Experimental and numerical investigation on mixing of dilute oil in water dispersions in a stirred tank

Study on the kinetics of formation process of emulsion of heavy oil and its functional group components

Enhanced oil recovery (EOR) by in situ formation of oil-in-water emulsion in heavy oil cold production technology has received growing interest from the petroleum industry. We present an experimental study of emulsification of model oils prepared by heavy oil and its functional group compositions dissolved into toluene brought into contact with a surfactant solution. The effects of functional group composition, emulsifier concentration, temperature, pH and stirring speed on the emulsification rate of heavy oil was investigated. A second-order kinetic model characterizing the temporal variation of conductivity during the emulsification has been established. The results show that acidic and amphoteric fractions exhibit higher interfacial activity, larger emulsification rate constant and faster emulsification rate. With the increase of emulsifier concentration, the emulsification rate constant increase to the maximum value at a concentration of 0.05 mol/L before decreasing. Temperature increase benefits the emulsification rate and the activation energy of the emulsification process is 40.28 kJ/mol. Higher pH and stirring speed indicate faster emulsification rate. The heterogeneity of emulsions limits the accuracy of dynamic characterization of the emulsification process and the determination method of emulsification rate has always been controversial. The conductivity method we proposed can effectively evaluates the emulsification kinetics. This paper provides theoretical guidance for an in-depth understanding of the mechanism and application of cold recovery technology for heavy oil.

Investigation of the Role of Impeller Structural Parameters on Liquid-Liquid Mixing Characteristics in Stirred Tanks

Liquid-liquid mixings in stirred tanks are commonly found in many industries. In this study, we performed computational fluid dynamics (CFD) modeling and simulation to investigate the liquid-liquid mixing behavior. Furthermore, the population balance model (PBM) was used to characterize the droplet size distribution. The PBM model parameters were calibrated using the experimental data of droplet sizes at different agitation speeds. Additionally, we employed the steady-state Sauter mean droplet size to validate the developed CFD-PBM coupled model at different dispersion phase holdups. Then, the validated CFD-PBM coupled model was employed to evaluate the role of impeller structural parameters on the liquid-liquid mixing efficiency based on a user-defined mixing index. It was found that the position of impellers significantly affects the mixing efficiency, and an increase in stirring speed and the number of impellers improved the mixing efficiency.

Review of applications of electrical resistance tomography to chemical engineering

In spite of decades of study and investigation, the research on tomography and electrical resistance tomography (ERT) in particular, remains to be focus of immense scientific significance. ERT provides the ability to measure conductivity distribution inside a process plant and delivers time evolving multidimensional information. Such important and otherwise inaccessible information enhances critical process knowledge whilst improving the design and function of the process equipment. ERT has been employed in a variety of fields including chemical engineering. This paper reviews previous research carried out on the application of ERT within the chemical engineering arena. The applications are classified based on the objective of ERT measurements, the unit operations ERT has been utilized on, the media under examination, and also other technologies and data processing techniques used in combination with ERT. The objective of this taxonomy is to offer the reader with a broad insight into the current situation of ERT related research and developed applications in the chemical engineering field and to assist in the identification of research gaps for future investigation.

Rehydration characteristics of milk protein concentrate powders monitored by electrical resistance tomography

Electrical resistance tomography (ERT) is a robust and low-cost method offering real-time visualization of processes. In this work, we developed an ERT-based method to characterize the rehydration behavior of milk protein concentrate (MPC) powders. Circular-type and linear configurations were used to achieve high resolution in the radial and axial directions, respectively. To evaluate the rehydration profile, MPC powders were reconstituted to 2.5% (wt/wt) total solids at room temperature, and the rehydration behavior of the MPC powders [MPC with 85% protein (MPC85) and milk protein isolate with 90% protein (MPI90)] was monitored for a dissolution time of 30 min using the ERT system. The MPC powders were characterized in terms of overall mean conductivity, area under the mean conductivity curve, slope at a dissolution time of 3 min, and the relative dissolution index. Additionally, the focus beam reflectance measurement (FBRM) was used as a reference method to follow rehydration characteristics. Particle count changes from the FBRM measurements showed that MPI90 had higher larger particle counts and more resistance to dispersing in water. As the dissolution time proceeded, mineral ions and proteins were released and consequently increased the overall conductivity, confirming the transfer of water into MPC particles. At lower protein contents, the particle dispersion rate was higher and an increase in overall mean conductivity was observed, indicating better powder dissolution. Both configurations were able to effectively monitor differences in the dissolution behavior of MPC powders. In the ERT circular configuration, MPC85 and MPI90 showed maximum conductivity of 0.201 ± 0.006 and 0.162 ± 0.001 mS/cm, respectively. In the linear probe configuration, MPC85 and MPI90 showed maximum conductivity of 0.161 ± 0.001 and 0.136 ± 0.001 mS/cm, respectively, suggesting increasingly inhibited water transfer as the protein content of the powder increased. In this study, we demonstrated the capability of ERT using the circular and linear probe configurations to offer, in addition to qualitative tomographic images, reliable quantitative data by which to characterize the dissolution behavior of high-protein dairy powders.

Progressing Towards the Sustainable Development of Cream Formulations

This work aims at providing the assumptions to assist the sustainable development of cream formulations. Specifically, it envisions to rationalize and predict the effect of formulation and process variability on a 1% hydrocortisone cream quality profile, interplaying microstructure properties with product performance and stability. This tripartite analysis was supported by a Quality by Design approach, considering a three-factor, three-level Box-Behnken design. Critical material attributes and process parameters were identified from a failure mode, effects, and criticality analysis. The impact of glycerol monostearate amount, isopropyl myristate amount, and homogenization rate on relevant quality attributes was estimated crosswise. The significant variability in product droplet size, viscosity, thixotropic behavior, and viscoelastic properties demonstrated a noteworthy influence on hydrocortisone release profile (112 ± 2–196 ± 7 μg/cm²/√h) and permeation behavior (0.16 ± 0.03–0.97 ± 0.08 μg/cm²/h), and on the assay, instability index and creaming rate, with values ranging from 81.9 to 120.5%, 0.031 ± 0.012 to 0.28 ± 0.13 and from 0.009 ± 0.000 to 0.38 ± 0.07 μm/s, respectively. The release patterns were not straightforwardly correlated with the permeation behavior. Monitoring the microstructural parameters, through the balanced adjustment of formulation and process variables, is herein highlighted as the key enabler to predict cream performance and stability. Finally, based on quality targets and response constraints, optimal working conditions were successfully attained through the establishment of a design space.