reliance on external heating. Furthermore, the introduction of a vapor phase benzene recycle stream enhances benzene conversion, suppresses secondary alkylation, and increases cumene yield. Overall, the integrated heat recovery and recycle strategy significantly improves energy efficiency, conversion performance, and sustainability in cumene production. Copyright © 2026 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 of Maleic Anhydride Production via Heat Integration and Feed Preheating
This study explores strategies to enhance energy efficiency in maleic anhydride production through heat integration and feed preheating modifications within an existing process configuration. The process, based on benzene oxidation in a plug flow reactor followed by absorption and distillation, was modeled under steady state conditions to evaluate energy utilization across key unit operations. In the baseline setup, the reactor feed depended entirely on external heating, while significant thermal energy in the reactor effluent was lost through cooling utilities. To address this inefficiency, a modified configuration was introduced in which part of the effluent heat was redirected to the feed preheater, enabling internal energy recovery and reducing reliance on external utilities. Simulation results demonstrated a marked improvement in energy efficiency, with energy savings rising from 1.219×108 kJ/h (93.93%) to 1.625×108 kJ/h (96.04%) after modification. The redistribution of thermal load across the heat exchanger network confirmed that internal heat was effectively harnessed without incurring additional utility costs or capital investment. Overall, these findings highlight heat integration as a practical and economically advantageous approach to improving energy efficiency in maleic anhydride production while preserving operability and separation performance. Copyright © 2026 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 Green Methanol Production via CO2 Hydrogenation: Process Intensification using Plug Flow Reactor and Vanden Bussche-Froment
The transition to renewable energy in Indonesia requires strategic solutions for carbon capture and utilization (CCU). Methanol synthesis from captured CO2 and green hydrogen offers a promising pathway but is hindered by thermodynamic equilibrium limitations and high energy consumption in the purification section. This study aims to develop an intensified process design for green methanol production integrated with a Direct Methanol Fuel Cell (DMFC) using Aspen HYSYS V11, specifically focusing on optimizing yield via a Plug Flow Reactor (PFR) and the Vanden Bussche-Froment (VBF) kinetic equation. The simulation results demonstrated that the Plug Flow Reactor (PFR) configuration achieved a single-pass CO2 conversion of 21.4% at 250 °C and 50 bar, highlighting the baseline challenge of equilibrium limitations in a conventional setup. Furthermore, the implementation of Heat Integration via a Plug Flow Reactor (PFR) and the Vanden Bussche-Froment (VBF) kinetic equation significantly reduced the total external heating utility requirement by utilizing the sensible heat of the hot reactor effluent. This strategy effectively lowered the energy load on external heaters, replacing high-cost utility usage with efficient internal heat recovery. The integrated DMFC system showed a potential electrical efficiency of 42%. Conclusion: The proposed process intensification significantly enhances the techno-economic feasibility of green methanol plants in Indonesia, offering a sustainable solution for industrial decarbonization. Copyright © 2026 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 Hydrogenation Production via Recycle Loop in Aspen HYSYS Simulated Water Gas Shift Reaction: Kinetic and Thermodynamic Analysis
Hydrogen production via the water–gas shift (WGS) reaction plays a central role in modern energy systems, where maximizing the conversion of carbon monoxide (CO) into hydrogen (H₂) and carbon dioxide (CO₂) is essential for process efficiency. This study develops a detailed Aspen HYSYS process model to simulate the WGS reaction in an equilibrium reactor, emphasizing process intensification through a recycle loop. The baseline configuration achieves 80.07% CO conversion at 469.6 °C, whereas introducing a recycle stream elevates conversion to 99.90% at a significantly lower reactor temperature of −91.91 °C. This enhancement is accompanied by an increase in hydrogen production from 44.05 kmol/h to 55.01 kmol/h. The recycle stream rich in CO₂ at low temperature functions as an in situ cooling mechanism, shifting the exothermic equilibrium toward greater H₂ formation in accordance with Le Chatelier’s principle. This behavior also increases the thermodynamic equilibrium constant, reinforcing the conversion improvement. Kinetic evaluation relies on Gibbs free energy minimization to determine equilibrium compositions, while thermodynamic analysis underscores the dominant influence of temperature on reaction performance. The findings are consistent with trends reported in the literature and carry meaningful industrial implications. By achieving near-complete CO conversion without additional catalysts or membrane technologies, the recycle strategy reduces reliance on downstream purification units such as PSA and enhances overall energy efficiency through process intensification. Copyright © 2026 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 Optimization of Chlorobenzene Production through the Integration of a Distillation Unit and Mixer in Gas–Liquid Benzene Chlorination
Chlorobenzene is a key intermediate in the synthesis of phenol, aniline, and dichlorodiphenyltrichloroethane (DDT), and is also utilized as a solvent, heat-transfer fluid, and occasionally in dry-cleaning. Given its wide industrial applications, production efficiency is essential for economic viability. This study explores yield enhancement in chlorobenzene manufacture through modifications to the benzene chlorination process. The intensification strategy involved the addition of a distillation column and a mixer unit, while sensitivity analyses were performed using chemical engineering simulation software to assess the influence of operating parameters. The modified process increased chlorobenzene yield from 83% to 98%. Sensitivity analysis revealed that higher benzene feed pressure negatively impacted liquid-phase product yield, whereas a greater benzene-to-chlorine mass flow ratio improved yield by enhancing selectivity toward chlorobenzene formation. These findings demonstrate that process modifications combined with optimized operating conditions can significantly improve chlorobenzene production efficiency. Copyright © 2026 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 of Temperature and Pressure in a Modified Plug Flow Reactor to Enhance Benzene Conversion with Process Simulation Software
The increase in industrial dependence on benzene demands a more efficient, high-conversion hydrodealkylation (HDA) process. The HDA of toluene is highly sensitive to temperature and pressure, and inaccuracies in operating conditions can cause side reactions and accelerate catalyst deactivation. This study determined optimal temperature–pressure conditions in a plug flow reactor through steady-state Aspen HYSYS simulation using the Peng–Robinson model and parameter interaction analysis in Design Expert. The results showed a synergistic effect, with temperature as the dominant factor and pressure enhancing conversion. Optimal conditions of 710.8 °C and 67.6 atm produced 90.39% conversion, while the lowest conditions resulted in < 5%. These findings confirm that precise control of operating parameters improves reactor performance and hydrogen utilization, supporting a more stable and energy-efficient HDA process. Copyright © 2026 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 Ethyl Acetate Conversion from Acetic Acid Esterification by Optimizing Reactant Mole Ratio and Reaction Temperature
Ethyl acetate is among the most widely utilized and produced compounds in the chemical industry, serving as a key solvent in coatings, adhesives, pharmaceuticals, and various synthesis processes. Its production typically occurs through the esterification of acetic acid with ethanol, a reaction that is both exothermic and reversible. These characteristics make the control of operating conditions critically important for achieving high conversion rates and minimizing energy consumption. In this study, the optimization of two primary operating parameters, reactant ratio and temperature, was undertaken to enhance the conversion of ethyl acetate. Simulation results revealed that the optimal conditions were achieved with a reactant mole ratio of 3:1 at a temperature of 135.7 °C, resulting in an ethyl acetate conversion of 97.21%. These findings underscore the significance of systematic parameter optimization in improving process efficiency, reducing costs, and supporting sustainable production practices within the chemical industry. Copyright © 2026 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 Propylene Glycol Purity and Profitability through Variations in Reactor Temperature and Distillation
Propylene glycol (PG) is a multifunctional diol widely used in food, pharmaceutical, cosmetic, and chemical industries due to its favorable physicochemical properties, high water solubility, and low toxicity. This study examines PG production through non-catalytic hydration of propylene oxide, focusing on the effect of reactor inlet temperature on process efficiency and economic performance. In the process, propylene oxide and water are mixed and fed into a continuous stirred-tank reactor (CSTR), followed by distillation for product purification. Temperature variations from 23.9 °C to 80 °C were analyzed to determine their impact on conversion and profitability. At 23.9 °C, the process was economically unfavorable, yielding a negative profit of –161.09 $/hour. Increasing the inlet temperature to 40 °C significantly improved conversion and distillation efficiency, resulting in a profit of 191.09 $/hour (552,689 $/year). Further temperature increases provided no additional economic benefit and increased energy demand. Therefore, 40 °C is recommended as the optimal operating condition, offering the best balance between technical performance and profitability. Copyright © 2026 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 with Reusage Outlet Stream of Heat Exchanger for Acrylic Acid Production from Propylene Oxidation
Acrylic acid is a pivotal chemical intermediate extensively utilized in the manufacture of superabsorbent polymers, coatings, adhesives, and acrylate esters. Conventional production via propylene oxidation is markedly energy intensive and generates substantial by products, highlighting the imperative for process enhancement. The objective of this study is to advance energy efficiency in acrylic acid synthesis by reusing outlet stream heat from the heat exchanger during propylene oxidation. Aspen Plus simulations were employed to model propylene oxidation in a plug flow reactor under isothermal conditions with external cooling. The revised design incorporated heat integration strategies, most notably redirecting surplus heat from heater H-302 to fulfill the reboiler duty of distillation column T-304. Comparative evaluation demonstrated that this modification reduces external energy demand, augments conversion efficiency, and stabilizes thermal performance. In addition, the implementation of a heat transfer fluid recycle loop curtailed energy losses and enhanced operational consistency across both reactor and separation units. Mass and energy balance analyses confirmed that the modified configuration delivers superior efficiency while diminishing reliance on external utilities. Collectively, the findings underscore that process intensification coupled with heat integration provides a more sustainable and economically advantageous pathway for acrylic acid production. Copyright © 2026 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 Operating Conditions to Increase the Effective Hydrogen Partial Pressure and Reduce Fresh Hydrogen in Vapor-Phase Cyclohexanol Production
Cyclohexanol is a vital intermediate in nylon precursor production, making its efficient synthesis highly relevant for large-scale chemical industries. Conventional processes often face inefficiencies such as excessive hydrogen consumption and poor energy utilization, which hinder economic viability. This study aims to optimize cyclohexanol production by improving hydrogen recovery and heat integration. Thermodynamic analysis confirmed the reaction is highly exothermic and favorable across the operating temperature range, emphasizing the need for strict thermal control. Process simulation was then employed to evaluate the baseline flowsheet and identify inefficiencies. A revised configuration was developed incorporating effluent cooling, vapor–liquid separation, and hydrogen recycling. The improved system significantly enhanced hydrogen efficiency, reactor performance, and energy utilization, leading to higher conversion rates and more stable operation. In conclusion, the optimized process demonstrates the importance of integrating reaction engineering with process-level design. The simulation framework also provides a foundation for future studies on intensified reactor–separator systems and advanced energy-saving strategies. Copyright © 2026 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 of Operating Conditions for Enhanced Efficiency in Green Ammonia Production toward Sustainable Fertilizer Applications
This study investigates the enhancement of reaction efficiency in green ammonia production through the optimization of operating conditions using Aspen HYSYS simulation. Conventional ammonia synthesis is limited by its high energy demand, driven largely by extreme operating pressures and temperatures as well as the substantial load on compressors. To address these constraints, the process was modified by lowering the operating temperature in the main heating unit (Q‑101) and adjusting compressor pressure and recycle streams, thereby shifting the reaction equilibrium toward product formation while reducing overall energy requirements. Simulation results reveal that decreasing the temperature from 482.5 °C to 368.9 °C significantly increased the molar flow rates of nitrogen, hydrogen, and particularly ammonia, which reached 185.5 kmol/h. This outcome confirms that lower temperatures in an exothermic reaction enhance conversion in accordance with Le Chatelier’s principle. Furthermore, reducing the heat generated during compression lessens the demand on intercoolers and cooling units, improving overall thermal efficiency. The integration of multistage compressors and the recovery of waste heat provide additional gains in energy efficiency. Collectively, these findings demonstrate that relatively simple adjustments to operating parameters can substantially increase ammonia yield, lower energy consumption, and contribute meaningfully to process sustainability, reinforcing the potential of green ammonia as a more efficient and environmentally responsible pathway for low‑carbon fertilizer production. Copyright © 2026 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 Operational Energy Efficiency in the Acetaldehyde Production Process Through the Addition of a Heat Exchanger and Optimization of Heat from Reactors' Outlet
Enhancing the energy efficiency of acetaldehyde production is essential for advancing operational performance and supporting sustainable chemical manufacturing. This study investigates the effect of integrating an additional heat exchanger into the ethanol dehydrogenation flowsheet, positioned before the feed stream enters the process unit, on overall thermal efficiency. Thermodynamic simulations were conducted to compare the baseline configuration with the modified design. The added heat exchanger recovers energy from existing process streams, thereby reducing dependence on external heating utilities and minimizing unnecessary heat losses. Simulation results reveal a significant reduction in total energy demand, with overall heat consumption lowered by 507,602.4 kJ/h relative to the original system. These findings highlight the potential of strategic heat integration to markedly enhance the energy performance of acetaldehyde production. In conclusion, incorporating a heat exchanger prior to downstream heating units offers a practical and effective means of optimizing energy use while promoting more efficient and environmentally responsible process designs. Copyright © 2026 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 Modification for Energy Demand Reduction in Acetic Acid Production
Methanol carbonylation via the Cativa Process is the dominant technology for acetic acid production, offering high selectivity and operational efficiency. In the initial design of plants based on this process, however, heating energy demand was substantial, particularly during the methanol preheating stage prior to compression, which increased operating costs. Energy optimization is therefore critical to improving the economic viability of the process. This study aims to reduce utility energy demand through modifications in the feed preheating stage. The modification involved installing heat exchangers in the stream supplying the main heater and utilizing the recycle stream as an internal heat source. Simulation results demonstrated a significant reduction in the heating load of the main heater, thereby lowering steam demand compared with the original design. Overall, the total heat load decreased by 102,015.82 kJ/h, equivalent to approximately 22.27% relative to baseline conditions. These findings confirm that simple heat integration in the preheating stage can substantially enhance energy efficiency without compromising process performance. Copyright © 2026 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).
Development and Optimization of a Laboratory-Scale Bubble Column Bioreactor for Bioethanol Fermentation: A Computational Approach
This study presents the design and optimization of a laboratory-scale bubble column bioreactor (BCB) for bioethanol fermentation. Python-based simulations in Google Colab were employed to analyze mass transfer dynamics, hydrodynamic behavior, and reactor scale-up strategies under varying aeration rates. Although ethanol production is an anaerobic process, oxygen transfer analysis was conducted to characterize reactor performance and establish oxygen-limited conditions suitable for Saccharomyces cerevisiae fermentation, incorporating mass transfer modeling, reaction kinetics, process control, and sparger design to enhance fermentation efficiency. To further enhance fermentation efficiency, Response Surface Methodology (RSM) was applied following a two-stage optimization approach. A working volume of 500 mL was defined using fermentation kinetics, including an oxygen uptake rate of 1.1 g O₂/g cells, biomass yield of 0.5 g/g glucose, and kLa of 50 h⁻¹. A perforated plate sparger with six 1.2 mm orifices achieved a gas velocity of 90.3 m/s and 2.68 mm bubble size. Aeration was dynamically controlled to maintain 0.002 g/L dissolved oxygen, while pH was regulated at 5.0–5.5 using NaOH dosing. These conditions yielded 44.3% ethanol. A full factorial design identified Time, Air Flow Rate, Cell Loading, and Bead Mass as significant factors. RSM with Central Composite Design confirmed a significant quadratic model (F = 14.14, p < 0.0001; R² = 0.9601, Adjusted R² = 0.9201). Cell Loading (F = 48.48) and Bead Mass (F = 26.53) had the strongest effects. Optimal conditions yielded 47.9% ethanol at 52.70 h, 1.55 L/min air, 1.51 g/L cells, and 47.20 g beads, with 0.84% prediction error. Copyright © 2026 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).