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New Trends in Hydrodynamics of Industrial Processes: Energy Efficiency and...
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New Trends in Hydrodynamics of Industrial Processes: Energy Efficiency and Optimization

A Special Issue of Processes (ISSN 2227-9717) belonging to the section "Chemical Processes and Systems".

Deadline for manuscript submissions: 15 October 2026 | Viewed by 9663

Editors

Prof. Dr. Sergio Alejandro Martinez-Delgadillo

E-Mail Website
Guest Editor
Departamento Ciencias Básicas, Universidad Autónoma Metropolitana, Av. San Pablo No. 420 Col. Nueva el Rosario, Alcaldía Azcapotzalco, Mexico City C.P. 02128, Mexico
Interests: modeling and simulation; CFD; mixing; reactors; photocatalysis; wastewater treatment
Dr. Alejandro Alonzo-Garcia

E-Mail Website
Guest Editor
SECIHTI, Tecnológico Nacional de México/Instituto Tecnológico de Nuevo León, Av. Eloy Cavazos No. 2001, Colonia Tolteca, Guadalupe C.P. 67160, NL, Mexico
Interests: CFD; porous media; turbulent flow; laminar flow; processes; mixing

Special Issue Information

Dear Colleagues,

Several types of industrial processes are carried out in aqueous media. Understanding local flow patterns at different temporal and spatial scales is important for technologies for contaminant removal; efficient mixing; mass transfer in stirred tanks, reactors, bioreactors, and photoreactors; and porous media. The hydrodynamic phenomena involved in these processes seek to increase efficiency, reduce energy consumption and its environmental impact, and lower operating costs.

Computational Fluid Dynamics (CFD) simulation is a tool that has been widely used because of its advantages in reducing cost and experimental time.

This technique is combined with experimental methods, such as Particle Image Velocimetry (PIV), which have been used to validate the models used in CFD.

In this sense, this Special Issue aims to present the different advances made so far in the production processes of chemical and biological products, as well as the removal of pollutants by biological, chemical, and photocatalytic processes in aqueous media. It also aims to present to the scientific community the progress achieved with the different geometries of impellers, deflectors, and other devices used in reactors to intensify processes with low energy consumption. In addition, some work will be presented that is relevant to the processes that take place in porous media, which can now be fabricated in a controlled manner using various additive manufacturing technologies, and which present the particular challenge of being difficult to study using some traditional experimental techniques.

Based on the above, researchers are invited to submit their recent results on the above-mentioned topics.

Prof. Dr. Sergio Alejandro Martínez Delgadillo
Dr. Alejandro Alonzo-Garcia
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 250 words) can be sent to the Editorial Office for assessment.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-anonymized peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Processes is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

 

Keywords

  • mixing
  • reactors
  • photocatalysis
  • computational fluid dynamics
  • wastewater treatment
  • porous media

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Published Papers (5 papers)

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Research

16 pages, 4051 KB  
Article
Optimization of Key Parameters of the Air Distributor for the KYF Flotation Machine
by Chao Lv, Ning Wei, Hongliang Zhao, Ming Wang, Hanwen Zhang and Hongru Qiu
Processes 2026, 14(8), 1262; https://doi.org/10.3390/pr14081262 - 15 Apr 2026
Viewed by 533
Abstract
With the decreasing availability of high-quality mineral resources and the increasing complexity of ore properties, efficient and sustainable flotation technology has become a research focus in the field of mineral processing. To optimize the taper angle of the air distributor in a KYF [...] Read more.
With the decreasing availability of high-quality mineral resources and the increasing complexity of ore properties, efficient and sustainable flotation technology has become a research focus in the field of mineral processing. To optimize the taper angle of the air distributor in a KYF flotation machine, numerical simulation was used in this study to investigate its influence on the internal flow field, gas-phase characteristics, structural pressure distribution, and stirring power consumption. The results show that the peak turbulent kinetic energy and gas holdup are concentrated in the shear zone between the impeller and stator. Under the +5° condition, the peak turbulent kinetic energy is the lowest, while its vertical distribution is the most uniform. The peak gas holdup in the impeller–stator region reaches 19.2%, and the number of efficient bubbles with a diameter of 0.5 mm reaches 3.8 × 106 per m3, which is significantly higher than under the other conditions. During stable operation, this condition exhibits the lowest stirring power consumption at 126.0 W, which is 7.557% and 4.255% lower than under the −5° and 0° conditions, respectively. The optimal taper angle is therefore determined to be +5°. However, the associated large pressure gradient on the impeller surface may accelerate blade wear, indicating that surface strengthening measures should be considered to balance performance and durability. Full article
(This article belongs to the Special Issue New Trends in Hydrodynamics of Industrial Processes: Energy Efficiency and Optimization)
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18 pages, 6462 KB  
Article
Effect of Different Impeller Types on Mixing Efficiency in Mechanically Stirred Tanks with Tubular Baffles
by Jesús Eduardo Lugo Hinojosa, Juan Antonio Yáñez Varela, Alejandro Alonzo García, Gabriela Rivadeneyra Romero and Sergio Alejandro Martínez Delgadillo
Processes 2026, 14(2), 225; https://doi.org/10.3390/pr14020225 - 8 Jan 2026
Cited by 1 | Viewed by 2774
Abstract
Efficient mixing in stirred tanks is essential for chemical and biochemical processes. Tubular baffles offer potential energy savings and multifunctionality (e.g., as heat exchangers); however, their interaction with common impeller types is not well understood. This study uses computational fluid dynamics (CFD) simulations [...] Read more.
Efficient mixing in stirred tanks is essential for chemical and biochemical processes. Tubular baffles offer potential energy savings and multifunctionality (e.g., as heat exchangers); however, their interaction with common impeller types is not well understood. This study uses computational fluid dynamics (CFD) simulations to evaluate the hydrodynamic performance of a novel tubular baffle design compared to conventional flat baffles with three impellers: a Rushton turbine (RT), a pitched blade turbine (PBT), and a hydrofoil (HE3). Dimensionless analysis (power number, NP; and pumping number, NQ), flow visualization, and vorticity dynamics were employed. The results show that, by attenuating large-scale recirculation, tubular baffles reduce power consumption by 64%, 13%, and 23% for the HE3, PBT, and RT, respectively. However, the HE3 impeller experienced a 30% decrease in pumping capacity, which confined the flow to the lower tank. The PBT showed a 10% increase in NQ and intensified bottom circulation. The RT uniquely generated distributed, high-intensity turbulence along the baffle height while maintaining its characteristic dual-loop structure. The analysis critiques the local pumping efficiency metric and advocates for a global flow assessment. The HE3 is optimal for efficient bulk blending at low power; the PBT is optimal for strong bottom circulation processes; and the RT is optimal for applications requiring enhanced interfacial processes, where baffles serve a dual function. This work provides a framework for selecting energy-efficient agitation systems by coupling impeller performance with global tank hydrodynamics. Full article
(This article belongs to the Special Issue New Trends in Hydrodynamics of Industrial Processes: Energy Efficiency and Optimization)
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18 pages, 2519 KB  
Article
Unsteady Natural Convection and Entropy Generation in Thermally Stratified Trapezoidal Cavities: A Comparative Study
by Md. Mahafujur Rahaman, Sidhartha Bhowmick and Suvash C. Saha
Processes 2025, 13(6), 1908; https://doi.org/10.3390/pr13061908 - 16 Jun 2025
Cited by 4 | Viewed by 1344
Abstract
This study numerically investigates unsteady natural convection (NC) heat transfer (HT) and entropy generation (Egen) in trapezoidal cavities filled with two thermally stratified fluids. Both air-filled and water-filled configurations are analyzed to evaluate and compare their thermal performance under varying [...] Read more.
This study numerically investigates unsteady natural convection (NC) heat transfer (HT) and entropy generation (Egen) in trapezoidal cavities filled with two thermally stratified fluids. Both air-filled and water-filled configurations are analyzed to evaluate and compare their thermal performance under varying conditions. The cavities are characterized by a heated base, thermally stratified sloped walls, and a cooled top wall. The governing equations are numerically solved using the finite volume (FV) approach. The study considers a Prandtl number (Pr) of 0.71 for air and 7.01 for water, Rayleigh numbers (Ra) ranging from 103 to 5 × 107, and an aspect ratio (AR) of 0.5. Flow behavior is examined through various parameters, including temperature time series (TTS), average Nusselt number (Nu), average entropy generation (Eavg), average Bejan number (Beavg), and ecological coefficient of performance (ECOP). Three bifurcations are identified during the transition from steady to chaotic flow for both fluids. The first is a pitchfork bifurcation, occurring between Ra = 105 and 2 × 105 for air, and between Ra = 9 × 104 and 105 for water. The second, a Hopf bifurcation, is observed between Ra = 4.7 × 105 and 4.8 × 105 for air, and between Ra = 105 and 2 × 105 for water. The third bifurcation marks the onset of chaotic flow, occurring between Ra = 3 × 107 and 4 × 107 for air, and between Ra = 4 × 105 and 5 × 105 for water. At Ra = 106, the average HT in the air-filled cavity is 85.35% higher than in the water-filled cavity, while Eavg is 94.54% greater in the air-filled cavity compared to water-filled cavity. At Ra = 106, the thermal performance of the cavity filled with water is 4.96% better than that of the air-filled cavity. These findings provide valuable insights for optimizing thermal systems using trapezoidal cavities and varying working fluids. Full article
(This article belongs to the Special Issue New Trends in Hydrodynamics of Industrial Processes: Energy Efficiency and Optimization)
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24 pages, 4696 KB  
Article
Treatment of Pharmaceutical Effluent Using Ultrasound-Based Advanced Oxidation for Intensified Biological Oxidation
by Akshara M. Iyer, Aditya V. Karande and Parag R. Gogate
Processes 2025, 13(4), 1191; https://doi.org/10.3390/pr13041191 - 15 Apr 2025
Cited by 5 | Viewed by 1894
Abstract
The current work investigates the intensification process of the biological oxidation (BO) of a pharmaceutical effluent using ultrasound (US)-based pretreatment methods. US, in combination with chemical oxidants, like hydrogen peroxide (H2O2), Fenton, potassium persulphate (KPS), and peroxone, was used [...] Read more.
The current work investigates the intensification process of the biological oxidation (BO) of a pharmaceutical effluent using ultrasound (US)-based pretreatment methods. US, in combination with chemical oxidants, like hydrogen peroxide (H2O2), Fenton, potassium persulphate (KPS), and peroxone, was used as a pretreatment technique to enhance the efficacy of BO, as BO alone could only bring about 16.67% COD reduction. The application of US under the optimized conditions of a 70% duty cycle, 120W of power, pH 2, and at a 30 °C temperature resulted in 12.3% COD reduction after 60 min, whereas its combination with oxidants at optimized loadings resulted in a higher COD reduction of 20% for H2O2 (2000 ppm), 23.08% for Fenton (1:1 Fe:H2O2), and 30.77% for the US + peroxone approach (400 mg/h of ozone with 2000 ppm H2O2). The pretreated samples did not produce any toxic by-products, as confirmed by a toxicity analysis using the agar well diffusion method. A cow-dung-based sludge was acclimatised specifically for use in BO. The treatment time for BO was set to 8 h, and the US + peroxone-pretreated samples showed a maximum overall COD reduction of 60%, which is about three times that observed with only BO. This work clearly demonstrates the enhancement of the biodegradation of a complex recalcitrant pharmaceutical effluent using a US-based pretreatment. Full article
(This article belongs to the Special Issue New Trends in Hydrodynamics of Industrial Processes: Energy Efficiency and Optimization)
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19 pages, 5221 KB  
Article
Thermal Performance and Entropy Generation of Unsteady Natural Convection in a Trapezoid-Shaped Cavity
by Md. Mahafujur Rahaman, Sidhartha Bhowmick and Suvash C. Saha
Processes 2025, 13(3), 921; https://doi.org/10.3390/pr13030921 - 20 Mar 2025
Cited by 13 | Viewed by 1620
Abstract
In this study, a numerical investigation of unsteady natural convection heat transfer (HT) and entropy generation (EG) is performed within a trapezoid-shaped cavity containing thermally stratified water. The cavity’s bottom wall is heated, the sloped walls are thermally stratified, and the top wall [...] Read more.
In this study, a numerical investigation of unsteady natural convection heat transfer (HT) and entropy generation (EG) is performed within a trapezoid-shaped cavity containing thermally stratified water. The cavity’s bottom wall is heated, the sloped walls are thermally stratified, and the top wall is cooled. The finite volume (FV) method is employed to solve the governing equations. This study uses a Prandtl number (Pr) of 7.01 for water, an aspect ratio (AR) of 0.5, and Rayleigh numbers (Ra) varying between 10 and 106. To examine the flow behavior within the cavity, various relevant parameters are determined for different Ra values. These parameters include streamline and isotherm contours, temperature time series, limit point and limit cycle analysis, average Nusselt number (Nu) at the heated walls, average entropy generation (Eavg), and average Bejan number (Beavg). It is found that the flow transitions from a steady symmetrical state to a chaotic state as the Ra value increases. During this transition, three bifurcations occur. The first is a pitchfork bifurcation between Rayleigh numbers of 9 × 104 and 105, followed by a Hopf bifurcation between Rayleigh numbers of 105 and 2 × 105. Finally, another bifurcation occurs, shifting the flow from periodic to chaotic between Rayleigh numbers of 4 × 105 and 5 × 105. The present study shows an increase in Eavg of 94.97% between Rayleigh numbers of 103 and 106, while the rate of increase in Nu is 81.13%. The findings from this study will enhance understanding of the fluid flow phenomena in a trapezoid-shaped cavity filled with stratified water. The current numerical results are compared and validated against previously published numerical and experimental data. Full article
(This article belongs to the Special Issue New Trends in Hydrodynamics of Industrial Processes: Energy Efficiency and Optimization)
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