Simulation of the mixing process in a straight tube with sudden changed cross-section

Homogeneous continuous flow nitration of O-methylisouronium sulfate and its optimization by kinetic modeling

Nitration of O-methylisouronium sulfate under mixed acid conditions gives O-methyl-N-nitroisourea, a key intermediate of neonicotinoid insecticides with high application value. The reaction is a fast and highly exothermic process with a high mass transfer resistance, making its control difficult and risky. In this paper, a homogeneous continuous flow microreactor system was developed for the nitration of O-methylisouronium sulfate under high concentrations of mixed acids, with a homemade static mixer eliminating the mass transfer resistance. In addition, the kinetic modeling of this reaction was performed based on the theory of NO2 + attack, with the activation energy and pre-exponential factor determined. Finally, based on the response surface generated by the kinetic model, the reaction was optimized with a conversion of 87.4% under a sulfuric acid mass fraction of 94%, initial reactant concentration of 0.5 mol/L, reaction temperature of 40 °C, molar ratio of reactants at 4.4:1, and a residence time of 12.36 minutes.

Study on the Effect of a Sudden Jump in Wettability on Two-Component Liquid Flow in Sudden Contraction Devices

This study experimentally investigated the effect of wettability and sudden changes in flow area on liquid-liquid extraction operation. The wall surface wettability has been altered by connecting the glass capillary (hydrophilic) and poly(tetrafluoroethylene) (PTFE)-coated capillary (hydrophobic) together in four different arrangements. In all of the arrangements, a 2 mm inner diameter tube of 35 cm length is used upstream, while a 1 mm inner diameter tube of 35 cm length is used downstream. Acetic acid mixed with toluene and water is used as a test fluid. Various flow patterns are observed: slug, droplet, slug with the droplet, and encapsulated drop in slug. The extraction efficiency is observed to be the maximum when the hydrophobic tube is used upstream, followed by a hydrophilic tube downstream. Due to the contraction effect, the specific surface area of the slug increases from 1.6 to 2.7 times. Further numerical simulations have been run using open CFD software OpenFoam to see the inner flow physics at the maximum efficiency due to a sudden jump in wettability. The presence of a recirculating zone downstream just after the plane of area change leads to the formation of encapsulated drop and enhances circulation within the slug.

Mixing Performance of a 3D Micro T-Mixer with Swirl-Inducing Inlets and Rectangular Constriction

In this paper, three novel 3D micro T-mixers, namely, a micro T-mixer with swirl-inducing inlets (TMSI), a micro T-mixer with a rectangular constriction (TMRC), and a micro T-mixer with swirl-inducing inlets and a rectangular constriction (TMSC), were proposed on the basis of the original 3D micro T-mixer (OTM). The flow and mixing performance of these micromixers was numerically analyzed using COMSOL Multiphysics package at a range of Reynolds numbers from 10 to 70. Results show that the three proposed 3D micro T-mixers have achieved better mixing performance than OTM. Due to the coupling effect of two swirl-inducing inlets and a rectangular constriction, the maximum mixing index and pressure drop appeared in TMSC among the four micromixers especially; the mixing index of TMSC reaches 91.8% at Re = 70, indicating that TMSC can achieve effective mixing in a short channel length, but has a slightly higher pressure drop than TMSI and TMRC.

Thermoformed fluoropolymer tubing for in-line mixing

We present a thermoforming method to make in-line micromixer in commercial fluoropolymer tubing.