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Malau, Jon Saul
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Chemical Engineering, Chemistry & Bioengineering Energy Engineering Materials Science & Nanotechnology

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Journal : Journal of Chemical Engineering Research Progress

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Enhancing Energy Efficiency in Methanol-Based Formaldehyde Production through Heat Recovery Integration Malau, Jon Saul; Hasby, Akhdan Mizbani; Adelia, Ammara Naifah; Khairunnisa, Atikah; Novya, Ayesha Imtiyaz; Amaanullah, Dzaki
Journal of Chemical Engineering Research Progress 2025: JCERP, Volume 2 Issue 2 Year 2025 (December)
Publisher : UPT Laboratorium Terpadu, Universitas Diponegoro

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.9767/jcerp.20564

Abstract

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).
Process Simulation and Optimization of Propane Dehydrogenation over Pt-Sn/Al₂O₃: A Langmuir-Hinshelwood Approach Alfarabi, Kemas Muhammad Fachmi; Setiawan, Flantino; Luqman, Muhammad Adlan; Hanani, Maryam Hilaifa; Haribowo, Praditya Rizky; Malau, Jon Saul
Journal of Chemical Engineering Research Progress 2026: Just Accepted Manuscript and Article In Press 2026
Publisher : UPT Laboratorium Terpadu, Universitas Diponegoro

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.9767/jcerp.20713

Abstract

Propane dehydrogenation (PDH) has emerged as a critical process for propylene production due to increasing global propylene demand and limitations of conventional methods such as steam cracking and fluid catalytic cracking. This study develops a kinetic model for propane dehydrogenation over a Pt-Sn/Al₂O₃ catalyst using a Langmuir–Hinshelwood Hougen Watson (LHHW) framework, wherein the second hydrogen abstraction step is assumed to be the rate-determining step. The kinetic model incorporates non-dissociative propane adsorption, competitive adsorption of propane, propylene, and hydrogen, as well as reverse reactions and catalyst deactivation associated with coke formation. The model was implemented in Aspen Plus/HYSYS using a plug flow reactor (PFR) under steady-state, isothermal conditions. Operating parameters included temperatures of 823–923 K, pressures of 1–5 bar, and feed ratios ranging from 1:0 to 1:2. Base-case simulation results revealed extremely low propane conversion on the order of 10⁻⁸, indicating significant kinetic limitations despite the endothermic heat duty of approximately –6.78 × 10⁴ kJ/h. A temperature sensitivity analysis conducted between 760°C and 1000°C showed no improvement in conversion with increasing temperature; instead, a slight decreasing trend was observed. This anomaly suggests that adsorption effects dominate under the Langmuir–Hinshelwood formulation, and that the selected kinetic parameters may be inadequate for the simulated temperature range. The results indicate that temperature variation alone is insufficient to enhance reactor performance. Further model refinement is required, including re-evaluation of kinetic parameters (pre-exponential factor and activation energy), adjustment of adsorption constants, consideration of non-isothermal reactor behavior, and increased catalyst loading or residence time.
Co-Authors Adelia, Ammara Naifah Alfarabi, Kemas Muhammad Fachmi Amaanullah, Dzaki Hanani, Maryam Hilaifa Haribowo, Praditya Rizky Hasby, Akhdan Mizbani Khairunnisa, Atikah Luqman, Muhammad Adlan Novya, Ayesha Imtiyaz Setiawan, Flantino