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Article

Liquid–Liquid Flow and Mass Transfer Enhancement in Tube-in-Tube Millireactors with Structured Inserts and Advanced Inlet Designs

by
Feng Zhu
1,2,
Xingxing Pan
2,
Xichun Cao
1,
Yandan Chen
1,
Rijie Wang
3,
Jiande Lin
1,* and
Hanyang Liu
1,3,*
1
College of Material Engineering, Fujian Agriculture and Forestry University, Fuzhou 350108, China
2
Fujian Fiber Inspection Center, Fuzhou 350026, China
3
School of Chemical Engineering and Technology, Tianjin University, Tianjin 300350, China
*
Authors to whom correspondence should be addressed.
Fluids 2025, 10(2), 26; https://doi.org/10.3390/fluids10020026
Submission received: 2 December 2024 / Revised: 3 January 2025 / Accepted: 23 January 2025 / Published: 24 January 2025
(This article belongs to the Special Issue Mass Transfer in Multiphase Reactors)
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Abstract

Liquid–liquid mass transfer is crucial in chemical processes like extraction and desulfurization. Traditional tube-in-tube millireactors often overlook internal flow dynamics, focusing instead on entry modifications. This study explores mass transfer enhancement through structured inserts (twisted tapes, multi-blades) and inlet designs (multi-hole injectors, T-mixers). Using high-speed imaging and water–succinic acid–butanol experiments, flow patterns and mass transfer rates were analyzed. Results show annular and dispersion flows dominate under tested conditions with structured inserts lowering the threshold for dispersion flow. Multi-hole injectors improved mass transfer by over 40% compared to T-mixers in plain tubes, while C-tape inserts achieved the highest volumetric mass transfer coefficient (2.43 s−1) due to increased interfacial area and droplet breakup from energy dissipation. This approach offers scalable solutions to enhance tube-in-tube millireactor performance for industrial applications.
Keywords: liquid–liquid mass transfer; tube-in-tube millireactor; structured inserts; process intensification liquid–liquid mass transfer; tube-in-tube millireactor; structured inserts; process intensification

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MDPI and ACS Style

Zhu, F.; Pan, X.; Cao, X.; Chen, Y.; Wang, R.; Lin, J.; Liu, H. Liquid–Liquid Flow and Mass Transfer Enhancement in Tube-in-Tube Millireactors with Structured Inserts and Advanced Inlet Designs. Fluids 2025, 10, 26. https://doi.org/10.3390/fluids10020026

AMA Style

Zhu F, Pan X, Cao X, Chen Y, Wang R, Lin J, Liu H. Liquid–Liquid Flow and Mass Transfer Enhancement in Tube-in-Tube Millireactors with Structured Inserts and Advanced Inlet Designs. Fluids. 2025; 10(2):26. https://doi.org/10.3390/fluids10020026

Chicago/Turabian Style

Zhu, Feng, Xingxing Pan, Xichun Cao, Yandan Chen, Rijie Wang, Jiande Lin, and Hanyang Liu. 2025. "Liquid–Liquid Flow and Mass Transfer Enhancement in Tube-in-Tube Millireactors with Structured Inserts and Advanced Inlet Designs" Fluids 10, no. 2: 26. https://doi.org/10.3390/fluids10020026

APA Style

Zhu, F., Pan, X., Cao, X., Chen, Y., Wang, R., Lin, J., & Liu, H. (2025). Liquid–Liquid Flow and Mass Transfer Enhancement in Tube-in-Tube Millireactors with Structured Inserts and Advanced Inlet Designs. Fluids, 10(2), 26. https://doi.org/10.3390/fluids10020026

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