Continuous double-step acid catalyzed esterification production of sludge palm oil using 3D-printed rotational hydrodynamic cavitation reactor

Sludge palm oil (SPO) with high free fatty acid (FFA) content was processed using a continuous and double-step esterification production process in a rotor-stator-type hydrodynamic cavitation reactor. Three-dimensional printed rotor was made of plastic filament and acted as a major element in minimizing the FFA content in SPO. To evaluate the reduced level of FFAs using both methods, five independent factors were varied: methanol content, sulphuric acid content (H₂SO₄), hole diameter, hole depth, and rotor speed. The first-step conditions for the esterification process included 60.8 vol% methanol content, 7.2 vol% H₂SO₄ content, 5.0 mm diameter of the hole, 6.1 mm depth of the hole, and 3000 rpm speed of the rotor. The initial free fatty acid content decreased from 89.16 wt% to 35.00 wt% by the predictive model, while 36.69 wt% FFA level and 94.4 vol% washed first-esterified oil yield were obtained from an actual experiment. In the second-step, 1.0 wt% FFA was achieved under the following conditions: 44.5 vol% methanol content, 3.0 vol% H₂SO₄ content, 4.6 mm hole diameter, 5.8 mm hole depth, and 3000 rpm rotor speed. The actual experiment produced 0.94 wt% FFA content and 93.9 vol% washed second-esterified oil yield. The entire process required an average electricity of 0.137 kWh/L to reduce the FFA level in the SPO below 1 wt%.     

Biodiesel production process intensification using a rotor-stator type generator of hydrodynamic cavitation

Triglyceride transesterification for biodiesel production is a model reaction which is used to compare the conversion efficiency, yield, reaction time, energy consumption, scalability and cost estimation of different reactor technology and energy source. This work describes an efficient, fast and cost-effective procedure for biodiesel preparation using a rotating generator of hydrodynamic cavitation (HC). The base-catalyzed transesterification (methanol/sodium hydroxide) has been carried out using refined and bleached palm oil and waste vegetable cooking oil. The novel HC unit is a continuous rotor-stator type reactor in which reagents are directly fed into the controlled cavitation chamber. The high-speed rotation of the reactor creates micron-sized droplets of the immiscible reacting mixture leading to outstanding mass and heat transfer and enhancing the kinetics of the transesterification reaction which completes much more quickly than traditional methods. All the biodiesel samples obtained respect the ASTM standard and present fatty acid methyl ester contents of >99% m/m in both feedstocks. The electrical energy consumption of the HC reactor is 0.030 kW h per L of produced crude biodiesel, making this innovative technology really quite competitive. The reactor can be easily scaled-up, from producing a few hundred to thousands of liters of biodiesel per hour while avoiding the risk of orifices clogging with oil impurities, which may occur in conventional HC reactors. Furthermore it requires minimal installation space due to its compact design, which enhances overall security.     

Investigation of ammonia stripping with a hydrodynamic cavitation reactor

Ammonia is a commonly used compound in the domestic and industrial fields. If ammonia found in wastewater after use is not treated, even at low concentrations it may cause toxic effects in the receiving environment. In this study, a hydrodynamic cavitation reactor (HDC) was designed with the aim of removing ammonia. The effect of parameters like different cavitation numbers, airflow, temperature and initial concentration on NH₃ removal was researched. The potential of hydrodynamic cavitation for removal of volatile gases, like NH₃, was assessed with the aid of two film theory mathematical equations. Experimental studies were performed at fixed pH = 11. Under the conditions of 0.12 cavitation number, 25 L/min airflow, 30 °C temperature and 2500 mg/L initial concentration, in 24 h 98.4% NH₃ removal efficiency was achieved. With the same experimental conditions without any air, the HDC reactor provided 89.5% NH₃ removal at the end of 24 h.The HDC reactor is very effective for the removal of volatile gases from wastewater and it was concluded that even in the absence of aeration, the desired NH₃ removal efficiency was provided.     

Sustained release formulations of citronella oil nanoemulsion using cavitational techniques

Nanoemulsion synthesis has proven to be an effective way for transportation of immobile, insoluble bioactive compounds. Citronella Oil (lemongrass oil), a natural plant extract, can be used as a mosquito repellent and has less harmful effects compared to its available market counterpart DEET (N, N-Diethyl-meta-toluamide). Nanoemulsion of citronella oil in water was prepared using cavitation-assisted techniques while investigating the effect of system parameters like HLB (Hydrophilic Lipophilic Balance), surfactant concentration, input energy density and mode of power input on emulsion quality. The present work also examines the effect of emulsification on release rate to understand the relationship between droplet size and the release rate. Minimum droplet size (60 nm) of the emulsion was obtained at HLB of 14, S/O¹ ratio of 1.0, ultrasound amplitude of 50% and irradiation time of 5 min. This study revealed that hydrodynamic cavitation-assisted emulsification is more energy efficient compared to ultrasonic emulsification. It was also found that the release rate of nanoemulsion enhanced as the droplet size of emulsion reduced.     

Cavitation characteristics analysis of a novel rotor-radial groove hydrodynamic cavitation reactor

Hydrodynamic cavitation was widely used in sterilization, emulsion preparation and other industrial fields. Cavitation intensity is the key performance index of hydrodynamic cavitation reactor. In this study, a novel rotor-radial groove (RRG) hydrodynamic cavitation reactor was proposed with good cavitation intensity and energy utilization. The cavitation performances of RRG hydrodynamic cavitation reactor was analyzed by utilizing computational fluid dynamics method. The cavitation intensity and the cavitation energy efficiency were used as evaluation indicators for RRG hydrodynamic cavitation reactor with different internal structures. The amount of generated cavitation for various shapes of the CGU, interaction distances and rotor speed were analyzed. The evolution cycle of cavitation morphology is periodicity (0.46 ms) in the CGU of RRG hydrodynamic cavitation reactor. The main cavitation regions of CGU were the outflow and inflow separation zones. The cavitation performance of rectangular-shaped CGU was better than the cylindrical-shaped CGU. In addition, the cavitation performance could be improved more effectively by increasing the rotor speed and decreasing the interaction distance. The research results could provide theoretical support for the research of cavitation mechanism of cavitation equipment.     

Intensification of biogas production using pretreatment based on hydrodynamic cavitation

The present work investigates the application of hydrodynamic cavitation (HC) for the pretreatment of wheat straw with an objective of enhancing the biogas production. The hydrodynamic cavitation reactor is based on a stator and rotor assembly. The effect of three different speeds of rotor (2300, 2500, 2700 rpm), wheat straw to water ratios (0.5%, 1% and 1.5% wt/wt) and also treatment times as 2, 4 and 6 min have been investigated in the work using the design of experiments (DOE) approach. It was observed that the methane yield of 31.8 ml was obtained with untreated wheat straw whereas 77.9 ml was obtained with HC pre-treated wheat straw confirming the favourable changes during the pre-treatment. The combined pre-treatment using KOH and HC gave maximum yield of biogas as 172.3 ml. Overall, it has been established that significant enhancement in the biogas production can be obtained due to the pretreatment using HC which can also be further intensified by combination with chemical treatment.     

The effects of waste-activated sludge pretreatment using hydrodynamic cavitation for methane production

Disintegration of waste-activated sludge (WAS) is regarded as a prerequisite of the anaerobic digestion (AD) process to reduce sludge volume and increase methane yield. Hydrodynamic cavitation (HC), which shares a similar underlying principle with ultrasonication but is energy-efficient, was employed as a physical means to break up WAS. Compared with ultrasonic (180–3600 kJ/kg TS) and thermal methods (72,000 kJ/kg TS), HC (60–1200 kJ/kg TS) found to consume significantly low power. A synergetic effect was observed when HC was combined with alkaline treatment in which NaOH, KOH, and Ca(OH)₂ were used as alkaline catalysts at pH ranging from 8 to 13. As expected, the production yield of CH₄ gas increased proportionally as WAS disintegration proceeded. HC, when combined with alkaline pretreatment, was found to be a cost-effective substitute to conventional methods for WAS pretreatment.     

Disinfection characteristics of an advanced rotational hydrodynamic cavitation reactor in pilot scale

Hydrodynamic cavitation is a promising technique for water disinfection. In the present paper, the disinfection characteristics of an advanced hydrodynamic cavitation reactor (ARHCR) in pilot scale were studied. The effects of various flow rates (1.4–2.6 m³/h) and rotational speeds (2600–4200 rpm) on the removal of Escherichia coli (E. coli) were revealed and analyzed. The variation regularities of the log reduction and reaction rate constant at various cavitation numbers were established. A disinfection rate of 100% was achieved in only 4 min for 15 L of simulated effluent under 4200 rpm and 1.4 m³/h, with energy efficiency at 0.0499 kWh/L. A comprehensive comparison with previously introduced HCRs demonstrates the superior performance of the presented ARHCR system. The morphological changes in E. coli were studied by scanning electron microscopy. The results indicate that the ARHCR can lead to serious cleavage and surface damages to E. coli, which cannot be obtained by conventional HCRs. Finally, a possible damage mechanism of the ARHCR, including both the hydrodynamical and sonochemical effects, was proposed. The findings of the present study can provide strong support to the fundamental understanding and applications of ARHCRs for water disinfection.     

Shear-induced hydrodynamic cavitation as a tool for pharmaceutical micropollutants removal from urban wastewater

In this study, the removal of clofibric acid, ibuprofen, naproxen, ketoprofen, carbamazepine and diclofenac residues from wastewater, using a novel shear-induced cavitation generator has been systematically studied. The effects of temperature, cavitation time and H₂O₂ dose on removal efficiency were investigated. Optimisation (50 °C; 15 min; 340 mg L⁻¹ of added H₂O₂) resulted in removal efficiencies of 47–86% in spiked deionised water samples. Treatment of actual wastewater effluents revealed that although matrix composition reduces removal efficiency, this effect can be compensated for by increasing H₂O₂ dose (3.4 g L⁻¹) and prolonging cavitation time (30 min). Hydrodynamic cavitation has also been investigated as either a pre- or a post-treatment step to biological treatment. The results revealed a higher overall removal efficiency of recalcitrant diclofenac and carbamazepine, when hydrodynamic cavitation was used prior to as compared to post biological treatment i.e., 54% and 67% as compared to 39% and 56%, respectively. This is an important finding since diclofenac is considered as a priority substance to be included in the EU Water Framework Directive.     

Multi-objective optimization of the cavitation generation unit structure of an advanced rotational hydrodynamic cavitation reactor

Hydrodynamic cavitation (HC) has been widely considered a promising technique for industrial-scale process intensifications. The effectiveness of HC is determined by the performance of hydrodynamic cavitation reactors (HCRs). The advanced rotational HCRs (ARHCRs) proposed recently have shown superior performance in various applications, while the research on the structural optimization is still absent. The present study, for the first time, identifies optimal structures of the cavitation generation units of a representative ARHCR by combining genetic algorithm (GA) and computational fluid dynamics, with the objectives of maximizing the total vapor volume, $V_{\mathit{vapor}}$ , and minimizing the total torque of the rotor wall, ${\overrightarrow{M}}_z$ . Four important geometrical factors, namely, diameter (D), interaction distance (s), height (h), and inclination angle (θ), were specified as the design variables. Two high-performance fitness functions for $V_{\mathit{vapor}}$ and ${\overrightarrow{M}}_z$ were established from a central composite design with 25 cases. After performing 10,001 simulations of GA, a Pareto front with 1630 non-dominated points was obtained. The results reveal that the values of s and θ of the Pareto front concentrated on their lower (i.e., 1.5 mm) and upper limits (i.e., 18.75°), respectively, while the values of D and h were scattered in their variation regions. In comparison to the original model, a representative global optimal point increased the $V_{\mathit{vapor}}$ by 156% and decreased the ${\overrightarrow{M}}_z$ by 14%. The corresponding improved mechanism was revealed by analyzing the flow field. The findings of this work can strongly support the fundamental understanding, design, and application of ARHCRs for process intensifications.     

Experimental and numerical studies on the cavitation in an advanced rotational hydrodynamic cavitation reactor for water treatment

Hydrodynamic cavitation (HC) has emerged as one of the most potential technologies for industrial-scale water treatment. The advanced rotational hydrodynamic cavitation reactors (ARHCRs) that appeared recently have shown their high effectiveness and economical efficiency compared with conventional devices. For the interaction-type ARHCRs where cavitation is generated from the interaction between the cavitation generation units (CGUs) located on the rotor and the stator, their flow field, cavitation generation mechanism, and interaction process are still not well defined. The present study experimentally and numerically investigated the cavitation flow characteristics in a representative interaction-type ARHCR which has been proposed in the past. The cavitation generation mechanism and development process, which was categorized into “coinciding”, “leaving”, and “approaching” stages, were analyzed explicitly with experimental flow visualization and computational fluid dynamics (CFD) simulations. The changes in the cavitation pattern, area ratio, and sheet cavitation length showed high periodicity with a period of 0.5 ms/cycle at a rotational speed of 3,600 rpm in the flow visualization. The experimental and CFD results indicated that sheet cavitation can be generated on the downstream sides of both the moving and the static CGUs. The sheet cavitation was induced and continuously enlarged in the “leaving” and “approaching” stages and was crushed after the moving CGUs coincided with the static CGUs. In addition, vortex cavitation was formed in the vortex center of each CGU due to high-speed rotating fluid motion. The shape and size of the vortex cavitation were determined by the compression effect produced by the interaction. The findings of this work are important for the fundamental understanding, design, and application of the ARHCRs in water treatment.     

Degradation of imidacloprid using combined advanced oxidation processes based on hydrodynamic cavitation

The harmful effects of wastewaters containing pesticides or insecticides on human and aquatic life impart the need of effectively treating the wastewater streams containing these contaminants. In the present work, hydrodynamic cavitation reactors have been applied for the degradation of imidacloprid with process intensification studies based on different additives and combination with other similar processes. Effect of different operating parameters viz. concentration (20–60 ppm), pressure (1–8 bar), temperature (34 °C, 39 °C and 42 °C) and initial pH (2.5–8.3) has been investigated initially using orifice plate as cavitating device. It has been observed that 23.85% degradation of imidacloprid is obtained at optimized set of operating parameters. The efficacy of different process intensifying approaches based on the use of hydrogen peroxide (20–80 ppm), Fenton’s reagent (H₂O₂:FeSO₄ ratio as 1:1, 1:2, 2:1, 2:2, 4:1 and 4:2), advanced Fenton process (H₂O₂:Iron Powder ratio as 1:1, 2:1 and 4:1) and combination of Na₂S₂O₈ and FeSO₄ (FeSO₄:Na₂S₂O₈ ratio as 1:1, 1:2, 1:3 and 1:4) on the extent of degradation has been investigated. It was observed that near complete degradation of imidacloprid was achieved in all the cases at optimized values of process intensifying parameters. The time required for complete degradation of imidacloprid for approach based on hydrogen peroxide was 120 min where as for the Fenton and advance Fenton process, the required time was only 60 min. To check the effectiveness of hydrodynamic cavitation with different cavitating devices, few experiments were also performed with the help of slit venturi as a cavitating device at already optimized values of parameters. The present work has conclusively established that combined processes based on hydrodynamic cavitation can be effectively used for complete degradation of imidacloprid.     

Oxidation of Sulphur pollutants in model and real fuels using hydrodynamic cavitation

Hydrodynamic Cavitation (HC) offers an attractive platform for intensifying oxidative desulphurization of fuels. In the first part of this work, we present new results on oxidising single ring thiophene in a model fuel over the extended range of volume fraction of organic phase from 2.5 to 80 v/v %. We also present influence of type and scale of HC device on performance of oxidative desulphurization. Further experiments revealed that oxidising radicals generated in-situ by HC alone were not able to oxidise dual ring thiophenes. External catalyst (formic acid) and oxidising agents (hydrogen peroxide, H₂O₂) were therefore used with HC. Based on our prior work with acoustic cavitation (AC), the volumetric ratios for H₂O₂ and formic acid were identified as 0.95 v/v % and 6.25 v/v % respectively. The data of oxidation of dual ring thiophenes with n-dodecane and n-hexane as model fuels and typical transport fuels (diesel, kerosene, and petrol) using these oxidant and catalyst is presented. The observed performance with HC was compared with results obtained from a stirred tank and AC set-up. The presented data indicates that HC is able to intensify oxidation of sulphur species. The presented results provide a sound basis for further developments on HC based oxidative desulphurization processes.     

Degradation of reactive orange 4 dye using hydrodynamic cavitation based hybrid techniques

In the present work, degradation of reactive orange 4 dye (RO4) has been investigated using hydrodynamic cavitation (HC) and in combination with other AOP’s. In the hybrid techniques, combination of hydrodynamic cavitation and other oxidizing agents such as H₂O₂ and ozone have been used to get the enhanced degradation efficiency through HC device. The hydrodynamic cavitation was first optimized in terms of different operating parameters such as operating inlet pressure, cavitation number and pH of the operating medium to get the maximum degradation of RO4. Following the optimization of HC parameters, the degradation of RO4 was carried out using the combination of HC with H₂O₂ and ozone. It has been found that the efficiency of the HC can be improved significantly by combining it with H₂O₂ and ozone. The mineralization rate of RO4 increases considerably with 14.67% mineralization taking place using HC alone increases to 31.90% by combining it with H₂O₂ and further increases to 76.25% through the combination of HC and ozone. The synergetic coefficient of greater than one for the hybrid processes of HC + H₂O₂ and HC + Ozone has suggested that the combination of HC with other oxidizing agents is better than the individual processes for the degradation of dye effluent containing RO4. The combination of HC with ozone proves to be the most energy efficient method for the degradation of RO4 as compared to HC alone and the hybrid process of HC and H₂O₂.     

Degradation of dichlorvos using hydrodynamic cavitation based treatment strategies

The degradation of an aqueous solution of dichlorvos, a commonly used pesticide in India, has been systematically investigated using hydrodynamic cavitation reactor. All the experiments have been carried out using a 20 ppm solution of commercially available dichlorvos. The effect of important operating parameters such as inlet pressure (over a range 3-6 bar), temperature (31 °C, 36 °C and 39 °C) and pH (natural pH = 5.7 and acidic pH = 3) on the extent of degradation has been investigated initially. It has been observed that an optimum value of pressure gives maximum degradation whereas low temperature and pH of 3 are favorable. Intensification studies have been carried out using different additives such as hydrogen peroxide, carbon tetrachloride, and Fenton’s reagent. Use of hydrogen peroxide and carbon tetrachloride resulted in the enhancement of the extent of degradation at optimized conditions but significant enhancement was obtained with the combined use of hydrodynamic cavitation and Fenton’s chemistry. The maximum extent of degradation as obtained by using a combination of hydrodynamic cavitation and Fenton’s chemistry was 91.5% in 1 h of treatment time. The present work has conclusively established that hydrodynamic cavitation in combination with Fenton’s chemistry can be effectively used for the degradation of dichlorvos.     

Degradation of diclofenac sodium using combined processes based on hydrodynamic cavitation and heterogeneous photocatalysis

Diclofenac sodium, a widely detected pharmaceutical drug in wastewater samples, has been selected as a model pollutant for degradation using novel combined approach of hydrodynamic cavitation and heterogeneous photocatalysis. A slit venturi has been used as cavitating device in the hydrodynamic cavitation reactor. The effect of various operating parameters such as inlet fluid pressure (2–4 bar) and initial pH of the solution (4–7.5) on the extent of degradation have been studied. The maximum extent of degradation of diclofenac sodium was obtained at inlet fluid pressure of 3 bar and initial pH as 4 using hydrodynamic cavitation alone. The loadings of TiO₂ and H₂O₂ have been optimised to maximise the extent of degradation of diclofenac sodium. Kinetic study revealed that the degradation of diclofenac sodium fitted first order kinetics over the selected range of operating protocols. It has been observed that combination of hydrodynamic cavitation with UV, UV/TiO₂ and UV/TiO₂/H₂O₂ results in enhanced extents of degradation as compared to the individual schemes. The maximum extent of degradation as 95% with 76% reduction in TOC has been observed using hydrodynamic cavitation in conjunction with UV/TiO₂/H₂O₂ under the optimised operating conditions. The diclofenac sodium degradation byproducts have been identified using LC/MS analysis.     

Development of a novel electric field-assisted modified hydrodynamic cavitation system for disintegration of waste activated sludge

In this current study, we present a modified hydrodynamic cavitation device that combines an electric field to substitute for the chemical addition. A modified HC system is basically an orifice plate and crisscross pipe assembly, in which the crisscross pipe imparts some turbulence, which creates collision events. This study shows that for maximizing disintegration, combining HC system, which called electric field-assisted modified orifice plate hydrodynamic cavitation (EFM-HC) in this study, with an electric field is important. Various HC systems were compared in terms of disintegration of WAS, and, among them, the EFM-HC system exhibited the best performance with the highest disintegration efficiency of 47.0 ± 2.0% as well as the destruction of WAS morphological characteristics. The experimental results clearly show that a conventional HC system was successfully modified. In addition, electric field has a great potential for efficient disintegration of WAS for as a additional option in a combination treatment. This study suggests continued research in this field may lead to an appropriate design for commercial use.     

Degradation of 2,4-dinitrophenol using a combination of hydrodynamic cavitation,chemical and advanced oxidation processes

In the present work, degradation of 2,4-dinitrophenol (DNP), a persistent organic contaminant with high toxicity and very low biodegradability has been investigated using combination of hydrodynamic cavitation (HC) and chemical/advanced oxidation. The cavitating conditions have been generated using orifice plate as a cavitating device. Initially, the optimization of basic operating parameters have been done by performing experiments over varying inlet pressure (over the range of 3–6 bar), temperature (30 °C, 35 °C and 40 °C) and solution pH (over the range of 3–11). Subsequently, combined treatment strategies have been investigated for process intensification of the degradation process. The effect of HC combined with chemical oxidation processes such as hydrogen peroxide (HC/H₂O₂), ferrous activated persulfate (HC/Na₂S₂O₈/FeSO₄) and HC coupled with advanced oxidation processes such as conventional Fenton (HC/FeSO₄/H₂O₂), advanced Fenton (HC/Fe/H₂O₂) and Fenton-like process (HC/CuO/H₂O₂) on the extent of degradation of DNP have also been investigated at optimized conditions of pH 4, temperature of 35 °C and inlet pressure of 4 bar. Kinetic study revealed that degradation of DNP fitted first order kinetics for all the approaches under investigation. Complete degradation with maximum rate of DNP degradation has been observed for the combined HC/Fenton process. The energy consumption analysis for hydrodynamic cavitation based process has been done on the basis of cavitational yield. Degradation intermediates have also been identified and quantified in the current work. The synergistic index calculated for all the combined processes indicates HC/Fenton process is more feasible than the combination of HC with other Fenton like processes.     

Decolorization of azo dyes Orange G using hydrodynamic cavitation coupled with heterogeneous Fenton process

The present work demonstrates the application of the combination of hydrodynamic cavitation (HC) and the heterogeneous Fenton process (HF, Fe⁰/H₂O₂) for the decolorization of azo dye Orange G (OG). The effects of main affecting operation conditions such as the inlet fluid pressure, initial concentration of OG, H₂O₂ and zero valent iron (ZVI), the fixed position of ZVI, and medium pH on decolorization efficiency were discussed with guidelines for selection of optimum parameters. The results revealed that the acidic conditions are preferred for OG decolorizaiton. The decolorization rate increased with increasing H₂O₂ and ZVI concentration and decreased with increasing OG initial concentration. Besides, the decolorization rate was strongly dependent on the fixed position of ZVI. The analysis results of degradation products using liquid chromatography–ESI–TOF mass spectrometry revealed that the degradation mechanism of OG proceeds mainly via reductive cleavage of the azo linkage due to the attack of hydroxyl radical. The present work has conclusively established that the combination of HC and HF can be more energy efficient and gives higher decolorization rate of OG as compared with HC and HF alone.