Interaction between Mixing, Chemical Reactions, and Precipitation

Method for predicting the size of Ni1/3Mn1/3Co1/3(OH)2 particles precipitated in a stirred-tank semi-batch crystallizer using CFD and particle agglomeration models

NixMnyCoz(OH)2 is widely used as a precursor for the cathode active material LiNixMnyCozO2 in lithium ion batteries, and the precursor size, which determines the size of the active cathode material, affects the characteristics of lithium-ion batteries. This paper proposes a method for predicting the particle size of Ni1/3Mn1/3Co1/3(OH)2 precipitated by semi-batch reaction crystallization. The distribution of supersaturated components formed in the reactor varies with the reactor scale, feed conditions of the raw material solution, and agitation conditions. Therefore, the method presented in this paper considers the effects of these conditions on particle growth. First, to identify the turbulent dispersion and concentration distribution of the supersaturated components formed in the reaction crystallizer, a computational fluid dynamics (CFD) model was constructed consisting of the governing equations of hydrodynamics and the mass balance equations of the supersaturated components considering the production by neutralization and consumption by precipitation. Next, a model of agglomeration was constructed that focused on the balance of the binding and breaking up energies for the particle pairs. The binding energy was quantified based on the bridging between particle pairs by surface deposition. The breaking up-energy was quantified based on the hydrodynamic forces when the agglomerate passes through the impeller. These models were fitted using experimental results for the final average size of the Ni1/3Mn1/3Co1/3(OH)2 secondary aggregate, which was precipitated in a small-scale stirred-tank type semi-batch reaction crystallizer. The models predicted the experimental results of the final average size in a large-scale crystallizer, with the feeding conditions of the raw material solution and stirring conditions as experimental parameters, within ±20%. The models may be used to analyze semi-batch reaction crystallization systems of NixMnyCoz(OH)2 of any composition by adjusting the model parameters according to the procedure developed in this study.

Controllable and Scale-Up Synthesis of Nickel-Cobalt Boride@Borate/RGO Nanoflakes via Reactive Impingement Mixing: A High-Performance Supercapacitor Electrode and Electrocatalyst

Large-scale synthesis of graphene-based nanomaterials in stirred tank reactor (STR) often results in serious agglomeration because of the poor control during micromixing process. In this work, reactive impingement mixing is conducted in a two-stage impinging jet microreactor (TS-IJMR) for the controllable and scale-up synthesis of nickel-cobalt boride@borate core-shell nanostructures on RGO flakes (NCBO/RGO). Benefiting from the good process control and improved micromixing efficiency of TS-IJMR, NCBO/RGO nanosheet provides a large BET surface area, abundant of suitable mesopores (2–5 nm), fast ion diffusion, and facile electron transfer within the whole electrode. Therefore, NCBO/RGO electrode exhibits a high specific capacitance of 2383 F g−1 at 1 A g−1, and still retains 1650 F g−1 when the current density is increased to 20 A g−1, much higher than those of nickel boride@borate/RGO (NBO/RGO) and cobalt boride@borate/RGO (CBO/RGO) synthesized in TS-IJMR, as well as NCBO/RGO-S synthesized in STR. In addition, an asymmetric supercapacitor (NCBO/RGO//AC) is constructed with NCBO/RGO and activated carbon (AC), which displays a high energy density of 53.3 W h kg−1 and long cyclic lifespan with 91.8% capacitance retention after 5000 charge-discharge cycles. Finally, NCBO/RGO is used as OER electrocatalyst to possess a low overpotential of 309 mV at a current density of 10 mA cm−2 and delivers a good long-term durability for 10 h. This study opens up the potential of controllable and scale-up synthesis of NCBO/RGO nanosheets for high-performance supercapacitor electrode materials and OER catalysts.

Recent Advance of Melt Crystallization, Towards Process Intensification and Techniques Development

Melt crystallization has been considered as a green separation technique and widely applied in industry and manufacture due to several attractive features, including no need for solvent, achieving specific product...

A perspective review on mixing effect for modeling and simulation of reactive and antisolvent crystallization processes

Reactive and antisolvent crystallization processes are sensitive to mixing effects on various scales.

Particle Formation Mechanisms in the Nanoprecipitation of Polystyrene

Numerous precipitation methods for creating nanoparticle dispersions that are based on mixing a solution with a miscible nonsolvent have been developed. Here, we show that for polymer particles, the formation is highly dependent on the rate of mixing. We also demonstrate the importance of the glass transition of the polymers on particle formation. A simple model of droplet formation during mixing provides a satisfactory description of the observed dependence of particle size on polymer molecular weight, concentration, solvent ratio, and mixing conditions.

Rapid and Controllable Synthesis of Nanocrystallized Nickel-Cobalt Boride Electrode Materials via a Mircoimpinging Stream Reaction for High Performance Supercapacitors

Nickel-cobalt borides (denoted as NCBs) have been considered as a promising candidate for aqueous supercapacitors due to their high capacitive performances. However, most reported NCBs are amorphous that results in slow electron transfer and even structure collapse during cycling. In this work, a nanocrystallized NCBs-based supercapacitor is successfully designed via a facile and practical microimpinging stream reactor (MISR) technique, composed of a nanocrystallized NCB core to facilitate the charge transfer, and a tightly contacted Ni-Co borates/metaborates (NCB_i ) shell which is helpful for OH^- adsorption. These merits endow NCB@NCB_i a large specific capacity of 966 C g^-1 (capacitance of 2415 F g^-1 ) at 1 A g^-1 and good rate capability (633.2 C g^-1 at 30 A g^-1 ), as well as a very high energy density of 74.3 Wh kg^-1 in an asymmetric supercapacitor device. More interestingly, it is found that a gradual in situ conversion of core NCBs to nanocrystallized Ni-Co (oxy)-hydroxides inwardly takes place during the cycles, which continuously offers large specific capacity due to more electron transfer in the redox reaction processes. Meanwhile, the electron deficient state of boron in metal-borates shells can make it easier to accept electrons and thus promote ionic conduction.

CFD Simulation of the Particle Dispersion Behavior and Mass Transfer–Reaction Kinetics in non-Newton Fluid with High Viscosity

Solid particle dispersion and chemical reactions in high-viscosity non-Newtonian fluid are commonly encountered in polymerization systems. In this study, an interphase mass transfer model and a finite-rate/eddy-dissipation formulation were integrated into a computational fluid dynamics model to simulate the dispersion behavior of particles and the mass transfer–reaction kinetics in a condensation polymerization-stirred tank reactor. Turbulence fields were obtained using the standard k–ε model and employed to calculate the mixing rate. Cross model was used to characterize the rheological property of the non-Newton fluid. The proposed model was first validated by experimental data in terms of input power. Then, several key operating variables (i.e. agitation speed, viscosity, and particle size) were investigated to evaluate the dispersive mixing performance of the stirred vessel. Simulation showed that a high agitation speed and a low fluid viscosity favored particle dispersions. This study provided useful guidelines for industrial-scale high-viscosity polymerization reactors.