Controlled Hydrodynamic Cavitation: A Review of Recent Advances and Perspectives for Greener Processing

Modifications of biological membranes, fat globules and liposomes promoted by cavitation processes. Consequences and applications

Cavitation-based technologies, such as ultrasound (or acoustic cavitation, AC) and hydrodynamic cavitation (HC), are gaining interest among green processing technologies due to their cost effectiveness in operation, toxic solvent use reduction, and ability to obtain superior processed products, compared to conventional methods. Both AC and HC generate bubbles, but their effects may differ and it is difficult to make comparisons as both are based on different phenomena and are subject to different operational variables. AC is one of the most used techniques in extraction and homogenization processes at the laboratory level. However, upscaling to an industrial level is hard. On the other hand, HC is based on the passage of the liquid through a constriction (orifice plate, Venturi, throttling valve), which causes an increase in liquid velocity at the expense of local pressure, forcing the pressure around the contraction below the threshold pressure that induces the formation of cavities. Some applications of cavitation technologies, such as the production of liposomes or lipid nanoparticles (LNPs) allow the generation of delivery systems for biomedical applications.Many others (inactivation of pathogenic viruses, bacteria and algae for water purification, extraction procedures, third generation of biofuel production, green extractions) are based on the disruption of lipid membranes. There are also applications aimed at the modification of membranes (like the milk fat globule) for the development of innovative products. Process parameters, such as cavitation intensity, duration and temperature define the impact of the process on the physical, chemical, and biological characteristics of the membranes. Thus, the adequate implementation of cavitation processes requires understanding of interactions and synergistic mechanisms in complex systems and of their effects on membranes at the microscopic or molecular level. In the present work, the use of cavitation technologies for the generation of LNPs or nanostructured lipid carriers, and the effects of AC and HC treatments on several types of membrane systems (liposomes, solid lipid nanoparticles, milk fat globules, algae and bacterial membranes) are discussed, focusing on the structural and chemical modifications of lipidic structures under cavitation.

Hydrodynamic Cavitation as a Method of Removing Surfactants from Real Carwash Wastewater

The present work aimed to evaluate whether the use of an innovative method such as hydrodynamic cavitation (HC) is suitable for the simultaneous removal of surfactants of different chemical natures (non-ionic, anionic and cationic) from actual car wash wastewater at different numbers of passes through the cavitation zone and different inlet pressures. An additional novelty was the use of multi-criteria decision support, which enabled the selection of optimal HC conditions that maximized the removal of each group of surfactants and chemical oxygen demand (COD) with minimal energy input. For the optimal HC variants, Fourier transform infrared spectroscopy (FT-IR/ATR) as well as investigations of surface tension, zeta potential, specific conductivity, system viscosity and particle size were carried out. The highest reduction of non-ionic surfactants was found at 5 bar inlet pressure and reached 35.5% after 120 min. The most favourable inlet pressure for the removal of anionic surfactants was 3 bar and the removal efficiency was 77.2% after 120 min, whereas the most favourable inlet pressure for cationic surfactant removal was 3 bar, with the highest removal of 20% after 120 min. The obtained results clearly demonstrate that HC may constitute an effective, fast and cost-efficient method for removing surfactants from real industrial wastewater.

Response surface optimization of a single-step castor oil-based biodiesel production process using a stator-rotor hydrodynamic cavitation reactor

In order to combat environmental pollution and the depletion of non-renewable fuels, feasible, eco-friendly, and sustainable biodiesel production from non-edible oil crops must be augmented. This study is the first to intensify biodiesel production from castor oil using a self-manufactured cylindrical stator-rotor hydrodynamic cavitation reactor. In order to model and optimize the biodiesel yield, a response surface methodology based on a 1/2 fraction-three-level face center composite design of three levels and five experimental factors was used. The predicted ideal operating parameters were found to be 52.51°C, 1164.8 rpm rotor speed, 27.43 min, 8.4:1 methanol-to-oil molar ratio, and 0.89% KOH concentration. That yielded 95.51% biodiesel with a 99% fatty acid methyl ester content. It recorded a relatively low energy consumption and high cavitation yield of 6.09 × 105 J and 12 × 10-3 g/J, respectively. The generated biodiesel and bio-/petro-diesel blends had good fuel qualities that were on par with global norms and commercially available Egyptian petro-diesel. The preliminary cost analysis assured the feasibility of the applied process.

Synergistic Degradation of Methylene Blue by Hydrodynamic Cavitation Combined with Hydrogen Peroxide/Vitamin C System

In this study, a new combined process of hydrodynamic cavitation (HC) and a hydrogen peroxide/vitamin C (H2O2/Vc) system was proposed for the degradation of methylene blue (MB) in wastewater. An impact-jet hydraulic cavitator was used as the cavitation generation equipment, and H2O2/Vc was selected as a homogeneous oxidation system. The degradation characteristics of MB were investigated. The results showed that the degradation effect of HC in combination with the H2O2/Vc system was more effective than that of the individual HC or H2O2/Vc system. A maximum degradation rate of 87.8% was achieved under the following conditions: H2O2 concentration of 0.03 mol/L, Vc concentration of 0.021 mol/L, inlet pressure of 0.3 MPa, initial solution concentration of 4 μmol/L, solution volume of 150 mL, and reaction time of 10 min. The synergy index was 1.615, indicating a synergistic effect between the HC and H2O2/Vc system. The data of the hydroxyl radical (·OH) yield under the conditions of HC, the H2O2/Vc system, and the HC + H2O2/Vc system were fitted and analyzed. A correlation equation for ·OH yield was established, further revealing the synergistic mechanism of the HC and H2O2/Vc system. The intermediate products of MB degradation were detected based on LC-MS, and three possible degradation pathways of MB degradation were proposed. The combined process of HC and H2O2/Vc systems exhibited relatively low energy efficiency and operating cost, indicating that it was in line with the development direction of wastewater treatment.

Kelvin-Helmholtz instability as one of the key features for fast and efficient emulsification by hydrodynamic cavitation

The paper investigates the oil-water emulsification process inside a micro-venturi channel. More specifically, the possible influence of Kelvin-Helmholtz instability on the emulsification process. High-speed visualizations were conducted inside a square venturi constriction with throat dimensions of 450 µm by 450 µm, both under visible light and X-Rays. We show that cavity shedding caused by the instability results in the formation of several cavity vortices. Their rotation causes the deformation of the oil stream into a distinct wave-like shape, combined with fragmentation into larger drops due to cavitation bubble collapse. Later on, the cavity collapse further disperses the larger drops into a finer emulsion. Thus, it turns out that the Kelvin-Helmholtz instability is similarly characteristic for hydrodynamic cavitation emulsification inside a microchannel as is the Rayleigh-Taylor instability for acoustically driven emulsion formation.

Enhanced fabrication of size-controllable chitosan-genipin nanoparticles using orifice-induced hydrodynamic cavitation: Process optimization and performance evaluation

Chitosan nanoparticles (NPs) possess great potential in biomedical fields. Orifice-induced hydrodynamic cavitation (HC) has been used for the enhancement of fabrication of size-controllable genipin-crosslinked chitosan (chitosan-genipin) NPs based on the emulsion cross-linking (ECLK). Experiments have been performed using various plate geometries, chitosan molecular weight and under different operational parameters such as inlet pressure (1-3.5 bar), outlet pressure (0-1.5 bar) and cross-linking temperature (40-70 °C). Orifice plate geometry was a crucial factor affecting the properties of NPs, and the optimized geometry of orifice plate was with single hole of 3.0 mm diameter. The size of NPs with polydispersity index of 0.359 was 312.6 nm at an optimized inlet pressure of 3.0 bar, and the maximum production yield reached 84.82 %. Chitosan with too high or too low initial molecular weight (e.g., chitosan oligosaccharide) was not applicable for producing ultra-fine and narrow-distributed NPs. There existed a non-linear monotonically-increasing relationship between cavitation number (Cv) and chitosan NP size. Scanning electron microscopy (SEM) test indicated that the prepared NPs were discrete with spherical shape. The study demonstrated the superiority of HC in reducing particle size and size distribution of NPs, and the energy efficiency of orifice type HC-processed ECLK was two orders of magnitude than that of ultrasonic horn or high shear homogenization-processed ECLK. In vitro drug-release studies showed that the fabricated NPs had great potential as a drug delivery system. The observations of this study can offer strong support for HC to enhance the fabrication of size-controllable chitosan-genipin NPs.

Can a Fraction of Flour and Sugar Be Replaced with Fruit By-Product Extracts in a Gluten-Free and Vegan Cookie Recipe?

Certain food by-products, including not-good-for-sale apples and pomegranate peels, are rich in bioactive molecules that can be collected and reused in food formulations. Their extracts, rich in pectin and antioxidant compounds, were obtained using hydrodynamic cavitation (HC), a green, efficient, and scalable extraction technique. The extracts were chemically and physically characterized and used in gluten-free and vegan cookie formulations to replace part of the flour and sugar to study whether they can mimic the role of these ingredients. The amount of flour + sugar removed and replaced with extracts was 5% and 10% of the total. Physical (dimensions, color, hardness, moisture content, water activity), chemical (total phenolic content, DPPH radical-scavenging activity), and sensory characteristics of cookie samples were studied. Cookies supplemented with the apple extract were endowed with similar or better characteristics compared to control cookies: high spread ratio, similar color, and similar sensory characteristics. In contrast, the pomegranate peel extract enriched the cookies in antioxidant molecules but significantly changed their physical and sensory characteristics: high hardness value, different color, and a bitter and astringent taste. HC emerged as a feasible technique to enable the biofortification of consumer products at a real scale with extracts from agri-food by-products.

Integrated physicochemical processes to tackle high-COD wastewater from pharmaceutical industry

Wastewater decontamination in pharmaceuticals is crucial to prevent environmental and health risks from API residues and other contaminants. Advanced oxidation processes (AOPs) combined with cavitational treatments offer effective solutions. Challenges include designing reactors on a large scale and monitoring the effectiveness and synergies of the hybrid technology. In the present work, pilot-scale treatment of a real high COD (485 g/L) pharmaceutical wastewater (PW) was investigated using hydrodynamic cavitation (HC) operated individually at 330 L/h or in combination with oxidants and electrical discharge (ED) with cold plasma (15 kV and 48 kHz). The first approach consisted of PW cavitational treatment alone of 7 L of 1:100 diluted PW at a HC-induced pressure of 60 bar and a flow rate of 330 L/h. However, this strategy did not provide satisfactory results for COD (∼15% less), and only when HC treatment was extended to more than 30 min in a recirculation mode, encouraging results were obtained (∼45% COD reduction). Consequently, a hybrid approach combining HC with ED-cold plasma was chosen to treat this high-COD PW. Aiming to establish an efficient flow-through hybrid process, after optimising all cavitation and electrical discharge parameters (45 bar HC pressure and 10 kHz ED frequency), the best COD abatement of ∼50 % was recorded with a 1:50 diluted PW. However, a subsequent adsorption step over activated carbon was required to achieve an almost quantitative COD reduction (95%+). Our integrated physicochemical process proved to be extremely efficient in treating high-COD industrial wastewater and resulted in a remarkable reduction of the COD value. In addition, the residual surfactants content in the PW were also drastically reduced (98%+) when a small amount of oxidants was added in the hybrid HC/ED treatment.

Hydrodynamic cavitation-enhanced activation of sodium percarbonate for estrogen removal

The present paper investigated the potential of hydrodynamic cavitation (HC) as an effective tool for activating sodium percarbonate (SPC). The method's efficiency was demonstrated by effectively removing estrogens, which are pollutants that have adverse impacts on aquatic ecosystems. The effects of the SPC concentration, temperature of solution, and cavitation time were evaluated. After SPC/HC treatment, the removal of estrogens was monitored by liquid chromatography-tandem mass spectrometry (LC -MS/MS). Already after 4 s of treatment and 24 h of reaction time, more than 97% of estrogens (initial concentration of 300 ng/L) were removed. The effect of post-treatment time is not considered in several papers, even though it seems to be crucial and is discussed here. The results were supported by the values of degradation rate constants, which fit the pseudo-first-order kinetic model. We also verified that HC alone was not effective for estrogen removal under the selected conditions. The sustainability of the SPC/HC system was evaluated based on electric energy per order calculation. The combination of SPC and HC is a promising approach for rapidly degrading micropollutants such as estrogenic compounds without the need for additional technological steps, such as pH or temperature adjustment.

Industrial application of microbubble generation methods for recovering fine particles through froth flotation: A review of the state-of-the-art and perspectives

The depletion of high-grade and coarse-grain ores has led to an increasing demand for the development of efficient separation technologies for low-grade and fine-grain ores. However, conventional froth flotation techniques are not adequate to efficiently recover fine and ultrafine particles (typically <10-15 μm) due to the low collision probability between these particles and the relatively large bubbles used in the process. The introduction of microbubbles has shown promise in enhancing particle recovery, making it a subject of significant interest. Thus, this review focuses on microbubble generation methods that have the potential to be scaled up for industrial applications, with a specific emphasis on their suitability for froth flotation. The methods are categorized based on their scalability: high-hydrodynamic cavitation, porous media/medium-dissolved air, electrolysis/low-microfluidics, and acoustic methods. The bubble generation mechanisms, characteristics, advantages and limitations of each method and its applications in froth flotation are discussed to provide suggestions for improvement. There is still no appropriate technology that can optimize bubble size distribution, production rate and cost together for industrial froth flotation application. Therefore, novel approaches of combining multiple methods are also explored to achieve the potential synergic effects. By addressing the limitations of current microbubble generation methods and proposing potential enhancements, this review aims to contribute to the development of efficient and cost-effective microbubble generation technologies for fine and ultrafine particles in the froth flotation industry.

Detergent Dissolution Intensification via Energy-Efficient Hydrodynamic Cavitation Reactors

In this study, we explored the potential of hydrodynamic cavitation (HC) for use in dissolution of liquid and powder detergents. For this, microfluidic and polyether ether ketone (PEEK) tube HC reactors with different configurations were employed, and the results from the reactors were compared with a magnetic stirrer, as well as a tergotometer. According to our results PEEK tube HC reactors present the best performance for dissolution of liquid and powder detergents. In the case of liquid detergent, for the same level of initial concentration and comparable final dissolution, the PEEK tube consumed 16.7 and 70% of the energy and time of a tergotometer and 16.7 and 14.8% of that of a magnetic stirrer, respectively. In the case of powder detergent, the PEEK tube used 12% less power than a tergotometer and 81.2% less power than a magnetic stirrer. Additionally, the time required to dissolve the detergent was reduced significantly from 1200 s in the tergotometer and 1800 s in the magnetic stirrer to just 50 s in the PEEK tube. These results suggest that HC could significantly improve the dissolution rate of liquid and powder detergents and energy consumption in washing machines.

Antioxidant Phytocomplexes Extracted from Pomegranate (Punica granatum L.) Using Hydrodynamic Cavitation Show Potential Anticancer Activity In Vitro

Hydrodynamic cavitation (HC), as an effective, efficient, and scalable extraction technique for natural products, could enable the affordable production of valuable antioxidant extracts from plant resources. For the first time, whole pomegranate (Punica granatum L.) fruits, rich in bioactive phytochemicals endowed with anti-cancer properties, were extracted in water using HC. Aqueous fractions sequentially collected during the process (M1-M5) were lyophilized (L), filtered (A), or used as such, i.e., crude (C), and analyzed for their biochemical profile and in vitro antioxidant power. The fractions M3 and M4 from the L and C series showed the highest antiradical activity and phytochemical content. While the lyophilized form is preferable for application purposes, sample L-M3, which was produced faster and with lower energy consumption than M4, was used to assess the potential antiproliferative effect on human breast cancer line (AU565-PAR) and peripheral blood mononuclear (PBMC) cells from healthy donors. In a pilot study, cell growth, death, and redox state were assessed, showing that L-M3 significantly reduced tumor cell proliferation and intracellular oxygen reactive species. No effect on PBMCs was detected. Thus, the antioxidant phytocomplex extracted from pomegranate quickly (15 min), at room temperature (30 °C), and efficiently showed potential anticancer activity without harming healthy cells.

Non-thermal, energy efficient hydrodynamic cavitation for food processing, process intensification and extraction of natural bioactives: A review

Hydrodynamic cavitation (HC) is the process of bubbles formation, expansion, and violent collapse, which results in the generation of high pressures in the order of 100-5000 bar and temperatures in the range of 727-9727 °C for just a fraction of seconds. Increasing consumer demand for high-quality foods with higher nutritive values and fresh-like sensory attributes, food processors, scientists, and process engineers are pushed to develop innovative and effective non-thermal methods as an alternative to conventional heat treatments. Hydrodynamic cavitation can play a significant role in non-thermal food processing as it has the potential to destroy microbes and reduce enzyme activity while retaining essential nutritional and physicochemical properties. As hydrodynamic cavitation occurs in a flowing liquid, there is a decrease in local pressure followed by its recovery; hence it can be used for liquid foods. It can also be used to create stable emulsions and homogenize food constituents. Moreover, this technology can extract food constituents such as polyphenols, essential oils, pigments, etc., via biomass pretreatment, cell disruption for selective enzyme release, waste valorization, and beer brewing. Other applications related to food production include water treatment, biodiesel, and biogas production. The present review discusses the application of HC in the preservation, processing, and quality improvement of food and other related applications. The reviewed examples in this paper demonstrate the potential of hydrodynamic cavitation with further expansion toward the scaling up, which looks at commercialization as a driving force.

An Overview of the Health Benefits, Extraction Methods and Improving the Properties of Pomegranate

Pomegranate (Punica granatum L.) is a polyphenol-rich edible food and medicinal plant of ancient origin, containing flavonols, anthocyanins, and tannins, with ellagitannins as the most abundant polyphenols. In the last decades, its consumption and scientific interest increased, due to its multiple beneficial effects. Pomegranate is a balausta fruit, a large berry surrounded by a thick colored peel composed of exocarp and mesocarp with edible arils inside, from which the pomegranate juice can be produced by pressing. Seeds are used to obtain the seed oil, rich in fatty acids. The non-edible part of the fruit, the peel, although generally disposed as a waste or transformed into compost or biogas, is also used to extract bioactive products. This review summarizes some recent preclinical and clinical studies on pomegranate, which highlight promising beneficial effects in several fields. Although further insight is needed on key aspects, including the limited oral bioavailability and the role of possible active metabolites, the ongoing development of suitable encapsulation and green extraction techniques enabling the valorization of waste pomegranate products point to the great potential of pomegranate and its bioactive constituents as dietary supplements or adjuvants in therapies of cardiovascular and non-cardiovascular diseases.

Impact of cavitation on the structure and functional quality of extracted protein from food sources - An overview

Increasing protein demands directly require additional resources to those presently and recurrently available. Emerging green technologies have witnessed an escalating interest in "Cavitation Processing" (CP) to ensure a non-invasive, non-ionizing and non-polluting extraction. The main intent of this review is to present an integrated summary of cavitation extraction methods specifically applied to food protein sources. Along with a comparative assessment carried out for each type of cavitation model, protein extraction yield and implications on the extracted protein's structural and functional properties. The basic principle of cavitation is due to the pressure shift in the liquid flow within milliseconds. Hence, cavitation emerges similar to boiling; however, unlike boiling (temperature change), cavitation occurs due to pressure change. Characterization and classification of sample type is also a prime candidate when considering the applications of cavitation models in food processing. Generally, acoustic and hydrodynamic cavitation is applied in food applications including extraction, brewing, microbial cell disruption, dairy processing, emulsification, fermentation, waste processing, crystallisation, mass transfer and production of bioactive peptides. Micro structural studies indicate that shear stress causes disintegration of hydrogen bonds and Van der Waals interactions result in the unfolding of the protein's secondary and/or tertiary structures. A change in the structure is not targeted but rather holistic and affects the physicochemical, functional, and nutritional properties. Cavitation assisted extraction of protein is typically studied at a laboratory scale. This highlights limitations against the application at an industrial scale to obtain potential commercial gains.

Green Surfactants (Biosurfactants): A Petroleum-Free Substitute for Sustainability-Comparison, Applications, Market, and Future Prospects

Surfactants are a group of amphiphilic molecules (i.e., having both hydrophobic and hydrophilic domains) that are a vital part of nearly every contemporary industrial process such as in agriculture, medicine, personal care, food, and petroleum. In general surfactants can be derived from (i) petroleum-based sources or (ii) microbial/plant origins. Petroleum-based surfactants are obvious results from petroleum products, which lead to petroleum pollution and thus pose severe problems to the environment leading to various ecological damages. Thus, newer techniques have been suggested for deriving surfactant molecules and maintaining environmental sustainability. Biosurfactants are surfactants of microbial or plant origins and offer much added advantages such as high biodegradability, lesser toxicity, ease of raw material availability, and easy applicability. Thus, they are also termed "green surfactants". In this regard, this review focused on the advantages of biosurfactants over the synthetic surfactants produced from petroleum-based products along with their potential applications in different industries. We also provided their market aspects and future directions that can be considered with selections of biosurfactants. This would open up new avenues for surfactant research by overcoming the existing bottlenecks in this field.

New Route to the Production of Almond Beverages Using Hydrodynamic Cavitation

Perceived as a healthy food, almond beverages are gaining ever-increasing consumer preference across nonalcoholic vegetable beverages, ranking in first place among oilseed-based drinks. However, costly raw material; time and energy consuming pre- and posttreatments such as soaking, blanching and peeling; and thermal sterilization hinder their sustainability, affordability and spread. Hydrodynamic cavitation processes were applied, for the first time, as a single-unit operation with straightforward scalability, to the extraction in water of almond skinless kernels in the form of flour and fine grains, and of whole almond seeds in the form of coarse grains, up to high concentrations. The nutritional profile of the extracts matched that of a high-end commercial product, as well as showing nearly complete extraction of the raw materials. The availability of bioactive micronutrients and the microbiological stability exceeded the commercial product. The concentrated extract of whole almond seeds showed comparatively higher antiradical activity, likely due to the properties of the almond kernel skin. Hydrodynamic cavitation-based processing might represent a convenient route to the production of conventional as well as integral and potentially healthier almond beverages, avoiding multiple technological steps, while affording fast production cycles and consuming less than 50 Wh of electricity per liter before bottling.

Optimization of combustion characteristics of novel hydrodynamic cavitation based waste cooking oil biodiesel fueled CI engine

The increment in the usage of automobiles is resulting in increased greenhouse gases (GHG) emissions continuously and there is a substantial need to reduce them effectively. The present research work investigates the emission behavior of waste cooking oil biodiesel doped with CuO nanoparticles during testing in Compression Ignition (CI) engines. This investigation is based on the effective emission reduction analysis emitted by diesel fuel during experimentation on CI engines. It suggests a cost effective modification of biodiesel as a fuel prepared from waste cooking oil (WCO) by a novel hydrodynamic cavitation technique which includes the hydrodynamic cavitation reaction mixture composed of 1.28 L of methanol and 10 g KOH and 5 L of preheated WCO at 45 °C in the cavitation reactor for 40 min. These reactants are synthesized utilizing the principle of cavitation and the final manufactured esterified oil is authenticated with ASTM Standard property measurement for suitability check. In the research work, two different investigations are carried out. In the first one, WCO biodiesel-diesel blends of 0, 30, and 100% (B0, B30, B100) ratio are prepared and the emission characteristics have investigated at 1500 rpm constant speed with varying load and indicated mean effective pressure (IMEP). In the second investigation, the emission suitable blend B30 is doped with CuO nanoparticles, keeping other parameters as per the previous setup, the emission characteristics investigated for the second one. For precise results, more experimental trials are needed to achieve this decrease in the emission of harmful gases. Using an amalgamation of L9 Taguchi and response surface methodology (RSM) the maximum emission control with a minimum number of experimental trials is achieved. The first investigation includes the predefined predictors as A (blend), B (load), and C (IMEP), where blends (0 ≤ A ≤ 100%), load (0 ≤ B ≤ 12 kg), IMEP (3.5 ≤ C ≤ 7.5 bar) are controllable features. Optimization process resulted into a minimum emission of CO, CO2, and NOx by appertaining the condemnatory merger of inputs such as blend B0 (Diesel), load 12 kg, and IMEP 3.48 bar in the first investigation, which has resulted into 0.08 ppm CO, 0.6 ppm CO2 and 30 ppm NOx emission. Taguchi analysis-based second experimental investigation includes the predefined predictors as A (CuO), B (load), and C (IMEP), including nanoparticles CuO in blend B30, and the prognosticated results of optimization are 0.03 ppm CO, 0.3 ppm CO2 and 21 ppm NOx emission. In current investigation, the percentage reduction is found to be 92.3%, 94.82%, and 96% compared to the emission of diesel in CO, CO2 and NOx gases, respectively. The coefficient of determination is almost equal to 1, which reveals the chosen optimization technique is very accurate in prediction. The investigation has provided suitable minimum emission characteristics in a cost-effective way.

Plant Extraction in Water: Towards Highly Efficient Industrial Applications

Since the beginning of this century, the world has experienced a growing need for enabling techniques and more environmentally friendly protocols that can facilitate more rational industrial production. Scientists are faced with the major challenges of global warming and safeguarding water and food quality. Organic solvents are still widely used and seem to be hard to replace, despite their enormous environmental and toxicological impact. The development of water-based strategies for the extraction of primary and secondary metabolites from plants on a laboratory scale is well documented, with several intensified processes being able to maximize the extraction power of water. Technologies, such as ultrasound, hydrodynamic cavitation, microwaves and pressurized reactors that achieve subcritical water conditions can dramatically increase extraction rates and yields. In addition, significant synergistic effects have been observed when using combined techniques. Due to the limited penetration depth of microwaves and ultrasonic waves, scaling up entails changes to reactor design. Nevertheless, the rich academic literature from laboratory-scale investigations may contribute to the engineering work involved in maximizing mass/energy transfer. In this article, we provide an overview of current and innovative techniques for solid-liquid extraction in water for industrial applications, where continuous and semi-continuous processes can meet the high demands for productivity, profitability and quality.

Using CFD simulations to investigate the shear stress in hydrodynamic cavitation reactors coupled with experimental validation using colony count measurements

The current work investigates the shear stress distribution in hydrodynamic cavitation reactors with two different geometries using CFD simulations. Venturi type (positive geometry) and bore (negative geometry) were used to induce cavitation. Experimental validation of the predictions from simulations was also conducted by calculating the reduction rate in the colony count of Legionella pneumophila, a pathogenic bacterial strain. Both the numerical and experimental studies revealed the significant influence of the shape of the cavitation-inducing geometry on the flow characteristics and the distribution of shear stress. The simulation data indicated high shear stress formation in the positive geometry as a venturi, with the cavitation ranges for the two reactors being far apart from each other. The experimental study also confirmed that the flow conditions in the venturi-type reactor were more favourable compared to the bore geometry, resulting in a bacterial reduction efficiency as high as 99.98%. It was clearly demonstrated that the geometry of the cavitating device plays a crucial role in deciding the shear stress and its efficacy for the desired applications as per the predictions of the simulation model validated by the experimental results.

Combined suppression effects on hydrodynamic cavitation performance in Venturi-type reactor for process intensification

Hydrodynamic cavitation is an emerging intensification technology in water treatment or chemical processing, and Venturi-type cavitation reactors exhibit advantages for industrial-scale production. The effects of temperature on hydrodynamic cavitating flows are investigated to find the optimum reaction conditions enhancing cavitating treatment intensity. Results show that the cavitation performance, including the cavitation intensity and cavitation unsteady behavior, is influenced by (1) cavitation number σ (the pressure difference affecting the vaporization process), (2) Reynolds number Re (the inertial/viscous ratio affecting the bubble size and liquid-vapor interface area), and (3) thermodynamic parameter Σ (the thermal effect affecting the temperature drop). With increasing temperature, the cavitation length first increases and then decreases, with a cavitation intensity peak at the transition temperature of 58 °C. With the growth of cavitation extent, the cavity-shedding regimes tend to transition from the attached sheet cavity to the periodic cloud cavity, and the vapor volume fluctuating frequency decreases accordingly. A combined suppression parameter (CSP) is provided to predict that, with increasing CSP value, the cavitation intensity can be decreased. Recommendations are given that working under the low-CSP range (55-60 °C) could enhance the intensification of the cavitation process.

Hydrodynamic cavitation for lignocellulosic biomass pretreatment: a review of recent developments and future perspectives

The hydrodynamic cavitation comes out as a promising route to lignocellulosic biomass pretreatment releasing huge amounts of energy and inducing physical and chemical transformations, which favor lignin-carbohydrate matrix disruption. The hydrodynamic cavitation process combined with other pretreatment processes has shown an attractive alternative with high pretreatment efficiency, low energy consumption, and easy setup for large-scale applications compared to conventional pretreatment methods. This present review includes an overview of this promising technology and a detailed discussion on the process of parameters that affect the phenomena and future perspectives of development of this area.

The effect of operating parameters of hydrodynamic cavitation – assisted alkaline catalyzed transesterification of sunflower oil with methanol on the degree of triglyceride conversion

The effect of operating parameters such as reaction mixture inlet pressure p 1 (101.3–1013.2 kPa), methanol to oil molar ratio M 1 (3–12), the concentration of catalyst C c (0.0–1.0 wt%), temperature T (25–50 °C) and the number of passes of the reaction mixture through the venturi type hydrodynamic cavitation reactor n (1–12) on alkali-catalyzed transesterification of sunflower oil with methanol assisted by hydrodynamic cavitation (ACTC) on the value of the degree of triglyceride conversion (DTC) was investigated. ACTC was performed by the venturi-type hydrodynamic cavitation reactor (VCR) of our construction. It was found that the values of DTC increase with the increase in p 1, M 1, C c, and n, and decrease with the increase in T. Cavitation yield (CY) values were calculated. The ACTC was proved to be the simplest, fastest, and most highly energy-efficient current technology for the production of biodiesel.

Sonoprocessing: From Concepts to Large-Scale Reactors

Intensification of ultrasonic processes for diversified applications, including environmental remediation, extractions, food processes, and synthesis of materials, has received attention from the scientific community and industry. The mechanistic pathways involved in intensification of ultrasonic processes that include the ultrasonic generation of cavitation bubbles, radical formation upon their collapse, and the possibility of fine-tuning operating parameters for specific applications are all well documented in the literature. However, the scale-up of ultrasonic processes with large-scale sonochemical reactors for industrial applications remains a challenge. In this context, this review provides a complete overview of the current understanding of the role of operating parameters and reactor configuration on the sonochemical processes. Experimental and theoretical techniques to characterize the intensity and distribution of cavitation activity within sonoreactors are compared. Classes of laboratory and large-scale sonoreactors are reviewed, highlighting recent advances in batch and flow-through reactors. Finally, examples of large-scale sonoprocessing applications have been reviewed, discussing the major scale-up and sustainability challenges.

Flow of Oil and Water through the Nozzle and Cavitation

Today, the correct understanding of the issue of oil and water cavitation is important due to the growing demands on working conditions in hydraulic systems (pressure and flow rate). This article deals with the measurement and subsequent mathematical modeling of cavitation in a convergent-divergent nozzle of circular cross-section. Cavitation depends on the physical properties of the flowing medium as a function of temperature. Usually, cavitation in water is defined by a two-phase flow of water and vapor, but the air contained in the water significantly affects cavitation. There is usually no vapor cavitation in the oil. Far more often, cavitation in oil is caused by the air it contains. For comparison, cavitation in water and oil was generated in experiments with an identical nozzle. The measurement was used to define boundary conditions in mathematical models and to verify simulations. The problem of cavitation was solved by three variants of multiphase flow, single-phase flow (water, oil), two-phase flow (water–vapor, oil–air) and three-phase flow (water–vapor–air, oil–vapor–air). A turbulent model with cavitation was used for all variants. The verification of simulations shows that for water cavitation it is necessary to use a three-phase model (water, vapor, air) and for oil cavitation a two-phase model (oil, air) is sufficient. The measurement results confirm the importance of the air phase in modeling cavitation in both water and oil.

Hydrodynamic cavitation: A feasible approach to intensify the emulsion cross-linking process for chitosan nanoparticle synthesis

Chitosan nanoparticles (NPs) exhibit great potential in drug-controlled release systems. A controlled hydrodynamic cavitation (HC) technique was developed to intensify the emulsion crosslinking process for the synthesis of chitosan NPs. Experiments were performed using a circular venturi and under varying operating conditions, i.e., types of oil, addition mode of glutaraldehyde (Glu) solution, inlet pressure (P_in), and rheological properties of chitosan solution. Palm oil was more appropriate for use as the oil phase for the HC-intensified process than the other oil types. The addition mode of water-in-oil (W/O) emulsion containing Glu (with Span 80) was more favorable than the other modes for obtaining a narrow distribution of chitosan NPs. The minimum size of NPs with polydispersity index of 0.342 was 286.5 nm, and the maximum production yield (P_y) could reach 47.26%. A positive correlation was found between the size of NPs and the droplet size of W/O emulsion containing chitosan at increasing P_in. Particle size, size distribution, and the formation of NPs were greatly dependent on the rheological properties of the chitosan solution. Fourier transform infrared spectroscopy (FTIR) analysis indicated that the molecular structure of palm oil was unaffected by HC-induced effects. Compared with ultrasonic horn, stirring-based, and conventional drop-by-drop processes, the application of HC to intensify the emulsion crosslinking process allowed the preparation of a finer and a narrower distribution of chitosan NPs in a more energy-efficient manner. The novel route developed in this work is a viable option for chitosan NP synthesis.

Nanobubble technology in anaerobic digestion: A review

Nanobubble technology has significant potential to improve the anaerobic digestion (AD) process by ameliorating the rate-limiting steps of hydrolysis and methanogenesis, as well as providing process stability by reducing sulfide and volatile fatty acid (VFA) levels. Nanobubbles (NB) can enhance substrate accessibility, digestibility, and enzymatic activity due to their minuscule size, high electrostatic interaction, and ability to generate reactive oxygen species. Air- and O₂-NB can create a microaerobic environment for higher efficiency of the electron transport system, thereby reducing VFAs through enhanced facultative bacterial activity. Additionally, H₂- and CO₂-NB can improve hydrogenotrophic methanogenesis. Recently, several studies have employed NB technology in the AD process. There is, however, a lack of concise, synthesized information on NB applications to the AD process. This review provides an in-depth discussion on the NB-integrated AD process and the putative mechanisms involved. General discussions on other potential applications and future research directions are also provided.

Two-stage continuous production process for fatty acid methyl ester from high FFA crude palm oil using rotor-stator hydrocavitation

Two-stage continuous production process for fatty acid methyl ester (FAME) from crude palm oil was performed using the rotor-stator hydrocavitation reactor. The novel ABS filament printed rotor having spherical holes on the surface of the rotor which is an efficient, fast and cost-effective procedure, was installed in the stainless steel stator of hydrosonic reactor. The 3D printed hydrosonic reactor was used to treat the FFA-rich in MCPO by esterification and followed by transesterification to produce the methyl ester. The optimum conditions of both esterification and transesterification processes were determined using the response surface methodology (RSM). For the 1st step esterification, the conditions of methanol 17.7 vol%, sulfuric acid 2.9 vol%, 3000 rpm rotor speed, hole's diameter and depth 4 and 6 mm, and 25 L/h MCPO, were used for decreasing the FFA from 11.456 to 1.028 wt%. For the 2nd step, transesterification was employed with the optimal condition of 28.6 vol% methanol, 6.2 g/L of potassium hydroxide, 3000 rpm rotor speed, the dimension of the spherical holes on the rotor's surface having diameter of 6.4 mm and 6.2 mm in depth, and esterified oil flow rate 25 L/h, for producing the methyl ester to over 99.163 wt%. Moreover, the purified biodiesel yields and the average energy consumption for the entire two-stage continuous process between hydrosonic and ultrasonic clamp reactors were compared. The results of purified methyl ester clearly indicate that the methyl esters of 99.163 wt% and 97.814 wt% were achieved from hydrosonic and ultrasonic clamp reactors, respectively, under the same optimized conditions. The maximum yields of purified biodiesel were 97.51 vol% and 88.69 vol% using hydrosonic and ultrasonic clamp reactors, respectively. The average energy consumption for the entire continuous two-stage process for both hydrosonic and ultrasonic clamp reactors were 0.049 and 0.056 kW h/L, respectively. For practical industrial processes, stainless steel rotors inside the stator was manufactured by CNC machine, which was also verified under the optimum conditions. The results showed that 1.07 wt% FFA and 99.221 wt% methyl ester of were obtained from first step and second step, respectively.

Degradation of Antibiotics in Wastewater: New Advances in Cavitational Treatments

Over the past few decades, antibiotics have been considered emerging pollutants due to their persistence in aquatic ecosystems. Even at low concentrations, these pollutants contribute to the phenomenon of antibiotic resistance, while their degradation is still a longstanding challenge for wastewater treatment. In the present literature survey, we review the recent advances in synergistic techniques for antibiotic degradation in wastewater that combine either ultrasound (US) or hydrodynamic cavitation (HC) and oxidative, photo-catalytic, and enzymatic strategies. The degradation of sulfadiazine by HC/persulfate (PS)/H2O2/α-Fe2O3, US/PS/Fe0, and sono-photocatalysis with MgO@CNT nanocomposites processes; the degradation of tetracycline by US/H2O2/Fe3O4, US/O3/goethite, and HC/photocatalysis with TiO2 (P25) sono-photocatalysis with rGO/CdWO4 protocols; and the degradation of amoxicillin by US/Oxone®/Co2+ are discussed. In general, a higher efficiency of antibiotics removal and a faster structure degradation rate are reported under US or HC conditions as compared with the corresponding silent conditions. However, the removal of ciprofloxacin hydrochloride reached only 51% with US-assisted laccase-catalysis, though it was higher than those using US or enzymatic treatment alone. Moreover, a COD removal higher than 85% in several effluents of the pharmaceutical industry (500-7500 mg/L COD) was achieved by the US/O3/CuO process.

Review of Evidence Available on Hesperidin-Rich Products as Potential Tools against COVID-19 and Hydrodynamic Cavitation-Based Extraction as a Method of Increasing Their Production

Based on recent computational and experimental studies, hesperidin, a bioactive flavonoid abundant in citrus peel, stands out for its high binding affinity to the main cellular receptors of SARS-CoV-2, outperforming drugs already recommended for clinical trials. Thus, it is very promising for prophylaxis and treatment of COVID-19, along with other coexistent flavonoids such as naringin, which could help restraining the proinflammatory overreaction of the immune system. Controlled hydrodynamic cavitation processes showed the highest speed, effectiveness and efficiency in the integral and green aqueous extraction of flavonoids, essential oils and pectin from citrus peel waste. After freeze-drying, the extracted pectin showed high quality and excellent antioxidant and antibacterial activities, attributed to flavonoids and essential oils adsorbed and concentrated on its surface. This study reviews the recent evidence about hesperidin as a promising molecule, and proposes a feasible and affordable process based on hydrodynamic cavitation for the integral aqueous extraction of citrus peel waste resulting in hesperidin-rich products, either aqueous extracts or pectin tablets. The uptake of this process on a relevant scale is urged, in order to achieve large-scale production and distribution of hesperidin-rich products. Meanwhile, experimental and clinical studies could determine the effective doses either for therapeutic and preventive purposes.