A new definition of mixing and segregation: Three dimensions of a key process variable

Particle Tracking and Micromixing Performance Characterization with a Mobile Device

Strategies to stir and mix reagents in microfluid devices have evolved concomitantly with advancements in manufacturing techniques and sensing. While there is a large array of reported designs to combine and homogenize liquids, most of the characterization has been focused on setups with two inlets and one outlet. While this configuration is helpful to directly evaluate the effects of features and parameters on the mixing degree, it does not portray the conditions for experiments that involve more than two substances required to be subsequently combined. In this work, we present a mixing characterization methodology based on particle tracking as an alternative to the most common approach to measure homogeneity using the standard deviation of pixel intensities from a grayscale image. The proposed algorithm is implemented on a free and open-source mobile application (MIQUOD) for Android devices, numerically tested on COMSOL Multiphysics, and experimentally tested on a bidimensional split and recombine micromixer and a three-dimensional micromixer with sinusoidal grooves for different Reynolds numbers and geometrical features for samples with fluids seeded with red, blue, and green microparticles. The application uses concentration field data and particle track data to evaluate up to eleven performance metrics. Furthermore, with the insights from the experimental and numerical data, a mixing index for particles (mp) is proposed to characterize mixing performance for scenarios with multiple input reagents.

Design and evaluation of additive manufactured highly efficient inclined-wing type continuous mixer

We develop a novel milli-scale mixer (tilted-wings mixing unit, TWM unit) based on the design for additive manufacturing (DfAM). The proposed tilted-wings mixer has basically designed to have three separate wings that split and combine fluids in order to mix together effectively. Its structure is simple for easy fabrication: two major design parameters of angle among three wings and connecting angle between tilted-unit, which are optimized using the computational fluid dynamics (CFD) analysis. From the CFD analysis, we obtain the best-combined mixing module from analyses of various combinations of TWM units for a highly effective mixing ratio. The mixing ratio of three combined units reaches near 100%, which is validated by the experiment and analysis. We believe that the proposed milli-scale mixer can be utilized in diverse chemical continuous mixers and reactors for minimizing of use of chemicals that can pollute the environment.

A novel method for assessing oral mixing ability based on the spatial clusters quantified by variogram

BACKGROUND

The two-colour chewing test (TCCT) has been widely used for assessing oral mixing ability, a critical component of masticatory performance. Most studies focused on quantifying the evenness of colour distribution. It remained unknown if the variation of colour clustering was a valid index of oral mixing ability.

OBJECTIVE

The study aims to investigate the oral mixing ability based on the spatial clusters quantified by variogram.

METHODS

Fifty older people (15 male/35 female, age: 66.0 ± 7.8 years) were assessed for the TCCT and the colour-changeable chewing gum test (CCGT). For the CCGT, we quantified the degree of colour change (ΔE). For the TCCT, the highest peak in colour histogram (HP), the standard deviation of colour values (SDC) and the range of variogram from colour spatial distribution (VARG) were quantified. The participants were grouped according to the contacts of posterior teeth, as assessed by Eichner Index (EI).

RESULTS

Highest peak, SDC and VARG showed statistically significant differences between the EI groups (two-tailed independent t test P < .05). Higher VARG (ie a lower degree of clustering) was significantly negatively correlated with ΔE (r = -.36, one-tailed P < .01). The binary logistic regression revealed that among the spatial indices (HP, SDC and VARG), only VARG achieved statistical significance in prediction to the EI group. Eliminating other indices was insignificant to the model performance.

CONCLUSIONS

Our results show that the averaged cluster sizes, quantified by variogram, are a valid index for quantifying the TCCT. Compared with other spatial indices, it had the best predictability to the condition of posterior contact.

Transformation of hazardous lead into aluminosilicate ceramics: structure evolution and lead leaching

This study investigated crystallization mechanisms for the formation of lead aluminosilicate by sintering lead stabilization with kaolin-based precursors. PbAl₂Si₂O₈ was found to be the only stable lead aluminosilicate in low-PbO system and demonstrates its highly intrinsic resistance to acid attack in leaching test. A three-stage PbAl₂Si₂O₈ formation mechanism was supported by the results of the changing temperature in the system. Amorphization of sintered products was observed in both PbO/kaolinite and PbO/mullite systems at 600-700°C. When the temperature was increased to 750-900°C, the crystallochemical formation of lead aluminosilicates (i.e., Pb₄Al₄Si₃O₁₆, Pb₆Al₆Si₂O₂₁, and PbAl₂Si₂O₈) was observed. Pb₄Al₄Si₃O₁₆ and Pb₆Al₆Si₂O₂₁ were found to be the intermediate phases at 700-900°C. Finally, PbAl₂Si₂O₈ was found to be the only crystallite phase to host Pb at above 950°C. A maximum of 80% and 96.7% Pb can be incorporated into PbAl₂Si₂O₈ in PbO/kaolinite and PbO/mullite systems, respectively, but the final products exhibited different microstructures. To reduce environmental hazard of lead, this strategy demonstrated a preferred mechanism of immobilizing lead into PbAl₂Si₂O₈ structure via kaolin-based precursors.

Sewage sludge incineration ash for coimmobilization of lead, zinc and copper: Mechanisms of metal incorporation and competition

Heavy metals such as lead, zinc, and copper always coexist in industrial wastes and tend to be released if the wastes are not treated properly. With abundant contents of aluminum, iron and silicon, sewage sludge incineration ash can provide a ceramic matrix for potential heavy metal stabilization. By using ceramic sintering, this study explored the coimmobilization mechanisms of lead, zinc and copper, with detailed explications on phase transformation, metal distribution and the effect of metal content. PbAl₂Si₂O₈ was identified as the major phase for lead immobilization in series with low heavy metal content, while most of the lead was incorporated into Pb₉(PO₄)₆ in high metal series. The Zn_xCu_1-xFe_yAl_2-yO₄ spinel solid solution was the predominant product phase for copper and zinc stabilization in both reaction series, but zinc was more competitively incorporated into the spinel structure. Moreover, the pattern of heavy metal distribution in the sintered products was largely affected by the metal type and elemental composition of the reaction system. Although different leaching behaviors were observed for the three heavy metals, their leachability was found to reach very low value after the thermal treatment processes. This study proposed a "waste-to-resource" strategy to largely alleviate the environmental burden of solid wastes and heavy metal pollution by using sewage sludge incineration ash as raw materials for low-temperature glass-ceramics, with a simultaneous effect on metal immobilization.

Scale-Up of Shear Thinning Fluid Mixing in an Unbaffled Stirred Vessel with Eccentrically Located and Modified Impellers

Mixing of a shear thinning fluid was scaled-up by maintaining equal Reynolds number (Re), tip speed, and power per volume. A standard 45° four-blade pitch blade turbine (PBT) and a modified version of the same impeller (DF-PBT) which provided simultaneous upward and downward flow were used. The impellers were located eccentrically, and the effects of scale-up were determined. The distribution of a tracer solution to evaluate mixing progress, power consumption, and flow fields were analyzed to compare the three different scale-up rules. The same endpoint of mixing was achieved in all cases of PBT with noticeable differences in flow profiles. Higher power consumption and less time were necessary to complete mixing with equal power per volume compared to that with equal Re and tip speed rules. For DF-PBT, only equal Re rule resulted in values similar to that obtained at the small scale. At a scale-up ratio of 2, the selection of scale-up rule should be based on the time and power requirements of the process. As the effects of scale-up on eccentrically located impellers do not differ significantly from those of concentrically located impellers, impellers which have complex dynamics such as DF-PBT require further studies to understand scale-up effects.

Laminar mixing of non-Newtonian fluids in static mixers: process intensification perspective

Static mixers are widely used in various industrial applications to intensify the laminar mixing of non-Newtonian fluids. Non-Newtonian fluids can be categorized into (1) time-independent, (2) time-dependent, and (3) viscoelastic fluids. Computational fluid dynamics studies on the laminar mixing of viscoelastic fluids are very limited due to the complexity in incorporating the multiple relaxation times and the associated stress tensor into the constitutive equations. This review paper provides recommendations for future research studies while summarizing the key research contributions in the field of non-Newtonian fluid mixing using static mixers. This review discusses the different experimental techniques employed such as electrical resistance tomography, magnetic resonance imaging, planar laser-induced fluorescence, and positron emission particle tracking. A comprehensive overview of the mixing fundamentals, fluid chaos, numerical characterization of fluid stretching, development of pressure drop correlations, and derivations of generalized Reynolds number is also provided in this review paper.

Lead extraction from Cathode Ray Tube (CRT) funnel glass: Reaction mechanisms in thermal reduction with addition of carbon (C)

This study quantitatively determined the extraction of lead from CRT funnel glass and examined the mechanisms of thermally reducing lead in the products of sintering Pb-glass with carbon in the pre-heated furnace. The experimentally derived results indicate that a 90.3 wt% lead extraction efficiency can be achieved with 20 wt% of C addition at 950 °C for 3 min under air. The formation of viscous semi-liquid glass blocked the oxygen supply between the interaction of C and Pb-glass, and was highly effective for the extraction of metallic Pb. A maximum of 87.3% lead recover was obtained with a C to Na₂CO₃ ratio of 1/3 at 1200 °C. The decrease of C/Na₂CO₃ ratio enhanced the metallic lead recovery by increasing the glass viscosity for effective sedimentation of metallic lead in the bottom. However, with the further increase of temperature and treatment time, re-vitrification of lead back to silicate-glass matrix was detected in both Pb-glass/C and Pb-glass/C/Na₂CO₃ systems. The findings indicated that with proper controls, using C as an inexpensive reagent can effectively reduce treatment time and energy, which is crucial to a waste-to-resource technology for economically recovering lead from the waste CRT glass.

Formation of lead-aluminate ceramics: Reaction mechanisms in immobilizing the simulated lead sludge

We investigated a strategy of blending lead-laden sludge and an aluminum-rich precursor to reduce the release of hazardous lead from the stabilized end products. To quantify lead transformation and determine its incorporation behavior, PbO was used to simulate the lead-laden sludge fired with γ-Al2O3 by Pb/Al molar ratios of 1/2 and 1/12 at 600-1000 °C for 0.25-10 h. The sintered products were identified and quantified using Rietveld refinement analysis of X-ray diffraction data from the products generated under different conditions. The results indicated that the different crystallochemical incorporations of hazardous lead occurred through the formation of PbAl2O4 and PbAl12O19 in systems with Pb/Al ratios of 1/2 and 1/12, respectively. PbAl2O4 was observed as the only product phase at temperature of 950 °C for 3h heating in Pb/Al of 1/2 system. For Pb/Al of 1/12 system, significant growth of the PbAl12O19 phase clearly occurred at 1000 °C for 3 h sintering. Different product microstructures were found in the sintered products between the systems with the Pb/Al ratios 1/2 and 1/12. The leaching performances of the PbO, Pb9Al8O21, PbAl2O4 and PbAl12O19 phases were compared using a constant pH 4.9 leaching test over 92 h. The leachability data indicated that the incorporation of lead into PbAl12O19 crystal is a preferred stabilization mechanism in aluminate-ceramics.

Effectiveness and Mechanisms of Defluorination of Perfluorinated Alkyl Substances by Calcium Compounds during Waste Thermal Treatment

The mineralization of perfluorinated alkyl substances (PFASs) by calcium compounds during the waste thermal treatment was systemically studied. Different calcium compounds showed different mineralization efficiencies of PFASs during the thermal process, owing to the different reaction mechanisms. Calcium hydroxide was recommended as the most effective Ca reagent for PFAS defluorination because the carbon-fluorine bonds in PFASs can be converted to carbon-hydrogen bonds via the hydrodefluorination reaction. PFASs with different chain lengths and functional groups were further investigated for their potentially different mineralization behavior. The results showed that the chain length of PFASs had an insignificant effect on the mineralization efficiency by calcium hydroxide. The thermogravimetric analysis-differential thermal analysis (TGA-DTA) also revealed that perfluorooctanesulfonate (PFOS) and perfluorohexanesulfonate (PFHxS) (with different chain lengths) had a similar thermal behavior. However, PFASs with different functional groups showed different mineralization behavior with calcium hydroxide in relation to their different thermal decomposition temperatures. Finally, the mineralization ratio of polytetrafluoroethylene (PTFE) particles by calcium hydroxide could reach 80% or higher when the temperature was above 400 °C. The gas chromatography/mass spectrometry (GC/MS) results demonstrated much reduced production of gaseous fluorocarbon fragments during PTFE decomposition when coexisting with calcium hydroxide.

Stabilization of simulated lead sludge with iron sludge via formation of PbFe₁₂O₁₉ by thermal treatment

This study investigated the feasibility of stabilizing lead sludge by reaction with iron sludge via the formation of PbFe12O19 through a thermal treatment process. Lead hydroxide was used to simulate lead-laden sludge and the sintering procedure was performed by firing a mixture of this simulated sludge together with iron sludge at a Fe/Pb molar ratio of 12 over the temperature range from 650 to 1400 °C. The accompanying phase transformations as well as the surface characteristic of sintered samples were observed by XRD and SEM, while the leaching behavior of the stabilized sludge in an acidic environment was evaluated by a modified Toxicity Characteristic Leaching Procedure (TCLP) test. The results confirmed that PbFe12O19 acts as a stabilization phase for lead, and showed that the formation of a PbFe12O19 phase began at 750 °C with the lead completely incorporated into the PbFe12O19 phase at 1050 °C. Above 1100 °C, the PbFe12O19 phase began to decompose, accompanied by the reappearance of Fe2O3. The volumes of compressed sludge samples were reduced significantly after thermal treatment, with accompanying volume reductions of 40% at 1050 °C. This study compared the leaching of lead from PbO and sintered sludge samples using a prolonged TCLP test, and the data showed that the PbFe12O19 phase was superior to the PbO and that the sintered sludge sample exhibited very high stability under acidic environments. These results suggest a promising and reliable method of reducing lead sludge mobility and toxicity has been identified.

Mineralization behavior of fluorine in perfluorooctanesulfonate (PFOS) during thermal treatment of lime-conditioned sludge

The fate and transport of the fluorine in perfluorooctanesulfonate (PFOS) during the thermal treatment of lime-conditioned sludge were observed using both qualitative and quantitative X-ray diffraction techniques. Two main fluorine mineralization mechanisms leading to the substantial formation of CaF2 and Ca5(PO4)3F phases were observed. They had a close relationship with the thermal treatment condition and the PFOS content of the sludge. At low temperatures (300-600 °C), CaF2 dominated in the product and increases in treatment time and temperature generally enhanced the fluorine transformation. However, at higher temperatures (700-900 °C), increases in treatment time and temperature had a negative effect on the overall efficiency of the fluorine crystallization. The results suggest that in the high temperature environment there were greater losses of gaseous products such as HF and SiF4 in the transformation of CaF2 to Ca5(PO4)3F, the hydrolysis of CaF2, and the reaction with SiO2. The quantitative analysis also showed that when treating sludge with low PFOS content at high temperatures, the formation of Ca5(PO4)3F may be the primary mechanism for the mineralization of the fluorine in PFOS. The overall results clearly indicate the variations in the fate and transport of fluorine in PFOS when the sludge is subject to different PFOS contents and treatment types, such as heat drying or incineration.

Metal stabilization mechanism of incorporating lead-bearing sludge in kaolinite-based ceramics

The feasibility and mechanism of incorporating simulated lead-laden sludge into low-cost ceramic products was investigated by observing the reaction of lead with two kaolinite-based precursors under sintering conditions. To investigate the phase transformation process of lead, lead oxide (PbO) mixed with a kaolinite or mullite precursor were fired at 500-950°C for 3h. Detailed X-ray diffraction analysis of sintered products revealed that both precursors had crystallochemically incorporated lead into the lead feldspar (PbAl(2)Si(2)O(8)) crystalline structure. By mixing lead oxide with kaolinite, lead feldspar begins to crystallize at 700°C; maximum incorporation of lead into this structure occurred at 950°C. However, two intermediate phases, Pb(4)Al(4)Si(3)O(16) and a polymorph of lead feldspar, were detected at temperatures between 700 and 900°C. By sintering lead oxide with the mullite precursor, lead feldspar was detected at temperatures above 750°C, and an intermediate phase of Pb(4)Al(4)Si(3)O(16) was observed in the temperature range of 750-900°C. This study compared the lead leachabilities of PbO and lead feldspar using a prolonged leaching test (at pH 2.9 for 23d) modified from the toxicity characteristic leaching procedure. The results indicate the superiority of lead feldspar in stabilizing lead and suggest a promising and reliable strategy to stabilize lead in ceramic products.

Phase transformation and its role in stabilizing simulated lead-laden sludge in aluminum-rich ceramics

This study investigated the mechanisms of stabilizing lead-laden sludge by blending it into the production process of aluminum-rich ceramics, and quantitatively evaluated the prolonged leachability of the product phases. Sintering experiments were performed using powder mixtures of lead oxide and γ-alumina with different Pb/Al molar ratios within the temperature range of 600-1000 °C. By mixing lead oxide with γ-alumina at a Pb/Al molar ratio of 0.5, the formation of PbAl2O4 is initiated at 700 °C, but an effective formation was observed when the temperature was above 750 °C for a 3-h sintering time. The formation and decomposition of the intermediate phase, Pb9Al8O21, was detected in this system within the temperature range of 800-900 °C. When the lead oxide and γ-alumina mixture was sintered with a Pb/Al molar ratio of 1:12, the PbAl12O19 phase was found at 950 °C and effectively formed at 1000 °C. In this system, an intermediate phase Pb3(CO3)2(OH)2 was observed at the temperature range of 700-950 °C. Over longer leaching periods, both PbAl2O4 and PbAl12O19 were superior to lead oxide in immobilizing lead. Comparing the leaching results of PbAl2O4 and PbAl12O19 demonstrated the higher intrinsic resistance of PbAl12O19 against acid attack. To reduce metal mobility, this study demonstrated a preferred mechanism of stabilizing lead in the aluminate structures by adding metal-bearing waste sludge to the ceramic processing of aluminum-rich products.

Influence of calcium hydroxide on the fate of perfluorooctanesulfonate under thermal conditions

To explore the potential fate and transport of perfluorochemicals in the thermal treatment of sludge, perfluorooctanesulfonate (PFOS), a perfluorochemical species commonly dominant in wastewater sludge, was mixed with hydrated lime (Ca(OH)(2)) to quantitatively observe their interaction under different temperatures. The phase compositions of the mixtures after the reactions were qualitatively identified and quantitatively determined using X-ray diffraction technique. The results of the thermogravimetry and differential scanning calorimetry analyses indicate that PFOS gasified directly during the thermal treatment process when the temperature was increased to around 425 °C. However, the formation of CaF(2) at 350 °C suggests that the presence of Ca(OH)(2) in the mixture can lead to the decomposition of PFOS at 350 °C, which is lower than the decomposition temperature of PFOS alone (425 °C). The increase of temperature promoted a solid state reaction between PFOS and Ca(OH)(2), and also enhanced the interaction between the gaseous products of PFOS and CaO (or Ca(OH)(2)). The preferred Ca/F molar ratio to achieve fluorine stabilization by Ca(OH)(2) was above 1:1 in the experiment involving 400 °C and 600 °C treatment. It also showed that equilibrium efficiency is achieved within 5 min at 400 °C and within 1 min above 600°C.