Static mixers: Mechanisms, applications, and characterization methods – A review

Modeling of Nitrogen Removal from Natural Gas in Rotating Packed Bed Using Artificial Neural Networks

Novel or unconventional technologies are critical to providing cost-competitive natural gas supplies to meet rising demands and provide more opportunities to develop low-quality gas fields with high contaminants, including high carbon dioxide (CO₂) fields. High nitrogen concentrations that reduce the heating value of gaseous products are typically associated with high CO₂ fields. Consequently, removing nitrogen is essential for meeting customers' requirements. The intensification approach with a rotating packed bed (RPB) demonstrated considerable potential to remove nitrogen from natural gas under cryogenic conditions. Moreover, the process significantly reduces the equipment size compared to the conventional distillation column, thus making it more economical. The prediction model developed in this study employed artificial neural networks (ANN) based on data from in-house experiments due to a lack of available data. The ANN model is preferred as it offers easy processing of large amounts of data, even for more complex processes, compared to developing the first principal mathematical model, which requires numerous assumptions and might be associated with lumped components in the kinetic model. Backpropagation algorithms for ANN Lavenberg-Marquardt (LM), scaled conjugate gradient (SCG), and Bayesian regularisation (BR) were also utilised. Resultantly, the LM produced the best model for predicting nitrogen removal from natural gas compared to other ANN models with a layer size of nine, with a 99.56% regression (R²) and 0.0128 mean standard error (MSE).

A Review of the Extruder System Design for Large-Scale Extrusion-Based 3D Concrete Printing

Extrusion-based 3D concrete printing (E3DCP) has been appreciated by academia and industry as the most plausible candidate for prospective concrete constructions. Considerable research efforts are dedicated to the material design to improve the extrudability of fresh concrete. However, at the time of writing this paper, there is still a lack of a review paper that highlights the significance of the mechanical design of the E3DCP system. This paper provides a comprehensive review of the mechanical design of the E3DCP extruder system in terms of the extruder system, positioning system and advanced fittings, and their effects on the extrudability are also discussed by relating to the extrusion driving forces and extrusion resistive forces which may include chamber wall shear force, shaping force, nozzle wall shear force, dead zone shear force and layer pressing force. Moreover, a classification framework of the E3DCP system as an extension of the DFC classification framework was proposed. The authors reckoned that such a classification framework could assist a more systematic E3DCP system design.

Pickering Emulsions Based in Inorganic Solid Particles: From Product Development to Food Applications

Pickering emulsions (PEs) have attracted attention in different fields, such as food, pharmaceuticals and cosmetics, mainly due to their good physical stability. PEs are a promising strategy to develop functional products since the particles’ oil and water phases can act as carriers of active compounds, providing multiple combinations potentiating synergistic effects. Moreover, they can answer the sustainable and green chemistry issues arising from using conventional emulsifier-based systems. In this context, this review focuses on the applicability of safe inorganic solid particles as emulsion stabilisers, discussing the main stabilisation mechanisms of oil–water interfaces. In particular, it provides evidence for hydroxyapatite (HAp) particles as Pickering stabilisers, discussing the latest advances. The main technologies used to produce PEs are also presented. From an industrial perspective, an effort was made to list new productive technologies at the laboratory scale and discuss their feasibility for scale-up. Finally, the advantages and potential applications of PEs in the food industry are also described. Overall, this review gathers recent developments in the formulation, production and properties of food-grade PEs based on safe inorganic solid particles.

Study on Experiment and Simulation of Shear Force on Membrane with Dynamic Cross-Flow for Lignin in Black Liquor

To address the problem of lignin membrane fouling caused by dynamic cross-flow in the process of retaining and concentrating the black liquor byproduct of papermaking, this paper uses three different rotating structures (vane, disk and propeller) to increase the surface shear force and filtration flux of the membrane. In this paper, under different rotating speeds and different transmembrane pressure differences, numerical simulations were conducted on the shear forces generated by the three structures and the retention process on the surface of the membrane. The variation laws were also studied and compared. Under the same filtration conditions, the vane structure demonstrates better results than the propeller and disk structures in terms of increasing filtration flux. Based on the result, the vane shear force was simulated in terms of changing the particle deposition, and compared with vane rotating speeds of 100-700 r/min, the surface particle deposition of the membrane was significantly reduced at a rotating speed of 800 r/min. Finally, the numerical simulation results were experimentally validated to ensure the accuracy of the simulation. The findings provide a theoretical basis and practical value for solving the problem of lignin membrane fouling caused by dynamic cross-flow in the process of retaining and concentrating the black liquor byproduct of papermaking.

Effects of static mixers on continuous methyl ester production: comparing four types of 3D-printed mixing elements

Four types of 3D-printed static mixer were employed in the continuous transesterification process to examine the pressure drop and mixing intensity. Methanol, KOH, and mixer length were also optimized using RSM to obtain the highest biodiesel purity.

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.

Reactive PLIF Method for Characterisation of Micromixing in Continuous High-Throughput Chemical Reactors

This work aimed to test and optimise reactive Planar Laser-Induced Fluorescence (PLIF) methods for the visualisation of the micromixing regions in chemical reactors using standard PLIF and Particle Image Velocimetry (PIV) equipment with the laser source 512 nm. Two methods were tested: (i) an acid–base reaction with fluorescein as the reaction-sensitive tracer and (ii) Fenton’s reaction, with Rhodamine B as the reaction tracer. Both test-reactions were studied in stopped-flow equipment to define suitable operational conditions, namely the chemical composition of the inflow streams, the concentration of reagents and fluorophore, and suitable excitation light wavelength. The visualisation of the micromixing regions was tested in a continuous flow reactor with a T-jet geometry. A laser light sheet emitted from an Nd:YAG laser illuminated the axial section of the demonstration reactor. The mixing dynamics and the reaction course were visualised with the acid–base reactive PLIF images. Fenton’s reactive PLIF method showed the overall distribution of mixing and reaction regions. The main contribution of this work is benchmarking two methods with costs that enable the visualisation of micromixing regions in continuous high-throughput reactors.

Heterogeneous metallaphotoredox catalysis in a continuous-flow packed-bed reactor

Metallaphotoredox catalysis is a powerful and versatile synthetic platform that enables cross-couplings under mild conditions without the need for noble metals. Its growing adoption in drug discovery has translated into an increased interest in sustainable and scalable reaction conditions. Here, we report a continuous-flow approach to metallaphotoredox catalysis using a heterogeneous catalyst that combines the function of a photo- and a nickel catalyst in a single material. The catalyst is embedded in a packed-bed reactor to combine reaction and (catalyst) separation in one step. The use of a packed bed simplifies the translation of optimized batch reaction conditions to continuous flow, as the only components present in the reaction mixture are the substrate and a base. The metallaphotoredox cross-coupling of sulfinates with aryl halides was used as a model system. The catalyst was shown to be stable, with a very low decrease of the yield (≈1% per day) during a continuous experiment over seven days, and to be effective for C–O arylations when carboxylic acids are used as nucleophile instead of sulfinates.

A novel design of in-line static mixer for permanganate/bisulfite process: Numerical simulations and pilot-scale testing

An increasing number of chemical technologies to wipe out contaminants within an incredibly short period of time have been developed recently, while their application was always hindered by the inefficient or improper mixing of reactants. To address this issue, the present work proposed a new static mixer named Tai-Chi which consists of blade, fin, and spoiler elements. Tai-Chi mixer can slice and divert the solutions inside and generate high shear flow to promote mixing process. Numerical simulations helped to determine the optimal operating conditions for Tai-Chi mixer, including laying its components anterior to the injection nozzles and keeping the velocity rate ratio of main pipe to branch pipe within the range of 0.5 to 1. Numerical simulations further proved that Tai-Chi mixer could strike a great balance between mixing performance (coefficient of variation [CoV] reaches 0.1 within 5 to 7 pipe diameters downstream) and head loss (nearly a half of other high shear static mixer in the market). Data of pilot-scale testing by Tai-Chi mixer confirm that 80% sulfamethoxazole could be eliminated in permanganate/bisulfite process within 8 pipe diameters, as well as showed the superiority of Tai-Chi's mixing performance in early stage compared with other static mixers in the market. PRACTITIONER POINTS: A Tai-Chi static mixer with blade, fin, and spoiler elements is devised. The optimal condition of flow rate and installment of Tai-Chi mixer is determined. Ultra-fast mixing is achieved by Tai-Chi (CoV < 0.1 within 5-7 pipe diameters). Pilot-scale test verifies the mixing efficiency of Tai-Chi mixer.

Influence of Hydrodynamic Conditions on Precipitation Kinetics of Barium Sulfate in a Multifunctional Reactor

In this paper, the influence of hydrodynamic conditions in Kenics static mixer, which acts as a multifunctional reactor, on precipitation kinetics of barium sulfate is investigated. The investigated range of the Reynolds number varied between 500 and 5000, which covered both laminar and turbulent flow regimes. In all experiments, the relative supersaturation was maintained at the constant level (σ = 205). The obtained precipitate was collected and used for crystal size distribution (CSD) determination. On that basis, the kinetic parameters of the process were calculated using the mixed suspension mixed product removal (MSMPR) mathematical model of the process. It was found that for the whole investigated range of Reynolds number, the mixing conditions were satisfactory. CSD analysis showed that in the laminar regime, a clear tendency in crystal behavior could not be noticed. However, during the analysis of the turbulent regime, the presence of a critical Reynolds number was noticed. Above this value, there is a change in the flow pattern, which results in a change of kinetic parameters (B, G), as well as manifests in a form of a decrease in the value of mean diameters of crystals. The flow pattern change is caused by the geometry of the reactor’s inserts.

Process Intensification in Chemical Reaction Engineering

In the present review article, the definitions and the most advanced findings within Process Intensification are collected and discussed. The intention is to give the readers the basic concepts, fixing the syllabus, as well as some relevant application examples of a discipline that is well-established and considered a hot topic in the chemical reaction engineering field at present.

A low-cost and high-performance 3D micromixer over a wide working range and its application for high-sensitivity biomarker detection

Homogenous mixing in microfluidic devices is often required for efficient chemical and biological reactions.Passive micromixing without external energy input has attracted much research interest. We have developed a high-performance 3D...

Soft hydraulics: from Newtonian to complex fluid flows through compliant conduits

Microfluidic devices manufactured from soft polymeric materials have emerged as a paradigm for cheap, disposable and easy-to-prototype fluidic platforms for integrating chemical and biological assays and analyses. The interplay between the flow forces and the inherently compliant conduits of such microfluidic devices requires careful consideration. While mechanical compliance was initially a side-effect of the manufacturing process and materials used, compliance has now become a paradigm, enabling new approaches to microrheological measurements, new modalities of micromixing, and improved sieving of micro- and nano-particles, to name a few applications. This topical review provides an introduction to the physics of these systems. Specifically, the goal of this review is to summarize the recent progress towards a mechanistic understanding of the interaction between non-Newtonian (complex) fluid flows and their deformable confining boundaries. In this context, key experimental results and relevant applications are also explored, hand-in-hand with the fundamental principles for their physics-based modeling. The key topics covered include shear-dependent viscosity of non-Newtonian fluids, hydrodynamic pressure gradients during flow, the elastic response (deformation and bulging) of soft conduits due to flow within, the effect of cross-sectional conduit geometry on the resulting fluid-structure interaction, and key dimensionless groups describing the coupled physics. Open problems and future directions in this nascent field of soft hydraulics, at the intersection of non-Newtonian fluid mechanics, soft matter physics, and microfluidics, are noted.

Research for a Non-Standard Kenics Static Mixer with an Eccentricity Factor

The Kenics static mixer is one of the most widely studied static mixers, whose structure–function relationship has been studied by varying its aspect ratio and modifying the surface. However, the effect of the symmetric structure of the Kenics static mixer itself on twisting the fluid has been neglected. In order to study how the symmetrical structure of the Kenics static mixer impacts the fluid flow, we changed the center position of elements at twist angle 90° and introduced the eccentricity factor γ. We applied LHS-PLS to study this non-standard Kenics static mixer and obtained the statistical correlations of the aspect ratio, Reynolds number, and eccentricity factor on relative Nusselt number and relative friction factor. We analyzed the results by comparing the PLS model with the univariate analysis, and it was found that the underlying logic of the Kenics static mixer with an asymmetric structure became different. In addition, a non-standard Kenics static mixer with an asymmetric structure was investigated using vortex generation and dissipation through fluid flow simulation. The results demonstrated that the classical symmetric structure has a minor pressure drop, but the backward eccentric one has a higher thermal-hydraulic performance factor. It was found that the nature of the eccentric structure is that two elements with different aspect ratios are being combined at θ=90°, and this articulation leads to non-standard Kenics static mixers with different underlying logic, which finally result in the differences between the PLS model and the univariate analysis.

Instrumentation-Compact Digital Microfluidic Reaction Interface-Extended Loop-Mediated Isothermal Amplification for Sample-to-Answer Testing of Vibrio parahaemolyticus

Vibrio parahaemolyticus is usually spread via consumption of contaminated seafood and causes vibriosis. By combination of digital microfluidic (DMF) and loop-mediated isothermal amplification (LAMP), we provided an automated instrumentation-compact DMF-LAMP device for sample-to-answer detection of V. parahaemolyticus. For the first time, how much the proper mixing might facilitate the DMF-LAMP process is explored. The results illustrated that increasing the number of flow configurations and decreasing the fluid-reversibility will extend the interfacial surface available for diffusion-based mass transfer within a droplet microreactor, thus contributing to the overall amplification reaction rate. Noticeably, the DMF-LAMP amplification plateau time is shortened by proper mixing, from 60 min in static mixing and traditional bulk LAMP to 30 min in 2-electrode mixing and 15 min in 3-electrode mixing. The device achieved much higher detection sensitivity (two copies per reaction) than previously reported devices. V. parahaemolyticus from spiked shrimps is detected by Q-tip sampling associated with 3-electrode mixing DMF-LAMPs. The detectable signal occurs within only 3 min at a higher concentration and, at most, is delayed to 18 min, with a detection limit of <0.23 × 10³ CFU/g. Thus, the developed DMF-LAMP device demonstrates potential for being used as a sample-to-answer system with a quick analysis time, high sensitivity, and sample-to-answer format.

Imposed dynamic irradiation to intensify photocatalytic reactions

Dynamic irradiation is a potent option to influence the interaction between photochemical reactions and mass transport to design high performant and efficient photochemical processes. To systematically investigate the impact of this parameter, the photocatalytic reduction of nitrobenzene was conducted as a test reaction. Dynamic irradiation was realized through provoked secondary flow patterns, multiple spatially distributed light emitting diodes (LEDs) and electrical pulsation of LEDs. A combined experimental and theoretical approach revealed significant potential to enhance photochemical processes. The reaction rate was accelerated by more than 70% and even more important the photonic efficiency was increased by more than a factor of 4. This renders imposed dynamic irradiation an innovative and powerful tool to intensify photoreactions on the avenue to large scale sustainable photochemical processes.

Continuous acid-catalyzed esterification using a 3D printed rotor-stator hydrodynamic cavitation reactor reduces free fatty acid content in mixed crude palm oil

Free fatty acid (FFA) content in FFA-rich mixed crude palm oil (MCPO) was reduced through a continuous esterification process. The reaction conditions were optimized, the yield purified esterified oil was determined, and the average total electricity consumption of the entire process was evaluated. The key component of this study was the cost-effective, 3D-printed rotor that was installed in a continuous rotor-stator hydrodynamic reactor. The surface of the rotor was designed with spherical holes where the center-to-center distance between them was fixed. Response surface methodology (RSM) using central composite design (CCD) was employed to analyze the design of experiments (DOE) and optimize FFA-content reduction. The optimized conditions were 17.7 vol% methanol, 2.9 vol% sulfuric acid, a 3000 rpm rotor speed, and surface holes measuring 4 mm in diameter and 6 mm in depth. The experimental results showed that the FFA content in MCPO was reduced from 11.456 to 1.028 wt% upon esterification under these optimal conditions. The maximum yield of esterified oil from the phase separation step was 96.07 vol%, and that of the purified esterified oil was 91.27 vol%. The average total energy consumed by this hydrodynamic cavitation reactor to produce this esterified oil was 0.0264 kW h/L. This 3D printed rotor-stator reactor is a promising, novel reactor technology for producing biodiesel from FFA-rich oils.

A continuous flow synthesis of [1.1.1]propellane and bicyclo[1.1.1]pentane derivatives

A continuous flow process to generate [1.1.1]propellane on demand is presented rendering solutions of [1.1.1]propellane that can directly be derivatised into various bicyclo[1.1.1]pentane (BCP) species. This was realised in throughputs up to 8.5 mmol h-1 providing an attractive and straightforward access to gram quantities of selected BCP building blocks. Lastly, a continuous photochemical transformation of [1.1.1]propellane into valuable BCPs bearing mixed ester/acyl chloride moieties was developed.

Effect of Process Conditions on Particle Size and Shape in Continuous Antisolvent Crystallisation of Lovastatin

Lovastatin crystals often exhibit an undesirable needle-like morphology. Several studies have shown how a needle-like morphology can be modified in antisolvent crystallisation with the use of additives, but there is much less experimental work demonstrating crystal shape modification without the use of additives. In this study, a series of unseeded continuous antisolvent crystallisation experiments were conducted with the process conditions of supersaturation, total flow rate, and ultrasound level being varied to determine their effects on crystal size and shape. This experimental work involved identifying acetone/water as the most suitable solvent/antisolvent system, assessing lovastatin nucleation behaviour by means of induction time measurements, and then designing and implementing the continuous antisolvent crystallisation experiments. It was found that in order to produce the smallest and least needle-like particles, the maximum total flow rate and supersaturation had to be combined with the application of ultrasound. These results should aid development of pharmaceutical manufacturing processes where the ability to control particle size and shape would allow for optimisation of crystal isolation and more efficient downstream processing.