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The hydrothermal synthesis of zeolites carried out in batch reactors takes a time so long (typically, on the order of days) that the crystallization of zeolites has long been believed to be very slow in nature. We herein present a synthetic process for ZSM-5, an industrially important zeolite, on the order of seconds in a continuous flow reactor using pressurized hot water as a heating medium. Direct mixing of a well-tuned precursor (90 °C) with the pressurized water preheated to extremely high temperature (370 °C) in the millimeter-sized continuous flow reactor resulted in immediate heating to high temperatures (240–300 °C); consequently, the crystallization of ZSM-5 in a seed-free system proceeded to completion within tens of or even several seconds. These results indicate that the crystallization of zeolites can complete in a period on the order of seconds. The subtle design combining a continuous flow reactor with pressurized hot water can greatly facilitate the mass production of zeolites in the future.

Continuous-flow production of liposomes using microfluidic reactors has demonstrated advantages compared to batch methods, including greater control over liposome size and size distribution and reduced reliance on post-production processing steps. However, the use of microfluidic technology for the production of nanoscale vesicular systems (such as liposomes) has not been fully translated to industrial scale yet. This may be due to limitations of microfluidic-based reactors, such as low production rates, limited lifetimes, and high manufacturing costs. In this study, we investigated the potential of millimeter-scale flow reactors (or millireactors) with a serpentine-like architecture, as a scalable and cost-effective route to the production of nanoscale liposomes. The effects on liposome size of varying inlet flow rates, lipid type and concentration, storage conditions, and temperature were investigated. Liposome size (i.e., mean diameter) and size dispersity were characterised by dynamic light scattering (DLS); z-potential measurements and TEM imaging were also carried out on selected liposome batches. It was found that the lipid type and concentration, together with the inlet flow settings, had significant effects on the properties of the resultant liposome dispersion. Notably, the millifluidic reactor was able to generate liposomes with size and dispersity ranging from 54 to 272 nm, and from 0.04 to 0.52 respectively, at operating flow rates between 1 and 10 mL/min. Moreover, when compared to a batch ethanol-injection method, the millireactor generated liposomes with a more therapeutically relevant size and size dispersity.

The study of macro continuous flow has a long history. Simultaneously, the exploration of heat and mass transfer in small systems with a particle number of several hundred or less has gained significant interest in the fields of statistical physics and nonlinear science. However, due to absence of suitable methods, the understanding of mesoscale behavior situated between the aforementioned two scenarios, which challenges the physical function of traditional continuous fluid theory and exceeds the simulation capability of microscopic molecular dynamics method, remains considerably deficient. This greatly restricts the evaluation of effects of mesoscale behavior and impedes the development of corresponding regulation techniques. To access the mesoscale behaviors, there are two ways: from large to small and from small to large. Given the necessity to interface with the prevailing macroscopic continuous modeling currently used in the mechanical engineering community, our study of mesoscale behavior begins from the side closer to the macroscopic continuum, that is from large to small. Focusing on some fundamental challenges encountered in modeling and analysis of near-continuous flows, we review the research progress of discrete Boltzmann method (DBM). The ideas and schemes of DBM in coarse-grained modeling and complex physical field analysis are introduced. The relationships, particularly the differences, between DBM and traditional fluid modeling as well as other kinetic methods are discussed. After verification and validation of the method, some applied researches including the development of various physical functions associated with discrete and non-equilibrium effects are illustrated. Future directions of DBM related studies are indicated.

Photocatalysis has been proved to be a promising approach in wastewater purification. However, it is hard to recycle powdery photocatalysts from wastewater in industry, but immobilizing them using larger materials can overcome this drawback. For that reason, TiO2@g-C3N4 was embedded into chitosan to synthesize a highly reusable and visible-light-driven chitosan/TiO2@g-C3N4 nanocomposite membrane (CTGM). CTGM showed enhanced photoactivity and the photocatalytic efficiencies of the toxic water pollutants methyl orange (M.O.), rhodamine B (Rh.B), chromium (VI) (Cr (VI)), 2,4-dichlorophenol (2,4-DCP) and atrazine (ATZ) were more than 90% under visible light at ambient conditions. Significantly, CTGM was easy to recycle and showed excellent reusability: there was no decrease in the photocatalytic decolorization efficiency of Rh.B throughout 10 cycles. A continuous-flow photocatalysis system was set up and 90% of Rh.B was effectively decolorized. A simple approach was developed to prepare a novel, effective and visible-light-driven membrane that was easy to reuse, and a feasible photocatalysis continuous-flow system was designed to be a reference for wastewater treatment in industry.

Aerobic granular sludge (AGS) in continuous-flow reactors (CFRs) has attracted significant interest, with notable progress in research and application over the past two decades. Cumulative studies have shown that AGS-CFRs exhibit comparable morphology, settleability, and pollutant removal efficiency to AGS cultivated in sequencing batch reactors, despite their smaller particle sizes. Shear force and selection pressure are the primary drivers of granulation. While not mandatory for granulation, feast/famine conditions play a crucial role in ensuring long-term stability and nutrient removal. Additionally, bioaugmentation can facilitate the granulation process. Furthermore, this paper comprehensively assesses the application of AGS-CFRs in full-scale wastewater treatment plants (WWTPs). Currently, AGS-CFRs have been implemented in nine WWTPs, encompassing two distinct processes. Hydrocyclone-based densified activated sludge significantly enhances sludge density, settleability, and biological phosphorus removal efficiency, thus increasing treatment capacity. The microaerobic–aerobic configuration with internal separators can induce granulation, ensuring long-term stability, eliminating the need for external clarifiers, and reducing land and energy requirements. This review demonstrates the high potential of AGS-CFRs for intensifying existing WWTPs with minimal retrofitting needs. However, further research is required in granulation mechanisms, long-term stability, and nutrient removal to promote the widespread adoption of AGS.

Transparent coiled flow inverters (CFI), which are superior to opaque coil reactors, are hardly explored in performing condensation reactions of organic molecules. Herein, the continuous flow condensation reaction of gallic acid using CFI is reported with a 4 mm internal diameter. The length of the flow reactor is varied by connecting CFIs in series. Real‐time images of reactor captured during flow synthesis resolve the intricacies of reaction dynamics and stages of desired product formation. Stack CFI provides a desired residence time for carrying out reaction at high flow rate. Condensation of gallic acid in dimethyl formamide yields a green emissive xanthene analog. The production of organic emitter is optimized by regulating reactant flow rate and temperature of the reaction. The presence of a vapour–liquid phase boundary enhances the interfacial area, that further contributes to increasing the product yield. The optimized condition for fluorescent product using stack CFI is 190 °C (±5) temperature at 5 mL h −1 (±0.5) flow rate. A residence time of about 14 h (±1) and a heat flux of 4.46 W m −2 (±0.5) are desired for maximizing product yield using stack CFI. These suggest that CFI‐based flow reactor can easily be tailor‐made and economical as well.

An electrochemical Meerwein arylation reaction was reported for the synthesis of aryl-benzoquinone derivatives. In this work, efficient electrochemical synthesis of aryl-benzoquinone derivatives by direct electrolysis of aqueous solution containing hydroquinone and aryldiazonium salts in batch and a homemade continuous-flow cells is reported. In the batch system, the products were obtained in a simple undivided cell equipped with a copper anode and a stainless steel cathode. In the continuous flow system, the products were obtained simply by passing hydroquinone and the aryldiazonium salt through a tube made of copper with a stainless steel rod in the center. All equipment required in both cell types is obtained from common commercial sources. This protocol is green and cost-effective due to the use of electricity and is performed under mild and safe conditions without the use of toxic solvents and catalysts.

In this paper, we evaluated the potential of two synthesized bio-based polyurethane foams, PU1 and PU2, for the removal of diesel and gasoline from water mixtures. We started the investigation with the experiment in batch. The total sorption capacity S (g/g) for the diesel/water system was slightly higher with respect to gasoline/water, with a value of 62 g/g for PU1 and 65 g/g for PU2. We found that the sorption follows a pseudo second-order kinetic model for both the materials. The experimental data showed that the best isotherm models were obtained with Langmuir and Redlich–Peterson models. In addition, to provide an idea of the process scalability for future industrial applications, we tested the sorption capacity of the foams using a continuous-flow of the same oil/water mixtures and we obtained performances even better with respect to the batch test. The regeneration can be performed up to 50 times by centrifuge, without losing efficacy.

While a few derivatives of cinnamamides exhibited anti-inflammatory and/ or analgesic activity, in this study, we developed a highly efficient method for the synthesis of cinnamamides from methyl cinnamates and phenylethylamines catalyzed by Lipozyme® TL IM in continuous-flow microreactors. The reaction parameters and broad substrate range of the new method was studied. Maximum conversion (91.3%) was obtained under the optimal condition of substrate molar ratio of 1:2 (methyl 4-chlorocinnamate: phenylethylamine) at 45 °C for about 40 min. The remarkable features of this work include short residence time, mild reaction conditions, easy control of the reaction process, and that the catalyst can be recycled or reused, which provide a rapid and economical strategy for the synthesis and design of cinnamamide derivatives for further research on drug activity.

There is an increasing interest in integrating aerobic granular sludge (AGS) technology into wastewater industries. Several projects are being performed to cultivate the aerobic granules for continuous flow reactors (AGS-CFR), while there is a scarcity of those projects that investigate the bio-energy recovery from AGS-CFR. This research was designed to examine the digestibility of AGS-CFR. Beyond that, it aimed at defining the role of the granule size on their digestibility. For this purpose, a series of bio-methane potential (BMP) tests have been run at mesophilic conditions. The results showed that AGS-CFR has a lower methane potential (107.43 ± 4.30 NmL/g VS) compared to activated sludge. This may be the result of the high sludge age (30 days) of AGS-CFR. Additionally, the results revealed that the average size of granules is among the main factors that reduce their digestibility, but it does not inhibit it. It was noticed that granules of size >250 μm have a significantly lower methane yield than the smaller ones. Kinetically, it was noticed that the kinetic models with two hydrolysis rates fit well with the methane curve of AGS-CFR. Overall, this work showed that the average size of AGS-CFR characterizes its biodegradability, which in turn defines its methane yield.