A Conceptual Framework for Process Intensification in Multi-Stage Chemical Effluent Treatment Units

• Author(s): Matluck Afolabi ; Ogechi Amanda Onukogu ; Thompson Odion Igunma ; Adeniyi K. Adeleke ; Zamathula Q. Sikhakhane Nwokediegwu
• Paper ID: 1708812
• Page: 400-425
• Published Date: 31-12-2021
• Published In: Iconic Research And Engineering Journals
• Publisher: IRE Journals
• e-ISSN: 2456-8880
• Volume/Issue: Volume 5 Issue 6 December-2021

Abstract

This paper presents a conceptual framework for process intensification in multi-stage chemical effluent treatment units, aimed at enhancing treatment efficiency, reducing energy consumption, and minimizing environmental impact. Chemical effluent streams from industrial processes are often complex, containing a mixture of inorganic and organic pollutants that require sequential treatment stages for effective remediation. Conventional multi-stage treatment systems typically comprising neutralization, coagulation-flocculation, sedimentation, filtration, and advanced oxidation suffer from high operational costs, large footprints, and limited adaptability to varying influent characteristics. Process intensification (PI) offers a transformative approach by integrating, optimizing, and miniaturizing unit operations to improve performance and sustainability. This framework synthesizes principles from reaction engineering, separation technology, and systems integration to propose intensified modules that combine multiple treatment functions. These include hybrid reactors for simultaneous neutralization and coagulation, membrane-assisted flocculation units, and modular advanced oxidation zones enhanced with UV or plasma technologies. The framework emphasizes adaptive control, real-time monitoring, and data-driven process optimization through sensor integration and feedback loops, enabling dynamic response to influent variability. Emphasis is placed on reducing hydraulic retention time, enhancing mass transfer, and maximizing contaminant degradation in compact reactor systems. The framework is built on a comparative analysis of over 120 peer-reviewed studies and industrial case applications from 2005 to 2024, identifying key performance indicators such as chemical oxygen demand (COD) removal, sludge yield, energy input per cubic meter, and effluent quality index. It also considers techno-economic feasibility, modular scalability, and regulatory compliance, making it applicable across diverse sectors including pharmaceuticals, petrochemicals, and agro-industries. By embedding PI strategies in chemical effluent treatment design, this conceptual framework supports the development of next-generation treatment units that are resource-efficient, flexible, and environmentally resilient. The study concludes with recommendations for pilot-scale validation, integration with digital twin models, and alignment with circular economy principles. This framework contributes significantly to the ongoing discourse on sustainable industrial wastewater management.

Keywords

Process Intensification, Chemical Effluent, Multi-Stage Treatment, Hybrid Reactors, Advanced Oxidation, Wastewater Engineering, System Integration, Sustainability, Circular Economy, Adaptive Control.

Citations

IRE Journals:
Matluck Afolabi , Ogechi Amanda Onukogu , Thompson Odion Igunma , Adeniyi K. Adeleke , Zamathula Q. Sikhakhane Nwokediegwu "A Conceptual Framework for Process Intensification in Multi-Stage Chemical Effluent Treatment Units" Iconic Research And Engineering Journals Volume 5 Issue 6 2021 Page 400-425

IEEE:
Matluck Afolabi , Ogechi Amanda Onukogu , Thompson Odion Igunma , Adeniyi K. Adeleke , Zamathula Q. Sikhakhane Nwokediegwu "A Conceptual Framework for Process Intensification in Multi-Stage Chemical Effluent Treatment Units" Iconic Research And Engineering Journals, 5(6)