Journal of Applied Research in Chemical-Polymer Engineering

Abstract Research topic:
Gas lift is an efficient artificial lift strategy, routinely used to overcome the low productivity of the wells. In this research, the possibility of using two gases, carbon dioxide and nitrogen instead of natural gas, in the gas lifting process is investigated and compared. To maximize oil production, the optimization of the allocation of the limited amount of gas between 10 wells in the Iranian offshore brown oil field is performed.
Research Method:
In this research, all the wells were modeled by PROSPER software. First, all 10 wells data of an Iranian offshore oil reservoir were collected. Secondly, their model has been built and after validation, a simulation of the artificial gas lift was performed using carbon dioxide and nitrogen gas separately, then, the Gas Lift Performance Curve (GLPC) of all the wells are fitted with the appropriate experimental model in MATLAB software. In the following, using Solver Excel, the allocation optimization with a limited amount of gas was performed using two different gases.
Main results:
According to the results obtained from the optimization, for a certain amount of available gas which is 15 MMSCFD, the total Oil production in the case of nitrogen gas injection is 3564 STBD more than carbon dioxide gas injection. Also, in all cases, due to the production potential capacity of well No. 8, the most amount of injected gas is allocated to it. The comparison of the two types of injected gas shows that the quantity of oil produced using nitrogen is 3424 and 3302 STBD (28 % and 24 %) greater than carbon dioxide gas when the gas is lowered to 12 and 9 MMSCFD, respectively.

Abstract Research subject: In recent decades, hybrid optimizations methods based on natural phenomenon have placed special position according to their capabilities in finding optimal solutions without expensive computational loads and disassociation on choosing initial points. Artificial Neural Network is used as one of the powerful tools of Artificial Intelligence for process simulation. The employment of the neural network in the modeling of m-Cresol alkylation process of with isopropanol as well as meta-heuristic methods in obtaining the optimal conditions for the catalyst and the reaction can prepare an effective step towards a high efficiency process.
Research approach: In the present study, the artificial neural network is applied to model alkylation of m‐Cresol with isopropanol process. In addition, the bee colony is employed in order to optimize the process yield. To verify its performance, the proposed method is used in prediction of the m‐Cresol conversion and Thymol selectivity of the alkylation process with isopropanol 120 data. In this process, the input variables are Weight Hourly Space Velocity (WHSV), pressure and temperature; m-cresol conversion and thymol selectivity are considered as the output variables of the neural network. Five hidden neurons are considered for the proposed neural network. 120 data is used to train the neural network. The meta-heuristic approach based on bee colony (BC) is applied to maximize the yield of the process.
Main results: The results confirm that the proposed method develops the accurate model with an R² value of greater than 97.5%. The maximum yield is obtained 28.9% by bee colony algorithm with adjustable variables that are WHSV of 0.062 hr^-1, the pressure of 1.5 bar and the temperature of 300^oC. In addition, in order to achieve the better performance of the optimization algorithm, the appropriate values of acceleration coefficient and population size are chosen 100 and 10 during the trial-and-error phase.

Abstract Research subject: Nowadays, due to the prevalence of coronavirus and the increasing use of disinfectant solutions and gels, the use of glycerin has also increased dramatically. But the suggested processes in this field need to be optimized in terms of production and energy consumption.

Research approach: In this paper, the transesterification method has studied and simulated, during which vegetable oil is converted into biofuel, and glycerin is also produced as a by-product of this process. For this purpose, process simulation of a conventional unit with 5.5 m³/min feed has been done in Hysys. Also, due to the importance of equipping the transesterification reactor, by importing the necessary process information, this equipment has been simulated in COMSOL MultiPhysics and the effective parameters have been studied in order to optimize the of product conversion. After validation of model, to better understand the factors affecting the performance of the transesterification reactor, the effect of selected parameters first examined by one-variable at the time design of experiment approach.
Main result: Finally, it has been shown that the feed temperature and the flowrate both have significance impact on quantity and quality of product and while providing a model for calculating the amount of glycerol produced per unit of energy consumed, the effective parameters are optimized by the response surface method. In optimal conditions of the ratio of product production to energy consumption, the temperature value was 470.7 K and the feed flow rate was 0.586 m³/s. According to the gained results, it can be obtained by adjusting the flow rate in the optimal amount, using a preheater in the production processes of biofuels and glycerin can have a significant effect on the amount of products produced so that the optimal temperature for the output of this preheater is at least 470.7 K should be considered. In the current research an optimization scheme has been suggested which can be used for different Biodiesel-Glycerol production units with varies range of flowrate.

Abstract Research subject: Saponin compounds have been considered as anti-cancer, antimicrobial, antifungal, anti-inflammatory, and antiviral activity agents. In addition, they are also used as foaming agents in some food industries. There are few studies for assessing the extraction of this substance, so far. The main purpose of this study is to assess and compare the extraction yield of Saponin by conventional extracting using solvent and super-critical fluid method.
Research approach: In the extraction with solvent, the effect of three independent parameters including mass of solid material, percentage of ethanol solvent, and time of extraction on process performance was investigated. Yield of extraction and Saponin concentration were considered as indexes for evaluating the process performance. In the super critical fluid extraction, the effects of extraction time, pressure, and temperature were investigated. In this method, carbon dioxide was used as super critical fluid and 80% ethanol was used as co-solvent. In order to design of experiment and process optimization, response surface methodology and central composite design was used.
Main results: In optimum condition of extraction with solvent, the mass of solid material, ethanol solvent percentage, and extraction time were 5.4 g, 77.5%, and 7 h, respectively. In this condition, the maximum efficiency of extraction yield of 1.12 mg of saponins per a gram of dry primary substance was obtained. The results indicated that time and solvent percentage were significant parameters. Further, interaction between two factors of time and solvent percentage was significant. For supercritical fluid extraction, in optimum condition, extraction time, pressure, and temperature were 10 h, 400 bar, and 50 °C, respectively. Extraction yield in this condition was 20% more than the yield of conventional method. It is concluded that the supercritical fluid extraction method has higher performance than conventional method.

Abstract Research subject: Superabsorbents are hydrophilic hydrogels that can accommodate large amounts of water in their three-dimensional structures and have wide applications in various sciences such as pharmaceuticals, medicine, and agriculture. These materials are hydrophilic polymers that are physically or chemically cross-linked. Conversion and swelling ratio of synthesized hydrogels are two counter effects. Therefore, determining the appropriate conditions for polymerization to achieve optimal properties and swelling rate of hydrogels is a challenge for researchers.
Research approach: In this study, optimizing the synthesis conditions of semi-interpenetrating poly (acrylic acid)/xanthan hydrogels, the response surface methodology (RSM) was used by Box-Behnken design (BBD). The variables of this method were the molar ratio of the cross-linking agent (X₁), the weight percentage of xanthan gum (X₂) as the reaction medium, and the amount of initiator (X₃), each of which was considered at three levels. The evaluated responses in RSM were the rate of polymerization conversion (Y₁) and the rate of swelling (Y₂) of the hydrogels in the water.

Main results: Based on the 17 experiments proposed by RSM (BBD), the cross-linker, xanthan gum, and initiator were combined and radical polymerization was performed into silicone molds at 65 ° C. The results of ANOVA analysis showed that the data error of this study was small and the coefficient of determination (R2) of both proposed models for the responses Y₁ and Y₂ was higher than 0.9. The 46 experiments proposed for the optimal point by RSM (BBD) with the desirability of more than 50% indicate the synthesis of hydrogels that have both a good conversion rate and an optimal amount of swelling. For example, by 13% of cross-linking agent, 0.043 g of initiator and 1% wt. the solution of xanthan, hydrogels with a 95% conversion rate, and 102% water uptake were prepared. These hydrogels can be used in a variety of fields, including the treatment of colored wastes in factories, agriculture, pharmaceutical systems, medical attractions, and more.

Abstract Research subject: Increasing plastic wastes of the packaging industry and concerns about their environmental problems, have attracted many researchers to use biopolymers. Therefore, the preparation of cheap biodegradable films with desirable properties for using in the packaging industry can be an attractive challenge.
Research approach: In this study, poly (lactic acid) (PLA) based ternary blends were prepared by experimental design (mixture method). For this purpose, thermoplastic starch (TPS) was first prepared using 28 wt% sorbitol and 14 wt% glycerol. Then, PLA / PCL (poly (caprolactone), PCL) / TPS ternary blends at different concentrations were prepared using the melt mixing method. Morphological, physical (tensile, water vapor permeability), biodegradability, and rheological tests were also carried out. Finally, the optimum sample was determined using Minitab software.
Main results: Scanning electron microscope (SEM) images revealed incompatibility and phase separation in the blends. Moreover, with increasing PCL and TPS contents, flexibility enhanced due to the plasticization effect of PCL and mechanical properties declined, respectively. The permeability test results showed that the samples containing less TPS due to its hydrophilic nature and more PCL leads to increase the crystallinity of the matrix, had lower water vapor permeability. The effect of TPS on the biodegradability test was also well established. In this way, the sample containing 35 wt% TPS loses about 50% of its weight within 14 weeks. Finally, the sample with 50/25/25 (PLA / PCL / TPS) composition was selected as the optimum sample by Minitab software. The results showed that the formulated films in this study have the potential to be used in biodegradable packaging materials with good mechanical and barrier properties.

Abstract Research subject: The rubber Springs with spong structure must have acceptable tear resistance in addition to desirable compression set. Usually enhancing each of these properties leads to the weakening of the other property.
Research approach: Simultaneously providing the optimum value of these two properties in the rubber spring compound requires consideration of the effective factors by performing several tests. Therefore, in this study, a test plan based on the Taguchi statistical analysis technique was presented to design the optimal formulation in exchange for reducing the number of tests required. Thus, the impact of four factors: weight percent of Natural rubber (NR), concentration of zinc oxide (ZnO), dicumyl peroxide (DCP) and ethylene glycol dimethacrylate (EDMA) on the ratio of tear resistance to compression set (design criterion, Q) was determined.
Main results: Data given of ANOVA showed that the amount of DCP with 66.93% has the highest influence on the design of the rubber spring compound. In addition, it was revealed that the curing system is a solution for the simultaneous optimization to maximum tear energy and minimum compression set of the compound. Statistical analysis predicted that the optimal formulation contained 60 weight percent of NR and 1, 4 and 2 phr of DCP, ZnO and EDMA, respectively. Experimental test results confirmed the predicted Q value for optimal conditions.

Abstract Propane and butane that are the contents of LPG are separated from natural gas in the unit 107 of 5^th refinery of South Pars Gas Company (SPGC). The concentration of methyl mercaptan and ethyl mercaptan in the propane stream are 551 and 46ppm, respectively, and the concentration of these components in butane stream are 1218 ppm and 0.8%, respectively. In order to remove mercaptans from butane and propane, aqueous solution of sodium hydroxide with 15 to 20% wt. is used for the scrubbing. In this research, using the Petro-SIM software, which is a particular simulator for oil and gas industries, the units 113, 114, and 115 of 5^th refinery of SPGC are simulated. The results of the simulation are compared with the data of both experimental data and design documents, and they are goodly match. Then, using the software optimizer the operating parameters is optimized. The optimization results show that by increasing the extraction temperature in the unit of 115 up to 46 ° C, the concentration of mercaptan in the products can be reduced. The other independent parameters do not affect the final result of the process.