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.     

Continuous production of nanoemulsion for skincare product using a 3D-printed rotor-stator hydrodynamic cavitation reactor

In this study, nanoemulsions for skincare products were continuously produced using a hydrodynamic cavitation reactor (HCR) designed with a rotor and stator. The key component of this research is the utilization of a 3D-printed rotor in a HCR for the production of an oil-in-water nanoemulsion. Response surface methodology was used to determine the process conditions, such as speed of the rotor, flow rate, as well as, Span60, Tween60, and mineral oil concentrations, for generating the optimal droplet size in the nanoemulsion. The results showed that a droplet size of 366.4 nm was achieved under the recommended conditions of rotor speed of 3500 rpm, flow rate of 3.3 L/h, Span60 concentration of 2.36 wt%, Tween60 concentration of 3.00 wt%, and mineral oil concentration of 1.76 wt%. Moreover, the important characteristics for consideration in skincare products, such as polydispersity index, pH, zeta potential, viscosity, stability, and niacin released from formulations, were also assessed. For the niacin release profile of emulsion and nanoemulsion formulations, different methods, such as magnetic stirring, ultrasound, and hydrodynamic cavitation, were compared. The nanoemulsion formulations provided a greater cumulative release from the formulation than the emulsion. Particularly, the nanoemulsion generated using the HCR provided the largest cumulative release from the formulation after 12 h. Therefore, the present study suggests that nanoemulsions can be created by means of hydrodynamic cavitation, which reduces the droplet size, as compared to that generated using other techniques. The satisfactory results of this study indicate that the rotor-stator-type HCR is a potentially cost-effective technology for nanoemulsion production.     

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.     

Degradation of benzene present in wastewater using hydrodynamic cavitation in combination with air

The degradation of benzene present in wastewater using hydrodynamic cavitation (HC) alone as well as in combination with air has been studied using nozzles as cavitating device of HC reactor. Initially, the energy efficiency of the HC reactor operated at different inlet pressures was determined using the calorimetric studies. Maximum energy efficiency of 53.4% was obtained at an inlet pressure of 3.9 bar. The treatment processes were compared under adiabatic as well as isothermal conditions and it was observed that under the adiabatic condition, the extent of degradation is higher as compared to isothermal condition. Studies related to the understanding the effect of inlet pressure (range of 1.8–3.9 bar) revealed that the maximum degradation as 98.9% was obtained at 2.4 bar pressure using the individual operation of HC under adiabatic conditions and in 70 min of treatment. The combination of HC with air was investigated at different air flow rates with best results for maximum degradation of benzene achieved at air flow rate of 60 mL/sec. A novel approach of using cavitation for a limited fraction of total treatment time was also demonstrated to be beneficial in terms of the extent of degradation as well as energy requirements and cost of operation. Based on the cavitational intensity, the resonant radius of aggregates of cavitation bubbles was also determined for distilled water as well as for aqueous solution of benzene. Overall, significant benefits of using HC combined with air have been demonstrated for degradation of benzene along with fundamental understanding into cavitation effects.     

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.     

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.     

Performance evaluation of a novel pilot-scale pinned disc rotating generator of hydrodynamic cavitation

This study investigates hydrodynamic performance of a novel pinned disc rotating generator of hydrodynamic cavitation in comparison with a serrated disc variant on a pilot-scale. Experimental results show that at a given rotational speed and liquid flow rate, the pinned disc generates more intense cavitation (i.e. lower cavitation number, higher volume fraction of vapor and higher amplitude of pressure fluctuations) than the serrated disc, while also consuming less energy per liquid pass (i.e., higher flow rate and pumping pressure difference of water at similar power consumption). Additionally, mechanical and chemical wastewater treatment performance of the novel cavitator was evaluated on an 800 L influent sample from a wastewater treatment plant. Mechanical effects resulted in a reduction of average particle size from 148 to 38 µm and increase of specific surface area, while the oxidation potential was confirmed by reduction of COD, TOC, and BOD up to 27, 23 and 30% in 60 cavitation passes, respectively. At optimal operating conditions and 30 cavitation passes, pinned disc cavitator had a 310% higher COD removal capacity while consuming 65% less energy per kg of COD removed than the serrated disc cavitator. Furthermore, the specific COD-reduction energy consumption of the pinned disc cavitator on the pilot scale is comparable to the best cases of lab-scale orifice and venturi devices operating at much lower wastewater processing capacity.     

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%.     

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.     

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.     

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.     

Degradation of organic wastewater by hydrodynamic cavitation combined with acoustic cavitation

In this paper, the decomposition of Rhodamine B (RhB) by hydrodynamic cavitation (HC), acoustic cavitation (AC) and the combination of these individual methods (HAC) have been investigated. The degradation of 20 L RhB aqueous solution was carried out in a self-designed HAC reactor, where hydrodynamic cavitation and acoustic cavitation could take place in the same space simultaneously. The effects of initial concentration, inlet pressure, solution temperature and ultrasonic power were studied and discussed. Obvious synergies were found in the HAC process. The combined method achieved the best conversion, and the synergistic effect in HAC was even up to 119% with the ultrasonic power of 220 W in a treatment time of 30 min. The time-independent synergistic factor based on rate constant was introduced and the maximum value reached 40% in the HAC system. Besides, the hybrid HAC method showed great superiority in energy efficiency at lower ultrasonic power (88–176 W). Therefore, HAC technology can be visualized as a promising method for wastewater treatment with good scale-up possibilities.     

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.     

Intensifying extraction of biomolecules from macroalgae using vortex based hydrodynamic cavitation device

Macroalgae have a tremendous potential to become an important renewable resource for valuable biomolecules and chemicals. New and improved ways of cell disruption and of enhancing rate as well as yield of extraction of valuable products from macroalgae are needed to fully realise this potential. In this work, hydrodynamic cavitation (HC) was used for intensifying rate and yield of extraction of phycoerythrin, proteins and carbohydrates from marine macroalgae Palmaria palmata. We use vortex-based HC devices which do not use small restrictions like orifice-based HC devices or moving parts like rotor–stator based HC devices. A bench scale setup with a nominal slurry flow rate of 20 LPM was established. Dried and powdered macroalgae was used. Influence of key operating parameters like pressure drop and number of passes on extraction performance (the rate and yield) was measured. A simple, yet effective model was developed and used for interpreting and describing experimental data. The results indicate that there exists an optimum pressure drop across the device at which extraction performance is maximum. The extraction performance with HC was found to be significantly better than the stirred vessels. HC has resulted in 2 to 20 times improvement in the rate of extraction of phycoerythrin (R-PE), proteins and carbohydrates. Based on the results obtained in this work, pressure drop of 200 kPa and number of passes through the HC devices of about 100 were found to be most effective for HC-assisted intensified extraction from macroalgae. The presented results and model will be useful for harnessing vortex-based HC devices for intensifying the extraction of valuable products from macroalgae.     

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.     

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.     

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.     

A parametrical study of disinfection with hydrodynamic cavitation

The physical and chemical conditions generated by cavitation bubbles can be used to destroy microorganisms and disinfect wastewater. The effect of different cavitation chamber designs and diverse operational parameters on the inactivation rate of Escherichia coli have been studied and used to understand the mechanisms involved in cell disruption.