L’objectif de ces travaux de thèse est d’améliorer les connaissances sur les réacteurs photochimiques afin de permettre une conception, un dimensionnement et un pilotage plus efficace, compatible avec des contraintes industrielles. Ces travaux se basent sur une méthode d’intensification des procédés et visent la mise en œuvre de réactions de photochimie préparative. La photochimie préparative est une voie de synthèse particulièrement attrayante dans le contexte de la chimie verte. Elle donne accès à des composés hautement fonctionnalisés (molécules à cycle tendu, hétéroatomes etc.) difficilement ou pas accessibles par voie thermique, de manière sélective, en très peu d’étapes réactionnelles et sans ajout des réactifs supplémentaires. Malgré ses potentialités, la transposition industrielle demeure limitée. Les principales contributions de cette thèse sont d’avoir analysé finement les bénéfices de la petite échelle pour la conduite de réactions photochimiques et d’avoir proposé une méthodologie pour transposer des réactions photochimiques dans des équipements industriels. Dans un premier temps, un outil numérique a été développé afin de modéliser le couplage entre les différents phénomènes rencontrés en microphotoréacteur (transfert radiatif, transport des espèces et cinétique photochimique). Une formulation du système d’équations basée sur des nombres sans dimension a été utilisée de façon à accéder à une vision indépendante de l’échelle de l’expérimentation. A cet effet, les nombres sans dimension classiquement rencontrés en génie de la réaction ont dû être adaptés aux spécificités des réactions photochimiques. Quatre nombres sans dimension contrôlant les performances en sortie de microphotoréacteur ont été mis en exergue : les nombres de Damköhler I et II, l’absorbance dans le milieu et le facteur de compétition d’absorption des photons incidents. A partir de ce modèle, une cartographie décrivant les différents régimes de fonctionnement rencontrés en microphotoréacteur a été établie. Une attention particulière a été ensuite portée sur les cas de fonctionnement où la conversion en sortie du réacteur est significativement réduite par la compétition des espèces pour absorber les photons. Cette compétition est liée au nombre de Damköhler II qui permet d’évaluer l’efficacité du mélange diffusif transverse. Ces simulations numériques ont abouti à la construction d’un abaque pour choisir les conditions opératoires à imposer afin de ne pas être limité par le mélange transverse. Dans un second temps, différents outils et dispositifs expérimentaux ont été développés afin de caractériser les réacteurs (notamment par actinométrie) et de suivre en ligne par spectrophotométrie différents systèmes réactionnels. Des microphotoréacteurs de type « capillary tower » et en spirale ont été conçus. Ces dispositifs expérimentaux ont permis d’opérer dans une très large gamme de conditions opératoires (flux de photons, temps de séjour) afin de valider les observations numériques. Pour cela, différents systèmes photochimiques ont été mis en œuvre : une photocycloaddition [2+2] intramoléculaire et deux systèmes photochromiques. Les résultats expérimentaux obtenus, avec ou sans limitation par le transfert diffusif transverse, ont clairement confirmé la pertinence des observations numériques. En outre, la faisabilité d’utiliser un microréacteur comme outils d’acquisition de données cinétiques de réactions photochimiques a été démontrée. Finalement, sur la base des observations expérimentales et numériques, une méthodologie générale est présentée sous forme de logigramme pour déterminer les paramètres de dimensionnement en microphotoréacteur (temps de séjour et densité de flux de photons reçus à la paroi). Des critères ont été proposés pour caractériser les microphotoréacteurs : la productivité, et de manière plus originale, le rendement énergétique global (incluant l’efficacité photonique). / This work aims at improving the knowledge on photochemical reactor engineering in order to propose a methodology to implement photochemical reactions in new continuous intensified technologies. Synthetic organic photochemistry is an extremely powerful method for the conversion of simple substrates into complex products, opening new perspectives. As photochemical substrate activation often occurs without additional reagents, the formation of by-products is also minimized, making photochemistry even more attractive in the modern context of Green Chemistry. The main contributions of this thesis are to finely analyze the benefits of the microreactor technology for performing photochemical reactions, and to propose methodology to transpose photochemical reactions from lab scale to industrial scale. Firstly, a numerical modeling has been proposed to describe the coupling between the different physical phenomena occurring inside a microphotoreactor (radiative transfer, mass and momentum transfers, photochemical kinetic). A formulation of the equation system based on dimensionless numbers has been used to access a generic view, independent of the scale of the experiment. For that, the dimensionless numbers classically encountered in chemical reaction engineering have been adapted to account for photochemical reaction specificity. Four dimensionless numbers controlling the performances at the microreactor’s outlet have been outlined: the Damköhler I and II numbers, the absorbance inside the medium and the competitive absorption factor. From these numbers, a map describing the different zones in which a microphotoreactor can operate has been established. A special attention has been then paid on the cases where the conversion at the microreactor’s outlet is significantly reduced due to the occurrence of a photon competitive absorption between several species. The influence of this competition phenomenon is directly linked to the Damköhler II number which assess for the transverse mixing efficiency. In a second time, various experimental tools and set-up have been developed to characterize photochemical reactors (measurement of the photon flux density received by actinometry) and to implement online analysis by spectrophotometry. A “capillary tower” and a “spiral” microphotoreactors have been developed. Both these microphotoreactors have enabled to operate in a wide range of operating conditions (photon flux, residence time) so as to validate numerical simulations. For that, three photochemical systems have been implemented: an intramolecular [2+2] photocycloaddition and two photochromic systems. The experimental results obtained have confirmed the relevancy of the numerical observations, whether some mass transfer limitations occur or not. Moreover, the feasibility to use a microphotoreactor as a tool for acquiring kinetic data on photochemical reactions has been demonstrated. Finally, based on the numerical and experimental observations, a detailed flow chart has been built to rapidly determine the key parameters for scaling a microphotoreactor (residence time and photon flux density). Some criteria have been proposed to characterize the microphotoreactor: the productivity and, more originally, the global energetic yield (including the photonic efficiency).

De nos jours, les limites du réacteur batch, outil conventionnel de l'industrie de la chimie fine, en termes de transfert thermique et de transfert de matière, conduisent à envisager le passage en continu de réactions dont les problématiques d'exothermie et de rapidité rendent leur industrialisation difficile. Les réacteurs-échangeurs compacts sont un exemple de technologies intensifiées continues alliant les performances d'un échangeur de chaleur couplées à un bon mélange ainsi qu'à un comportement de type piston offert par le design spécifique de leurs canaux. L'objectif de ces travaux est de démontrer la faisabilité de la transposition en continu d'une réaction fondamentale de la chimie des silicones, recensée comme l'une des plus exothermiques, dans un réacteur-échangeur intensifié conçu dans un matériau innovant : le Carbure de Silicium. La démarche a consisté à étudier les différentes phases de la réaction à plusieurs échelles afin de construire un modèle cinétique. L'exploitation de ce modèle a permis de définir les conditions optimales de la réaction permettant de répondre aux contraintes industrielles en termes de conversion, de consommation de catalyseur et de production industrielle. Enfin, une démarche d'optimisation et d'extrapolation du réacteur a été mise en place pour le pilotage industriel de la réaction étudiée. / Nowadays in the field of fine chemistry, limitations of conventional batch reactors in term of heat and mass transfer lead to increase the interest in the transposition of reactions from batch to continuous mode. It is particularly the case of fast and highly exothermic reactions as they raise safety issues in batch reactor. Compact heat-exchanger reactors (HEX reactor) are an example of continuous intensified technologies as they offer the heat transfer performances of heat exchangers coupled with high mixing and plug-flow behaviour, thanks to specific designs of channels. The aim of this work is to demonstrate the feasibility of the transposition of a fast and highly exothermic hydrosilylation reaction, a fundamental method for the industrial synthesis of organosilicon compounds, into a continuous heat-exchanger reactor made of a very innovative material: the silicone carbide. The methodology adopted consists in investigating hydrosilylation kinetics studies at different residence time scales. Then kinetics modelling and optimisation allow defining the features for process industrialization. Industrials objectives in terms of conversion and catalyst reduction are reached with a shorter time. Moreover the outstanding heat transfer performances of the HEX reactor, which entirely absorb the high exothermicity, successfully demonstrate the feasibility of the transposition into continuous

L'objectif de cette thèse est de proposer un réacteur continu et intensifié pour la transformation d’huiles végétales de récupération en produits ou intermédiaires qui seront ensuite utilisés ou formulés en applications destinées au BTP. Ce travail s’inscrit dans le cadre du FUI AGRIBTP, projet de recherche collaboratif qui a pour finalité la création d'un outil industriel de valorisation des sous-produits de l'agro-industrie. Le réacteur se veut pluri-réactionnel, c’est-à-dire adapté et efficace pour réaliser les réactions de transestérification ou d’estérification par le méthanol ou par le glycérol, pour une consigne de production fixée à 100 kg/h. Pour parvenir à cet objectif, une revue de la littérature a permis de dégager une liste de technologies de réacteurs adaptés à ces réactions. L’analyse comparative de ces systèmes a conduit à sélectionner trois types de réacteurs intensifiés existant dans le commerce et qui ont été ensuite testés expérimentalement: les réacteurs microstructurés (type Corning®), les réacteurs micro-ondes et les réacteurs pulsés à chicanes (type NiTech®). De bonnes conversions sont obtenues pour les réactions de transestérification et d’estérification par le méthanol, montrant une meilleure efficacité de ces réacteurs intensifiés par rapport aux réacteurs conventionnels; en revanche les résultats sont encore insuffisants pour l’estérification avec le glycérol en raison de limitations en température. Concernant le réacteur micro-ondes, les excellents résultats rapportés dans la littérature sont à modérer en raison d’une imprécision de mesure de la température. La technologie de réacteurs pulsés à chicanes a finalement été retenue : leur flexibilité, l’indépendance entre le débit et le mélange généré, et enfin leur diamètre suffisamment étendu pour ne pas générer de blocage éventuel dû à l’encrassement du réacteur par la matière entrante sont les principaux arguments qui ont guidé ce choix. Le système disponible construit en verre a tout de même montré ses limites en montée en température et en pression et il a donc été envisagé d’étoffer nos investigations dans des gammes de fonctionnement plus larges. Ainsi une collaboration avec le laboratoire TNO de Delft, aux Pays-Bas a permis d’avoir accès à un réacteur pulsé à chicanes en acier inoxydable. Les résultats obtenus pour la réaction d’estérification par le glycérol - qui n’offrait pas jusqu’à présent des données concluantes - sont satisfaisants, et même de qualité supérieure comparés à ceux obtenus avec un réacteur tubulaire hélicoïdal lui aussi pulsé. Parallèlement à ces études, des simulations numériques des écoulements dans le réacteur ont permis de proposer des améliorations de la forme des chicanes, celle-ci étant déterminante pour la bonne capacité de dispersion liquide-liquide des réactifs immiscibles et la qualité du mélange. Ces simulations ont été comparées à des mesures de vitesses obtenues sur un pilote expérimental conçu pour permettre la visualisation par technique laser des écoulements dans un élément du réacteur à chicanes. Pour terminer, l’extrapolation des résultats obtenus sur les pilotes étudiés à une échelle de production de 100 kg/h a été initiée, aboutissant à la proposition d’un procédé permettant la production sélective de monoglycérides via l’estérification par le glycérol, mais également la fabrication de biodiesel par la transestérification, incluant un réacteur intensifié pulsé dont la géométrie de chicanes a été optimisée, et ce afin de répondre à l’objectif initial de la thèse. / The objective of this thesis is to propose a continuous and intensified reactor to transform waste cooking oil into products that will be used in applications in the building and public works sector. This work is part of the FUI AGRIBTP, a collaborative research project whose finality is to the creation of an industrial tool for the reuse of co-products from agroindustries. The reactor must be able to handle transesterification and esterification (with methanol or with glycerol) reactions efficiently with a total flow rate of 100 kg/h. To achieve this objective, a literature review has identified a list of suitable reactor technologies for these reactions. The comparative analysis of these different technologies has led to the selection of three types of intensified reactors microstructured reactors (Corning® type), microwave reactors and oscillatory baffled reactors (NiTech® type). The performance of these reactors for transesterification and esterification reactions has then been investigated experimentally. High conversions have been obtained for transesterification and esterification with methanol reactions, thereby showing the improved performance of these intensified reactors compared with conventional reactors; however results obtained with esterification with glycerol reaction are still rather low due to limitations in operating temperature. Concerning the microwave reactor, the excellent results previously reported in the literature should be taken with care because of the inaccuracy of temperature measurements, as proven in this work. The oscillatory baffled reactor technology has been selected has the most industrially viable equipment for the considered reactions. The flexibility of this reactor, the independency of the flow rate and mixing, as well as the diameter ,which is large enough to avoid fouling caused by the quality of the feed line, are the main reasons for this choice. The commercial available system, built in glass, has nevertheless shown limitations in terms of operating temperature and pressure. As a result, further work has focused on reactor operation in a wider range of operating conditions. To do this, a collaboration with the TNO laboratory in Delft, Netherlands, was set up in order to investigate reaction performance an oscillatory baffled reactor made of stainless steel. The reaction performance obtained for esterification with glycerol is more than satisfactory, being significantly greater that that obtained in the glass Nitech reactor and even of higher quality compared to that obtained with a oscillatory helicoidal tubular reactor. In parallel to these studies, CFD simulations of flow in the reactor have enable the investigation of new baffle designs, which play a major role in the capacity to generation liquid-liquid dispersions of the immiscible reactants and in the quality of the mixing. These simulations have been compared with velocity measurements and flow patterns obtained in a transparent experimental rig using Particle Image Velocimetry. Finally, the results obtained on the pilot-scale rigs have been used to size a the oscillatory flow reactor for a total flow rate of 100 kg/h, which would be dedicated to the selective production of monoglycerides by esterification with glycerol reaction and also biodiesel production by transesterification reaction.

Dans un contexte de croissance des diagnostics préventifs, la demande en produits de contraste augmente, tandis que leur prix de revient industriel doit être revu à la baisse pour des raisons de compétitivité. La voie de synthèse d’un produit de contraste à rayons X, molécule iodée aux branchements hydrophiles, comporte plusieurs réactions : certaines sont limitées par le transfert de matière (milieu réactionnel polyphasique) ou par le transfert de chaleur (réaction exothermique) tandis que d’autres sont limitées cinétiquement. Les performances des équipements continus intensifiés permettent de favoriser les phénomènes de transfert de matière et de chaleur, tout en garantissant une bonne sélectivité et reproductibilité. La chaine de synthèse globale est repensée en vue d’un passage en mode continu intensifié et les réactions à étudier en intensification locale sont classées par ordre de priorité selon leur potentiel d’intensification. A partir d’une approche combinée alliant résultats expérimentaux et simulation, des modèles réactionnels peuvent être construits pour orienter les essais, afin de converger rapidement vers des conditions opératoires menant aux performances souhaitées. La nouvelle voie de synthèse proposée mettra ainsi en jeu une alternance entre étapes continues et discontinues, ce qui induit des difficultés en termes de gestion de procédé. Une voie de synthèse entièrement soluble permettrait de contourner les limitations d’intensification dues à la présence de solides et d’envisager la chaine de synthèse globale en continu / Preventing diagnostics are increasing and so is the demand for contrast media while its industrial cost needs to be decreased for competitiveness reasons. The synthesis route for a contrast media used in X-ray medical imaging, an iodinated molecule with hydrophilic functional groups, is made of several reactions: some of them are limited by heat transfer (exothermic reactions) or/and mass transfer (multiple-phase media) while others are kinetically limited. The use of continuous intensified equipment leads to enhanced heat and mass transfer performances while keeping good selectivity and reproducibility. The synthesis route is globally modified in the first place in order to shift from batch to continuous intensified and the reactions are classified for local intensification studies. A combined approach based on experimental measurements and simulation enables the building of reaction models which can be used as a guideline for the experiments towards finding the operating conditions that lead to the desired performances at laboratory scale. The new synthesis route production is based on an alternation between continuous and discontinuous steps, which leads to difficult production management. New prospects are created with a new hydrophilic synthesis route, where the limitations for shifting from batch to continuous due to the presence of solids are solved and the whole synthesis route can be transferred from batch to continuous mode

L’étude traite la réalisation et la validation d’un microréacteur destiné à l’électrosynthèse organique. Le système électrochimique modèle est l’oxydation du 4-méthylanisole en 4-méthoxy-benzaldéhyde-diméthylacétal. La simulation du comportement théorique d’un réacteur électrochimique travaillant à haute conversion pour l’oxydation du 4-méthylanisole a permis de déterminer les conditions pour lesquelles le réacteur apporte un meilleur rendement. Les essais expérimentaux effectués sur un microréacteur travaillant en continu et à haute conversion ont montré l’influence de la concentration de l’électrolyte support KF sur le rendement de la réaction. Pour un débit optimal de 0,2 ml min-1, une concentration initiale en réactif de 0,1 M et en appliquant un courant égal à 85% du courant théorique nécessaire à convertir totalement le réactif en une seule passe dans la cellule, la sélectivité atteint 86% (pour une conversion de 95%), alors qu’elle n’est que de 68% dans le procédé BASF. / This work concerns the realization and the validation of a microstructured reactor for organic electrosynthesis. The electrochemical reaction is the oxidation of 4-methylanisole to 4-methoxy-benzaldehyde-dimethylacetal. Theoretical behaviour simulations of high conversion thin-gap flow cell of the 4-methylanisole show conditions for which the reactor has best productivity. The experimental tests carried out on high conversion thin-gap flow reactor showed the influence of the supporting electrolyte (KF) concentration on the reaction yield. For an optimal flow rate of 0.2 ml min-1, an initial reagent concentration of 0.1 M and a current equal to 85% of the theoretical current necessary to convert all reagent, it is possible to reach selectivity of 86% with single pass high conversion (95%) , whereas selectivity on BASF process doesn’t exceed 68%.

I rapporten framgår det en termodynamisk analys för reverse water gas shift med att sammanmata etanol för att undvika det långsammaste steget i reaktionen för att producera högre alkoholer. Ifrån ett termodynamiskt perspektiv, verkar det möjligt att utgå ifrån reverse water gas shift för att producera högre alkoholer vid 100 bar med en temperatur på 300C . Reaktionen är exotermisk, vilket gynnas av det låga temperaturer och det rekommenderas höga tryck p.g.a. en mol kontraktion. Jämviktshalterna var låga, det föreslås att ta bort vatten ifrån jämvikten.  I den matematiska modellen utgick det ifrån en kedja-reaktion för att producera högre alkoholer med reverse water gas shift i processförhållanden på 10–200 bar. I modellen utfördes en senstivty-analysis för jämvikten på tryck och vattenborttagning. Genom att ta bort vatten ifrån jämvikten låg CO2 utbytet kring 95% vid 200 bar även vid låga tryck som 10 bar. Inom CO2 hydrering till högre alkoholer är det begränsat med data och reaktionsmekanismen bakom reaktionen är inte riktigt förstådd. Experimentella försök krävs för att få en mer ökad förståelse. I modellen beskrevs CO2 hydrering och resterande reaktioner som en funktion av en sigmoid. Inom litteraturstudien kom det fram till att det fanns ingen kommersiell tillgänglig membran förtillfället för att ta bort vatten inom krävande process förhållanden. Tekniken ser dock lovande ut. / In this work, a thermodynamic analysis for CO2 hydrogenation by co-feeding ethanol to higher alcohols was performed with the HSC software package. The results suggested a high pressure and a low temperature for the reaction. However, it yielded low equilibrium compositions for the higher alcohols even at a high pressure of 100 bar at 300C . Increasing the equilibrium compositions for the higher alcohols can be done by removing water.  A mathematical model was used to analyse the rate-limiting step in a process for the production of higher alcohols from CO2.  In this process, reverse water gas shift (RWGS) reaction was used to convert CO2 to CO, subsequently, the obtained CO reacts with ethanol and hydrogen to produce higher alcohols directly. The mathematical model was developed in MATLAB to simulate how the reaction could behave by feeding CO2, H2 and ethanol at different pressures ranging from 10-200 bars. The water removal effect on the equilibrium is measured in terms of CO2   conversion by achieving 95% for removing water.  The results indicated that the process can be used to convert CO2 to higher alcohols and at a lower pressure. The limiting factor for CO2 hydrogenation is the reaction mechanism, it’s an urgent problem for the development of the catalysts. In this model it was assumed to be a logistic function. The conversion of CO2 into higher alcohols is an important problem that is required to be addressed by more experimental verifications to understand the mechanism. The literature review shows that there is no available membrane for removal of water for the process currently, due to the harsh process conditions, mainly because of the membrane stability. However, membrane technology is a promising method for separation of water/organic mixtures that can be studied further in the future.

The production of methanol by use of water electrolysis and hydrogenation of carbon dioxide (Power-to-Methanol) is a promising pathway to reduce greenhouse gas emissions. The concept of process intensification and the associated utilization of an in-situ coupling of methanol synthesis with proton-conducting Solid Oxide Electrolysis Cells (H+-SOEC) is a possible way to increase the energy efficiency of this process. Based on an extensive literature research, a novel Power-to-Methanol reactor concept for a concentric in-situ-integration of a tubular H+-SOEC has been designed, manufactured and operated at the Chair of Hydrogen and Nuclear Energy at the Technische Universität Dresden. The conducted experiments served as reference points for the process simulations performed in the second part of this thesis. Here, the Power-to-Methanol process has been modelled and simulated by means of process systems engineering methods to evaluate the in-situ-process in comparison to an conventional uncoupled set-up based on planar H+-SOECs. For this task, a novel and firm H+-SOEC process model was developed and implemented. In addition, the heat integration potential and profitability of the two Power-to-Methanol concepts have been investigated by Pinch Point and Techno-Economic Analysis. On the experimental side, a proof-of-concept of the novel reactor design was demonstrated, but limitations regarding the optimal thermal profile and operational flexibility of each process were identified. Furthermore, the methanol production rate showed potential for further improvement. The simulation results have helped to understand the process characteristics and to locate optimal operation points regarding current density, temperature and pressure. In an optimised operation scenario, high energy efficiencies for both tubular in-situ and planar set-ups have been achieved, by means of harnessing the heat integration potential through exothermic H+-SOEC operation. Notwithstanding the above, planar set-ups have demonstrated to be substantially more profitable than tubular systems. This has been the first investigation on Power-to-Methanol processes based on H+-SOEC. The present work helps to identify remaining development objectives for the use of H+-SOEC and Power-to-Methanol processes in general. The results from experiments and simulations indicate the challenging utilization of tubular electrolysis cells, but also revealed new research priorities that should be addressed in the future.

Due to the remote and dispersed nature of Alberta’s oil wells, it is not economical for the energy industry to capture all of the solution gas produced and as a result, the gas is being flared and vented in significant amounts. The objective of this research is to aid in the conversion of solution gas into dimethyl ether (DME) in a remote location by designing a distillation column that purifies DME and its reaction by-products, carbon dioxide, methanol and water. In order to develop an implementable solution, the distillation equipment must fit inside of a 40-foot shipping container to be transported to remote locations. Given the size constraint of the system, process intensification is the best strategy to efficiently separate the mixture. Several process intensification distillation techniques are explored, including semicontinuous distillation, the dividing wall column (DWC) and a novel semicontinuous dividing wall column (S-DWC). The traditional semicontinuous distillation column purifies DME to fuel grade purity, however the other components are not separated to a high enough grade given the height constrain of the system. The DWC and S-DWC both purify DME to its desired purity along with producing high purity waste streams. The S-DWC purifies the reaction intermediate methanol to a grade slightly higher than the DWC and is pure enough to recycle back to the reactor. An economic comparison is made between the three systems. While the DWC is a cheaper method of producing DME, the trade-off is the purity of the methanol produced. Overall, this research shows that it is possible to purify DME and its reaction by-products in a 40-foot distillation column at a cost that is competitive with Diesel. / Thesis / Master of Applied Science (MASc)

Process industries are cornerstones in today’s industrialized society. They contribute significantly in the manufacturing of various goods and products that are used in our day-to-day life. Our society’s paradigm of consumerism accompanied by a rise in global population drives an ever increasing demand for goods. One of many strategies developed to satisfy these demands and at the same time improve production capabilities is known as process intensification. As an example, this can be accomplished by implementation of devices using the principle of hydrodynamic and acoustic cavitation. High-intensity cavitation in the ultrasonic range can change the physical and chemical properties of a wide range of substances and hence, improve the production rate or quality. Despite the generally accepted benefits of hydrodynamic and acoustic cavitation, applications in the process industry are yet limited. The reasons are that the method requires extensive optimization, which depends on multiple process parameters and encounters problem in the implementation on a larger scale. Scalable cavitation reactor concepts for industrial applications need to meet challenges like stability and robustness, energy efficiency and high flow rates. This thesis focuses on the methodology for the design and optimization of a flow through cavitation reactor. An ultrasound reactor concept has been developed and tested for two different applications: i) Fibrillation processes typical for paper and pulp industry; ii) Metal leaching of mineral concentrates. Simulations were carried out using a commercially available software for multiphysics modeling which combines acoustics, structural dynamics, fluid dynamics and piezoelectrics. However, the optimization procedure requires extensive experimental work in parallel with multi-physical simulations. In general, the application leads to hydrodynamic initiation of small gas bubbles in the fluid to be excited and collapsed by high-intensity ultrasound. This transient collapse of the cavitation bubbles provides both mechanical and chemical effect on materials. The developed reactor has a power conversion efficiency of 36% in batch mode and is well suited for a scale-up. In flow-through mode, the cavitation effect improves extensively and provides stable results. Energy efficiency requires hydrodynamic initiation of cavitation bubbles, high acoustic cavitation intensity by multiple excitation frequencies adapted to the optimized reactor geometry, as well as optimal process pressure and temperature with respect to the materials to be treated. The impact of flow conditions and hydrodynamic cavitation is significant and almost doubles the yield at the same ultrasonic power input. In the case of fibrillation of cellulose fibers, results obtained indicate that generated cavitation intensity changes the mechanical properties of the fiber wall. In the case of leaching, experiments show that six hours of exposure gave a 57% recovery of tungsten from the scheelite concentrate at 80°C and atmospheric pressure. Future research will focus on different types of excitation signals, extended reactor volume, increased flow rates and use of a higher process temperature.

Facing the pressure of population growth and global warming, this dissertation provided an array of innovative carbon-efficient wastewater treatment technologies for resource recovery, process intensification, and anammox featured next generation biological nutrient removal (BNR) technologies. These technologies aim to supplant traditional carbon-intensive treatment processes with more sustainable alternatives. To this end, the dissertation first comprehensively reviewed what resources can be recovered from wastewater, and how these valuable resources can contribute to the carbon neutrality in water resource reclamation facilities (WRRFs) and help achieve sustainable society development. Then, the effect of mixed liquor recycle (MLR) configurations on the process intensification through continuous-flow aerobic granulation was explored in plug flow reactors. The results demonstrated that MLR configuration could hinder the sludge granulation, but the hindrance could be alleviated to some extent by its location change. In order to eliminate the energy consuming MLR, endogenous denitrification was taken advantage through a synergistic integration with partial nitrification, partial denitrification anammox (PdNA), and enhanced biological phosphorus removal (EBPR). This idea was tested in a pilot setup treating real primary effluent under highly variable influent conditions and low temperatures. The results showcased substantial carbon savings while meeting the stringent effluent requirements. To take a deeper dive into the PdNA performance and the underlying mechanisms, two parallel pilot-scale moving bed biofilm reactor (MBBR) treatment trains fed with methanol and glycerol, respectively, were operated in a local WRRF. Their efficacies in achieving stringent nutrient removal targets and carbon savings were compared. The impacts of operational conditions on the mechanisms and performance were elucidated. In the culmination of this dissertation, a sidestream process intensification and resource recovery technique, namely thermal hydrolysis pretreatment (THP) enhanced anaerobic digestion (AD), was experimented to compare the efficiencies between thermophilic and mesophilic AD when integrated with THP. To sum up, this dissertation not only advanced our understanding of carbon-efficient wastewater treatment processes but also laid the groundwork for their practical implementation, contributing to the global effort towards sustainability. / Doctor of Philosophy / Wastewater treatment consumes 3-4% of the energy produced in the U.S. and contributes to approximately 1.6% global greenhouse gas emissions. This dissertation aims to advance a series of carbon-efficient technologies specifically tailored for sustainable wastewater treatment. To this end, a variety of valuable resources that can be recovered or reused in wastewater treatment plants was firstly reviewed. Then, an advanced technology that can turn dispersed bacteria into bacteria aggregates was tested with real wastewater in a local wastewater treatment plant. Although these bacteria aggregates allow more wastewater to be treated with less small footprint, which was great, it was realized from this study that the formation of these bacteria aggregates was hindered by the nitrate water recycle which has been commonly practiced for using influent carbon for nitrogen removal. This nitrate water recycle consumed excessive energy for its high flow rate. To save this energy, a novel bioprocessing design was developed to eliminate the need for this nitrate water recycle by using carbon stored in bacterial cells. This new design also incorporated phosphorus recovery capacity and a low carbon nitrogen removal technique into one consolidated system to create an all-in-one solution to meet the stringent wastewater treatment requirement. This low carbon nitrogen removal technique harnessed a special group of bacteria that can use ammonia to reduce nitrite to nitrogen gas. Hence, only minor carbon source needs to be provided to reduce nitrate to nitrite for these bacteria to utilize. Two types of carbon sources, namely methanol and glycerol, were compared in a pilot-scale study to understand their efficiencies in generating nitrite. Results indicated that although both types of carbon sources can work, methanol is better suited for low strength wastewater treatment. These results provided an engineering basis for the full-scale application of the technology in the same wastewater treatment plant where the pilot study was performed. Besides liquid treatment, a carbon efficient solid treatment technology was also studied. The bottleneck constraining the rate of sewage sludge conversion to flammable menthane gas was identified, which provided engineering guidance for the design of the solid treatment process that can destroy more sewage sludge within smaller reactor spaces. In essence, this dissertation offers promising solutions for modern wastewater treatment plants to achieve low carbon wastewater treatment without compromising the treatment performance.