Search Results (59)

This paper describes the development of a new hybrid composite for the metal joints of aluminium and glass fibre composite adherents. The aluminium adherend is manufactured using friction stir-formed studs that are inserted into the composite adherend in the through-thickness direction during the composite manufacturing process, where the dry fibres are displaced to accommodate the studs before the resin infusion process. The materials used were AA6082-T6 aluminium and plain-woven E-glass fabric reinforced epoxy, with primary applications in naval vessels. This joining approach offers a cost-effective solution that does not require complicated onsite welding. The joint design was developed based on a simulation test program with finite element analysis, followed by experimental characterisation and validation. The design solution was analysed in terms of the force displacement response, sequence of load transfer, and characterisation of the joint failure modes. Full article

The complete dissolution of the Ti and Fe content of ilmenite is a necessary first step for the production of TiO₂ directly from ilmenite. Hydrochloric acid is one of the possible solubilizing agents. However, the ability to dissolve ilmenite in hydrochloric acid depends on the nature of the source material. Here, we consider the effect that the oxidation state of Fe in the ilmenite has on the dissolution rate. Three placer ilmenite fractions from New Zealand and India were dissolved in concentrated hydrochloric acid in a stirred vessel. The dissolution rate constants for Fe and Ti for each fraction based on a shrinking sphere model were compared with the Fe(III)/Fe(II) ratio. Pre-edge Fe K-edge XANES as a measure of Fe(III)/Fe(II) has been shown to extend to ilmenite, which has a complex pre-edge region due to the involvement of Ti electronic levels. It was found that there is a relationship between the oxidation state of Fe and the dissolution rate, with a higher Fe(II) content resulting in more rapid dissolution. A higher Fe(II) content reflects a younger, less weathered material, closer to the “standard” stoichiometry of ilmenite. These data and the presented correlation may support the design of industrial processes to digest ilmenite in hydrochloric acid from varying feedstocks. Full article

In industrial mixing processes, impeller design, rotational speed, and mixing conditions play a crucial role in determining process efficiency, product quality, and energy consumption. Optimizing the performance of stirring systems for non-Newtonian fluids is essential for achieving better results. This study examines the hydrodynamic and thermal performance of stirring systems for viscoplastic fluids, utilizing close-clearance anchor impellers with chamfered angles of 22.5°, 45°, and 67.5° in cylindrical, flat-bottom and unbaffled vessels. Through a comprehensive comparative analysis between standard and chamfered impeller designs, the study evaluates their efficacy in overcoming yield stress, enhancing flow dynamics, and improving thermal homogeneity. The effects of Reynolds number and yield stress on the hydrodynamic and thermal states are analyzed. The results indicate that the 67.5° chamfered impeller significantly improves flow distribution and minimizes dead zones, particularly in critical areas between the anchor blades and vessel walls, where mixing stagnation typically occurs. It also enhances vertical mixing by promoting a broader shear spread along the vessel height and a more uniform temperature distribution. These insights contribute to the development of more efficient agitation systems, applicable across various industries handling complex fluids. Full article

Combining carboxylation reactions using carbon dioxide (CO₂) as a reactant with phenol results in creation of new C-C bonds, and represents one of the most promising routes in sustainable utilization of ubiquitous and readily available resources for production of highly valuable products. This study provides a detailed and well-structured investigation of the effect of various reaction conditions (reactant loading, reaction duration, temperature, CO₂ pressure) on the carboxylation of phenol. Sodium phenoxide carboxylation showed well-resolved trends with variation of temperature and time, and resulted in production of salicylic acid (SA) in the range of 11.4 to 47.8%, 4-hydoxybenzoic acid (4HBA) in the range of 2.0 to 8.2%, while the dicarboxylated 4-hydroxyisophthalic acid (4HiPh) was only detected in trace amounts. The effect of the variation of reactant content was shown to be significantly influenced by the reactor size, solid/vessel and gas/solid contact area, as well as the efficiency of the stirring. CO₂ pressure was shown to be a crucial element, where reactions carried out below 2 MPa CO₂ did not show any activity. While investigating the reaction mechanism, it was shown that the salt analogues of potential products could be acidified in situ by the moisture present, and immediately degraded back to phenol, thus lowering yields of potentially obtained products. The experimental results were successfully used to compose a kinetic model, which very well describes the experimentally obtained results. As such, this study provides a valuable dataset for valorization of lignocellulosic aromatic compounds as well as highly abundant and environmentally detrimental carbon dioxide into industrially valuable mono- and dicarboxylic acids. Full article

High-density polyethylene (HDPE) has emerged as a promising alternative to fiber-reinforced plastic (FRP) for small vessel manufacturing due to its durability, chemical resistance, lightweight properties, and recyclability. However, while thermoplastic polymers like HDPE have been extensively used in gas and water pipelines, their application in large, complex marine structures remains underexplored, particularly in terms of joining methods. Existing techniques, such as ultrasonic welding, laser welding, and friction stir welding, are unsuitable for large-scale HDPE components, where extrusion welding is more viable. This study focuses on evaluating the impact of key process parameters, such as the preheating temperature, hot air movement speed, and nozzle distance, on the welding performance of HDPE. By analyzing the influence of these variables on heat distribution during the extrusion welding process, we aim to conduct basic research to derive optimal conditions for achieving strong and reliable joints. The results highlight the critical importance of a uniform temperature distribution in preventing defects such as excessive melting or thermal degradation, which could compromise weld integrity. This research provides valuable insights into improving HDPE joining techniques, contributing to its broader adoption in the marine and manufacturing industries. Full article

The dextrinization of potato starch was performed using a sophisticated single-mode microwave reactor with temperature and pressure control using 10 cycles of heating with stirring between cycles. Microwave power from 150 to 250 W, a cycle time from 15 to 25 s, and two types of vessels with different internal diameters (12 and 24 mm) and therefore different thicknesses of the heated starch layer were used in order to estimate the impact of vessel size used for microwave dextrinization. The characteristics of resistant dextrins (RD) including solubility in water, total dietary fiber (TDF) content, color parameters, the share of various glycosidic bonds, and pasting and rheological properties were carried out. The applied conditions allowed us to obtain RDs with water solubility up to 74% at 20 °C, as well as TDF content up to 47%, with a predominance of low-molecular-weight soluble fiber fraction, with increased content of non-starch glycosidic bonds, negligible viscosity, and a slightly beige color. The geometry of the reaction vessel influenced the properties of dextrins obtained under the same heating power, time, and repetition amounts. Among the conditions used, the most favorable conditions were heating 10 times for 20 s at 200 W in a 10 mL vessel and the least favorable were 15 s cycles. Full article

Micro- and nano-bubble jet stirring, as an emerging technology, shows great potential in complex mineral sorting. Flow field characteristics and structural parameters of the gas–liquid two-phase system can lead to uneven bubble distribution inside the reaction vessel. Gas–liquid mixing uniformity is crucial for evaluating stirring effects, as increasing the contact area enhances reaction efficiency. To improve flotation process efficiency and resource recovery, further investigation into flow field characteristics and structural optimization is necessary. The internal flow field of the jet-stirred tank was analyzed using computational fluid dynamics (CFDs) with the Eulerian multiphase flow model and the Renormalization Group (RNG) k − ε turbulence model. Various operating (feeding and aerating volumes) and structural parameters (nozzle direction, height, inner diameter, and radius ratio) were simulated. Dimensionless variance is a statistical metric used to assess gas–liquid mixing uniformity. The results indicated bubbles accumulated in the middle of the vessel, leading to uneven mixing. Lower velocities resulted in low gas volume fractions, while excessively high velocities increased differences between the center and near-wall regions. Optimal mixing uniformity was achieved with a circumferential nozzle direction, 80 mm height, 5.0 mm inner diameter, and 0.55 radius ratio. Full article

Prodigiosin is a red bacterial pigment with great potential as a natural dye and drug precursor, while presenting several pharmacological properties, including antimicrobial and anticancer activities. Its commercialization for biomedical applications, however, remains scarce. The major limitations are related to the lack of efficient bioprocesses and scaling up from laboratory to production. In the present work, the upstream process for prodigiosin production was developed using a marine Serratia rubidaea isolated from a sample collected near a shallow-water hydrothermal vent. The yield of product per biomass was found to be influenced by the cell concentration in the inoculum. The system was scaled up to 2 L stirred tank reactors with two different vessel geometries. It was shown that the vessel geometry and a cascade control mode for regulating the dissolved oxygen concentration influenced the volumetric oxygen mass transfer coefficient (k_La) and thus prodigiosin production. To improve product yields, strategies to mimic the aeration conditions found at the sampling site were tested. When the inoculum was grown for 5 h at 200 rpm and for 19 h at 25 rpm, which significantly decreased the oxygen available, the cells produced 588.2 mg_product/g_biomass, corresponding to a production of 1066.2 mg of prodigiosin in 24 h and a productivity of 36.1 mg_product/(L.h). This is a 3.7-fold increase in prodigiosin yield and a 4.5-fold increase in productivity in relation to when no particular strategy was promoted. Additionally, it was shown that lipid analysis and flow cytometry may be used as reliable at-line analytical tools, allowing the monitoring of cell condition and prodigiosin production during fermentation. Full article

The growing demand for bio-pharmaceuticals necessitates improved methods for the characterization of stirred tank reactors (STRs) and their mixing heterogeneities. Traditional Eulerian measurement approaches fall short, culminating in the use of Lagrangian Sensor Particles (LSPs) to map large-scale STRs and track the lifelines of microorganisms such as Chinese Hamster Ovary cells. This study investigates the hydrodynamic characteristics of LSPs, specifically examining the effects that the size and position of the Center of Mass (CoM) have on their flow-following capabilities. Two Lagrangian Particle (LP) designs are evaluated, one with the CoM and a Geometric Center aligned, and another with a shifted CoM. The experimental study is conducted in a rectangular vessel filled with deionized water featuring a stationary circular flow. Off-center LPs exhibit higher velocities, an increased number of floor contacts, and moreover, a less homogeneous particle probability of presence within the vessel compared to LPs with CoM and Geometric Center aligned. Lattice Boltzmann Large Eddy Simulations provide complementary undisturbed fluid velocity data for the calculation of the Stokes number $St$. Building upon these findings, differences in the Stokes number $St$ between the two LP variants of $\Delta St$ = 0.01 (25 mm LP) and $\Delta St$ = 0.13 (40 mm LP) are calculated, highlighting the difference in flow behavior. Furthermore, this study offers a more representative calculation of particle response time approach, as the traditional Stokes number definition does not account for non-homogeneous particles, resulting in an alternative Stokes number ($\Delta {St}_{\mathrm{alt}}$ = 0.84 (25 mm LP) and $\Delta {St}_{\mathrm{alt}}$ = 2.72 (40 mm LP)). This study contributes to the improved characterization of STRs through the use of Lagrangian Sensor Particles. Results highlight the implications the internal mass distribution has on LSP design, offering crucial considerations for researchers in the field. Full article

Fructose is a carbohydrate with essential applications in the food industry, mainly due to its high sweetness and low cost. The present investigation focused on optimising fructose production from commercial inulin using the enzymatic immobilisation method and applying the response surface methodology in a 12-run central composite design. The independent variables evaluated were the pH (−) and temperature (°C). The substrate consisted of a commercial inulin solution at a concentration of 1 g/L, while the catalyst consisted of the enzyme inulinase from Aspergillus niger (EC 232-802-3), immobilised in 2% m/v sodium alginate. A stirred vessel reactor was used for 90 min at 120 rpm, and quantification of reducing sugars was determined using DNS colorimetric and UV–Vis spectrophotometric methods at a 540 nm wavelength. After applying the response surface methodology, it was determined that the catalytic activity using the immobilisation method allows for a maximum total productivity of 16.4 mg/h under pH and temperature of 3.9 and 37 °C, respectively, with an efficiency of 96.4%. The immobilised enzymes’ reusability and stability compared to free enzymes were evaluated, obtaining activity up to the fifth reuse cycle and showing significant advantages over the free catalyst. Full article

The utilization of CO₂ mineralization fly ash (F) and coal gangue (G) technology is proposed in this research work to prepare underground backfilling materials. The test process can be divided into pre-treatment and post-treatment stages. In the pre-treatment stage, a sealed stirring vessel is used to conduct CO₂ wet mineralization. The ratios of F and G were selected as follows: 20%:60% (F2G6), 30%:50% (F3G5), 40%:40% (F4G4), 50%:30% (F5G3), and 60%:20% (F6G2). The ratios were prepared into Φ50 mm × 100 mm cylindrical samples, with curing durations of 3 d, 7 d, 14 d, and 28 d. In the post-processing stage, the SANS microcomputer-controlled electronic universal testing machine and FLIR A615 infrared thermal imager were used to carry out uniaxial loading and temperature detection, respectively. The unconfined compressive strength (UCS), X-ray diffraction (XRD), average infrared radiation temperature (AIRT), variance of original infrared image temperature (VOIIT), and variance of successive minus infrared image temperature (VSMIT) of the samples were compared and analyzed. The results indicated that when curing reaches 14 d, the strength approaches its peak, with minimal changes in strength over a delayed period; furthermore, as the ratio of F to G continues to increase, the mineralization effect gradually strengthens, reaching its optimum level at a ratio of 5:3. However, when the ratio exceeds 5:3, signs of deteriorating mineralization effect start to appear. During the loading process, the AIRT of the mineralized samples showed a continuous increase, but the VOIIT and VSMIT of the mineralized sample both exhibited significant fluctuations or rapid increases during damage rupture. Moreover, the rise in the AIRT value was found to be linked to the increase in the ratio of F to G. This indicates that F has a higher thermal–mechanical conversion efficiency compared to G, so the temperature change will be greater during the loading process. The drastic changes in the VOIIT and VSMIT indicate that they can be used as sensitive response indicators for sample rupture, and can predict and warn of damage rupture in mineralized samples. Research work can provide practical guidance and reference for underground backfilling of CO₂ mineralization industrial waste. Full article

Chitosan-triphosphate (TPP) nanogels are widely studied drug delivery carrier systems, typically prepared via a simple mixing process. However, the effects of the processing factors on nanogel production have not been extensively explored, despite the importance of understanding and standardising such factors to allow upscaling and commercial usage. This study aims to systematically evaluate the effects of various fabrication and processing factors on the properties of nanogels using a Design of Experiment approach. Hydrodynamic size, polydispersity index (PDI), zeta potential, and encapsulation efficiency were determined as the dependent factors. The temperature, stirring rate, chitosan grade, crosslinker choice, and the interaction term between temperature and chitosan grade were found to have a significant effect on the particle size, whereas the effect of temperature and the addition rate of crosslinker on the PDI was also noteworthy. Moreover, the addition rate of the crosslinker and the volume of the reaction vessel were found to impact the encapsulation efficiency. The zeta potential of the nanogels was found to be governed by the chitosan grade. The optimal fabrication conditions for the development of medium molecular weight chitosan and TPP nanogels included the following: the addition rate for TPP solution was set at 2 mL/min, while the solution was then stirred at a temperature of 50 °C and a stirring speed of 600 rpm. The volume of the glass vial used was 28 mL, while the stirrer size was 20 mm. The second aim of the study was to evaluate the potential for scaling up the nanogels. Size and PDI were found to increase from 128 nm to 151 nm and from 0.232 to 0.267, respectively, when the volume of the reaction mixture was increased from 4 to 20 mL and other processing factors were kept unchanged. These results indicate that caution is required when scaling up as the nanogel properties may be significantly altered with an increasing production scale. Full article

Interrupted blood flow in the brain due to ischemic injuries such as ischemic stroke or traumatic brain injury results in irreversible brain damage, leading to cognitive impairment associated with inflammation, disruption of the blood–brain barrier (BBB), and cell death. Since the BBB only allows entry to a small class of drugs, many drugs used to treat ischemia in other tissues have failed in brain-related disorders. The administration of mesenchymal stem cell (MSC)-derived extracellular vesicles (EVs) has shown promise in improving the functional recovery of the brain following cerebral ischemia by inducing blood vessel formation. To facilitate such a treatment approach, it is necessary to develop bioprocesses that can produce therapeutically relevant MSC-EVs in a reproducible and scalable manner. This study evaluated the feasibility of using stirred suspension bioreactors (SSBs) to scale-up the serum-free production of pro-angiogenic MSC-EVs under clinically relevant physioxic conditions. It was found that MSCs grown in SSBs generated EVs that stimulated angiogenesis in cerebral microvascular endothelial cells, supporting the use of SSBs to produce MSC-EVs for application in cerebral ischemia. These properties were impaired at higher cell confluency, outlining the importance of considering the time of harvest when developing bioprocesses to manufacture EV populations. Full article

In this study, laser-induced fluorescence is used to investigate the homogenization in stirred vessels equipped with single- and two-stage stirrers. The acquired local mixing times across the reactor cross-section are plotted as mixing time distribution (MTD) and then compared with the previously measured flow fields of the identical systems. With the help of a novel evaluation method, the mixing times are characterized with a normal distribution fit. With mean value and standard deviation as determined parameters, the mixing results of different installation heights and stirrer combinations are quantitatively evaluated and lead to clear recommendations for installations that enable efficient mixing. Full article

Crystal morphology plays a critical role in the processability and physicochemical behavior of active pharmaceutical ingredients. Manipulating crystal morphology involves consideration of crystallization conditions such as temperature, supersaturation, and solvent choice. Typically, experimental screenings on a small scale are conducted to find targeted crystal morphologies. However, results from such small-scale experiments do not assure direct success at a larger scale, particularly if the small-scale setup differs significantly from a conventional stirred crystallizator. In this study, we successfully validated the morphologies observed in the small-scale experiments of an exemplary API, Bitopertin, when scaled up by a factor of 200, through the maintenance of identical process conditions and geometrical vessel relations. This successful scalability highlights the significant potential of small-scale crystallization studies to provide a reliable foundation for further exploration in large-scale endeavors. Full article