The Role of Operating Conditions in the Precipitation of Magnesium Hydroxide Hexagonal Platelets Using NaOH Solutions.

Magnesium hydroxide, Mg(OH)2, is an inorganic compound extensively employed in several industrial sectors. Nowadays, it is mostly produced from magnesium-rich minerals. Nevertheless, magnesium-rich solutions, such as natural and industrial brines, could prove to be a great treasure. In this work, synthetic magnesium chloride and sodium hydroxide (NaOH) solutions were used to recover Mg(OH)2 by reactive crystallization. A detailed experimental campaign was conducted aiming at producing grown Mg(OH)2 hexagonal platelets. Experiments were carried out in a stirred tank crystallizer operated in single- and double-feed configurations. In the single-feed configuration, globular and nanoflakes primary particles were obtained, as always reported in the literature when NaOH is used as a precipitant. However, these products are not complying with flame-retardant applications that require large hexagonal Mg(OH)2 platelets. This work suggests an effective precipitation strategy to favor crystal growth while, at the same time, limiting the nucleation mechanism. The double-feed configuration allowed the synthesis of grown Mg(OH)2 hexagonal platelets. The influence of reactant flow rates, reactant concentrations, and reaction temperature was analyzed. Scanning electron microscopy (SEM) pictures were also taken to investigate the morphology of Mg(OH)2 crystals. The proposed precipitation strategy paves the road to satisfy flame-retardant market requirements.

Computational Modeling of Magnesium Hydroxide Precipitation and Kinetics Parameters Identification.

Magnesium is a critical raw material and its recovery as Mg(OH)2 from saltwork brines can be realized via precipitation. The effective design, optimization, and scale-up of such a process require the development of a computational model accounting for the effect of fluid dynamics, homogeneous and heterogeneous nucleation, molecular growth, and aggregation. The unknown kinetics parameters are inferred and validated in this work by using experimental data produced with a T2mm-mixer and a T3mm-mixer, guaranteeing fast and efficient mixing. The flow field in the T-mixers is fully characterized by using the k-ε turbulence model implemented in the computational fluid dynamics (CFD) code OpenFOAM. The model is based on a simplified plug flow reactor model, instructed by detailed CFD simulations. It incorporates Bromley's activity coefficient correction and a micro-mixing model for the calculation of the supersaturation ratio. The population balance equation is solved by exploiting the quadrature method of moments, and mass balances are used for updating the reactive ions concentrations, accounting for the precipitated solid. To avoid unphysical results, global constrained optimization is used for kinetics parameters identification, exploiting experimentally measured particle size distribution (PSD). The inferred kinetics set is validated by comparing PSDs at different operative conditions both in the T2mm-mixer and the T3mm-mixer. The developed computational model, including the kinetics parameters estimated for the first time in this work, will be used for the design of a prototype for the industrial precipitation of Mg(OH)2 from saltwork brines in an industrial environment.

Nanoprobes to investigate nonspecific interactions in lipid bilayers: from defect-mediated adhesion to membrane disruption.

When a lipid membrane approaches a material/nanomaterial, nonspecific adhesion may occur. The interactions responsible for nonspecific adhesion can either preserve the membrane integrity or lead to its disruption. Despite the importance of the phenomenon, there is still a lack of clear understanding of how and why nonspecific adhesion may originate different resulting scenarios and how these interaction scenarios can be investigated. This work aims at bridging this gap by investigating the role of the interplay between cationic electrostatic and hydrophobic interactions in modulating the membrane stability during nonspecific adhesion phenomena. Here, the stability of the membrane has been studied employing anisotropic nanoprobes in zwitterionic lipid membranes with the support of coarse-grained molecular dynamics simulations to interpret the experimental observations. Lipid membrane electrical measurements and nanoscale visualization in combination with molecular dynamics simulations revealed the phenomena driving nonspecific adhesion. Any interaction with the lipidic bilayer is defect-mediated involving cationic electrostatically driven lipid extraction and hydrophobically-driven chain protrusion, whose interplay determines the existence of a thermodynamic optimum for the membrane structural integrity. These findings unlock unexplored routes to exploit nonspecific adhesion in lipid membranes. The proposed platform can act as a straightforward probing tool to locally investigate interactions between synthetic materials and lipid membranes for the design of antibacterials, antivirals, and scaffolds for tissue engineering.

Numerical Methods for the Solution of Population Balance Equations Coupled with Computational Fluid Dynamics.

This review article discusses the solution of population balance equations, for the simulation of disperse multiphase systems, tightly coupled with computational fluid dynamics. Although several methods are discussed, the focus is on quadrature-based moment methods (QBMMs) with particular attention to the quadrature method of moments, the conditional quadrature method of moments, and the direct quadrature method of moments. The relationship between the population balance equation, in its generalized form, and the Euler-Euler multiphase flow models, notably the two-fluid model, is thoroughly discussed. Then the closure problem and the use of Gaussian quadratures to overcome it are analyzed. The review concludes with the presentation of numerical issues and guidelines for users of these modeling approaches.

An experimental rheological phase diagram of a tri-block co-polymer in water validated against dissipative particle dynamics simulations.

Aqueous solutions of tri-block co-polymer surfactants are able to aggregate into a rich variety of microstructures, which can exhibit different rheological behaviors. In this work, we study the diversity of structures detected in aqueous solutions of Pluronic L64 at various concentrations and temperatures by experimental rheometry and dissipative particle dynamics (DPD) simulations. Mixtures of Pluronic L64 in water (ranging from 0 to 90 wt% Pluronic L64) have been studied in both linear and non-linear regimes by oscillatory and steady shear flow. The measurements allowed for the determination of a complete rheological phase diagram of the Pluronic L64-water system. The linear and non-linear regimes have been compared to equilibrium and non-equilibrium DPD bulk simulations of similar systems obtained by using the software LAMMPS. The molecular results are capable of reproducing the equilibrium structures, which are in complete agreement with the ones predicted through experimental linear rheology. The simulations also depict micellar microstructures after long time periods when a strong flow is applied. These structures are directly compared, from a qualitative point of view, with the corresponding experimental results and differences between the equilibrium and non-equilibrium phase diagrams are highlighted, proving the capability of detecting morphological changes caused by deformation in both experiments and DPD simulations. The effect of temperature on the rheology of the systems has been eventually investigated and compared with the already existing non-rheological phase diagram.

Dissipative particle dynamics simulations of tri-block co-polymer and water: Phase diagram validation and microstructure identification.

In this study, the phase diagram of Pluronic L64 and water is simulated via dissipative particle dynamics (DPD). The peculiar structures that form when the concentration varies from dilute to dense (i.e., spherical and rod-like micelles, hexagonal and lamellar phases, as well as reverse micelles) are recognized, and predictions are found to be in good agreement with experiments. A novel clustering algorithm is used to identify the structures formed, characterize them in terms of radius of gyration and aggregation number and cluster mass distributions. Non-equilibrium simulations are also performed, in order to predict how structures are affected by shear, both via qualitative and quantitative analyses. Despite the well-known scaling problem that results in unrealistic shear rates in real units, results show that non-Newtonian behaviors can be predicted by DPD and associated with variations of the observed microstructures.

Computational Fluid Dynamics data for improving freeze-dryers design.

Computational Fluid Dynamics (CFD) can be used to simulate different parts of an industrial freeze-drying equipment and to properly design them; in particular data concerning the freeze-dryer chamber and the duct connecting the chamber with the condenser, with the valves and vanes eventually present are given here, and can be used to understand the behavior of the apparatus allowing an improved design. Pilot and large scale freeze-drying chambers have been considered; data of a detailed simulation of a complete pilot scale apparatus, including duct and condenser, are included. Data on conductance of an empty duct with different L/D ratio, on disk valves with different geometry, and on mushroom valve are presented. Velocity, pressure, temperature and composition fields are reported on selected planes for chambers and valves. Results of dynamic simulations are also presented, to evaluate possible performance of monitoring devices in the chamber. Some further data, with detailed interpretation and discussion of the presented data can be found in the related research article by Barresi et al. [1] and Marchisio et al. [2].

Use of computational fluid dynamics for improving freeze-dryers design and process understanding. Part 1: Modelling the lyophilisation chamber.

This manuscript shows how computational models, mainly based on Computational Fluid Dynamics (CFD), can be used to simulate different parts of an industrial freeze-drying equipment and to properly design them; in particular, the freeze-dryer chamber and the duct connecting the chamber with the condenser, with the valves and vanes eventually present are analysed in this work. In Part 1, it will be shown how CFD can be employed to improve specific designs, to perform geometry optimization, to evaluate different design choices and how it is useful to evaluate the effect on product drying and batch variance. Such an approach allows an in-depth process understanding and assessment of the critical aspects of lyophilisation. This can be done by running either steady-state or transient simulations with imposed sublimation rates or with multi-scale approaches. This methodology will be demonstrated on freeze-drying equipment of different sizes, investigating the influence of the equipment geometry and shelf inter-distance. The effect of valve type (butterfly and mushroom) and shape on duct conductance and critical flow conditions will be instead investigated in Part 2.

Extended Charge-On-Particle Optimized Potentials for Liquid Simulation Acetone Model: The Case of Acetone-Water Mixtures.

It is well-known that classical molecular dynamics simulations of acetone-water mixtures lead to a strong phase separation when using most of the standard all-atom force fields, despite the well-known experimental fact that acetone is miscible with water in any proportion at room temperature. We describe here the use of a charge-on-particle model for accounting for the induced polarization effect in acetone-water mixtures which can solve the demixing problem at all acetone molar fractions. The polarizability effect is introduced by means of a virtual site (VS) on the carbonyl group of the acetone molecule, which increases its dipole moment and leads to a better affinity with water molecules. The VS parameter is set by fitting the density of the mixture at different acetone molar fractions. The main novelty of the VS approach lies on the transferability and universality of the model because the polarizability can be controlled without modifying the force field adopted, like previous efforts did. The results are satisfactory also in terms of the transport properties, that is, diffusivity and viscosity coefficients of the mixture.

Use of computational fluid dynamics for improving freeze-dryers design and process understanding. Part 2: Condenser duct and valve modelling.

This manuscript shows how computational models, mainly based on Computational Fluid Dynamics (CFD), can be used to simulate different parts of an industrial freeze-drying equipment and to properly design them; in particular in this part the duct connecting the chamber with the condenser, with its valves, is considered, while the chamber design and its effect on drying kinetics have been investigated in Part 1. Such an approach allows a much deeper process understanding and assessment of the critical aspects of lyophilisation. This methodology will be demonstrated on freeze-drying equipment of different sizes, investigating influence of valve type (butterfly and mushroom) and shape on duct conductance and critical flow conditions. The role of the inlet and boundary conditions considered has been assessed, also by modelling the whole apparatus including chamber and condenser, and the influence of the duct diameter has been discussed; the results show a little dependence of the relationship between critical mass flux and chamber pressure on the duct size. Results concerning the fluid dynamics of a simple disk valve, a profiled butterfly valve and a mushroom valve installed in a medium size horizontal condenser are presented. Also in these cases the maximum allowable flow when sonic flow conditions are reached can be described by a correlation similar to that found valid for empty ducts; for the mushroom valve the parameters are dependent on the valve opening length. The possibility to use the equivalent length concept, and to extend the validity of the results obtained for empty ducts will be also discussed. Finally the presence of the inert gas modifies the conductance of the duct, reducing the maximum flow rate of water that can be removed through it before the flow is choked; this also requires a proper over-sizing of the duct (or duct-butterfly valve system).

Recirculation zones induce non-Fickian transport in three-dimensional periodic porous media.

In this work, the influence of pore space geometry on solute transport in porous media is investigated performing computational fluid dynamics pore-scale simulations of fluid flow and solute transport. The three-dimensional periodic domains are obtained from three different pore structure configurations, namely, face-centered-cubic (fcc), body-centered-cubic (bcc), and sphere-in-cube (sic) arrangements of spherical grains. Although transport simulations are performed with media having the same grain size and the same porosity (in fcc and bcc configurations), the resulting breakthrough curves present noteworthy differences, such as enhanced tailing. The cause of such differences is ascribed to the presence of recirculation zones, even at low Reynolds numbers. Various methods to readily identify recirculation zones and quantify their magnitude using pore-scale data are proposed. The information gained from this analysis is then used to define macroscale models able to provide an appropriate description of the observed anomalous transport. A mass transfer model is applied to estimate relevant macroscale parameters (hydrodynamic dispersion above all) and their spatial variation in the medium; a functional relation describing the spatial variation of such macroscale parameters is then proposed.

Cotton fabric functionalisation with menthol/PCL micro- and nano-capsules for comfort improvement.

OBJECTIVE: Cotton functionalisation with poly-ɛ-caprolactone (PCL) micro- and nano-capsules containing menthol was carried out with the aim of introducing a long-lasting refreshing sensation. MATERIALS AND METHODS: The preparation of the polymer micro- and nano-capsules was carried out by solvent displacement technique. A confined impinging jets mixer was used in order to ensure fast mixing and generate a homogeneous environment where PCL and menthol can self-assemble. RESULTS: The micro- and nano-capsules and the functionalised fabrics were characterised by means of DSC, FT-IR spectroscopy and SEM imaging. Micro- and nano-capsules of different size, from about 200 to about 1200 nm, were obtained varying menthol to PCL ratio (from 0.76 to 8), overall concentration and flow rate (i.e. mixing conditions). The inclusion of menthol was confirmed by DSC analysis. DISCUSSION AND CONCLUSION: A patch test was carried out by 10 volunteers. Micro-capsules were found to be effective in conferring the fabric a refreshing sensation without altering skin physiology.

An extended and total flux normalized correlation equation for predicting single-collector efficiency.

In this study a novel total flux normalized correlation equation is proposed for predicting single-collector efficiency under a broad range of parameters. The correlation equation does not exploit the additivity approach introduced by Yao et al. (1971), but includes mixed terms that account for the mutual interaction of concomitant transport mechanisms (i.e., advection, gravity and Brownian motion) and of finite size of the particles (steric effect). The correlation equation is based on a combination of Eulerian and Lagrangian simulations performed, under Smoluchowski-Levich conditions, in a geometry which consists of a sphere enveloped by a cylindrical control volume. The normalization of the deposited flux is performed accounting for all of the particles entering into the control volume through all transport mechanisms (not just the upstream convective flux as conventionally done) to provide efficiency values lower than one over a wide range of parameters. In order to guarantee the independence of each term, the correlation equation is derived through a rigorous hierarchical parameter estimation process, accounting for single and mutual interacting transport mechanisms. The correlation equation, valid both for point and finite-size particles, is extended to include porosity dependency and it is compared with previous models. Reduced forms are proposed by elimination of the less relevant terms.

Solvent structuring and its effect on the polymer structure and processability: the case of water-acetone poly-ε-caprolactone mixtures.

One of the most common processes to produce polymer nanoparticles is the solvent-displacement method, in which the polymer is dissolved in a "good" solvent and the solution is then mixed with an "anti-solvent". The polymer processability is therefore determined by its structural and transport properties in solutions of the pure solvents and at the intermediate compositions. In this work, we focus on poly-ε-caprolactone (PCL) which is a biocompatible polymer that finds widespread application in the pharmaceutical and biomedical fields, performing full atomistic molecular dynamics simulations of one PCL chain of different molecular weight in a solution of pure acetone (good solvent), of pure water (antisolvent), and their mixtures. Our simulations reveal that the nanostructuring of one of the solvents in the mixture leads to an unexpected identical polymer structure irrespectively of the concentration of the two solvents. In particular, although in pure solvents the behavior of the polymer is, as expected, very different, at intermediate compositions, the PCL chain shows properties very similar to those found in pure acetone as a result of the clustering of the acetone molecules in the vicinity of the polymer chain. We derive an analytical expression to predict the polymer structural properties in solution at different solvent compositions and show that the solvent clustering affects in an unpredictable way the polymer diffusion coefficient. These findings have important consequences on the optimization of the nanoparticle production process and in the implementation of continuum modeling techniques to model it.

Pore-scale simulation of fluid flow and solute dispersion in three-dimensional porous media.

In the present work fluid flow and solute transport through porous media are described by solving the governing equations at the pore scale with finite-volume discretization. Instead of solving the simplified Stokes equation (very often employed in this context) the full Navier-Stokes equation is used here. The realistic three-dimensional porous medium is created in this work by packing together, with standard ballistic physics, irregular and polydisperse objects. Emphasis is placed on numerical issues related to mesh generation and spatial discretization, which play an important role in determining the final accuracy of the finite-volume scheme and are often overlooked. The simulations performed are then analyzed in terms of velocity distributions and dispersion rates in a wider range of operating conditions, when compared with other works carried out by solving the Stokes equation. Results show that dispersion within the analyzed porous medium is adequately described by classical power laws obtained by analytic homogenization. Eventually the validity of Fickian diffusion to treat dispersion in porous media is also assessed.

Dynamic light scattering and X-ray photoelectron spectroscopy characterization of PEGylated polymer nanocarriers: internal structure and surface properties.

In this work, nanospheres and nanocapsules are precipitated in confined impinging jet mixers through solvent displacement and characterized. Acetone and water are used as the solvent and antisolvent, respectively, together with polymethoxypolyethylene glycol cyanoacrylate-co-hexadecylcyanoacrylate and Miglyol as the copolymer and oil, respectively. Characterization is performed with dynamic light scattering, with electrophoretic measurements, and for the first time with X-ray photoelectron spectroscopy. Results show that the presence of polyethylene glycol chains seems to be more pronounced on the surface of nanospheres than on that of nanocapsules. The thickness of the copolymer layer in nanocapsules ranges from 1 to 10 nm, depending on the value of the oil:copolymer mass ratio. Fast dilution is confirmed to have a positive effect in suppressing aggregation but can induce further copolymer precipitation.

Size control in production and freeze-drying of poly-ε-caprolactone nanoparticles.

This work is focused on the control of poly-ε-caprolactone nanoparticle characteristics, notably size and size distribution, in both the production and preservation (by using freeze-drying) stages. Nanoparticles were obtained by employing the solvent displacement method in a confined impinging jets mixer. The effect of several operating conditions, namely, initial polymer concentration and solvent-to-antisolvent flow rate ratio, and the influence of postprocessing conditions, such as final dilution and solvent evaporation, on nanoparticle characteristics was investigated. Further addition of antisolvent (water) after preparation was demonstrated to be effective in obtaining stable nanoparticles, that is, avoiding aggregation that would result in larger particles. On the contrary, solvent (acetone) evaporation was shown to have a small effect on the final nanoparticle characteristics. Eventually, freeze-drying of the solutions containing nanoparticles, after solvent evaporation, was also investigated. To ensure maximum nanoparticles stability, lyoprotectants (e.g., sucrose and mannitol) and steric stabilizers (e.g., Cremophor EL and Poloxamer 388) had to be added to the suspensions. The efficacy of the selected lyoprotectants, in the presence (or absence) of steric stabilizers, and in various concentrations, to avoid particle aggregation during the freeze-drying process was investigated, thus pointing to the optimal formulation.

Microscale simulation of particle deposition in porous media.

In this work several geometries, each representing a different porous medium, are considered to perform detailed computational fluid dynamics simulation for fluid flow, particle transport and deposition. Only Brownian motions and steric interception are accounted for as deposition mechanisms. Firstly pressure drop in each porous medium is analyzed in order to determine an effective grain size, by fitting the results with the Ergun law. Then grid independence is assessed. Lastly, particle transport in the system is investigated via Eulerian steady-state simulations, where particle concentration is solved for, not following explicitly particles' trajectories, but solving the corresponding advection-diffusion equation. An assumption was made in considering favorable collector-particle interactions, resulting in a "perfect sink" boundary condition for the collectors. The gathered simulation data are used to calculate the deposition efficiency due to Brownian motions and steric interception. The original Levich law for one simple circular collector is verified; subsequently porous media constituted by a packing of collectors are scrutinized. Results show that the interactions between the different collectors result in behaviors which are not in line with the theory developed by Happel and co-workers, highlighting a different dependency of the deposition efficiency on the dimensionless groups involved in the relevant correlations.

Mixing atoms and coarse-grained beads in modelling polymer melts.

We present a simple hybrid model for macromolecules where the single molecules are modelled with both atoms and coarse-grained beads. We apply our approach to two different polymer melts, polystyrene and polyethylene, for which the coarse-grained potential has been developed using the iterative Boltzmann inversion procedure. Our results show that it is possible to couple the two potentials without modifying them and that the mixed model preserves the local and the global structure of the melts in each of the case presented. The degree of resolution present in each single molecule seems to not affect the robustness of the model. The mixed potential does not show any bias and no cluster of particles of different resolution has been observed.

Production of PEGylated nanocapsules through solvent displacement in confined impinging jet mixers.

The growth of importance of nanocapsules (and other particulate systems) in different fields requires fast and reproducible methods for their production. Confined impinging jet mixers were successfully used for the production of nanospheres and are now tested for the first time for the production of nanocapsules. This work focuses on the understanding of formation mechanisms and on the quantification of the effect of the most important operating parameters involved in their production. Solvent displacement is employed here for the assembly of the nanocapsules by using a PEGylated derivative of cyanoacrylate as copolymer. A comparison with nanospheres obtained under the same operating conditions is also reported. Results show that the oil-to-copolymer mass ratio (MR) is the main factor affecting the final size distribution and that small nanocapsules are obtained only at low oil-to-copolymer MR. The effect of mixing is significant, proving that mixing of solvent and antisolvent also affects the final size distribution; this depends mainly on the inlet jet velocity, but the size of the mixer is also important. The Reynolds number may be useful to take this into account for geometrically similar systems. Quenching by dilution allows to stabilize the nanocapsules, evidencing the role of aggregation and ripening.