Effect of liquid bridge evolution on the droplet non-coalescence under a DC electric field

The droplet non-coalescence characteristics and mechanism under a DC electric field are investigated by comprehensively using high-speed microscopic experiments, molecular dynamics simulations, and interface dynamics simulations. The researches show whether two droplets coalesce or not depends on the evolution of liquid bridge. The liquid bridge evolution is not only dominated by the electric force F_E and the capillary force F_i, but also slowed down by the viscous force. The relative strength of F_E and capillary force F_i relies on the electric capillary number Ca and the maximum liquid bridge radius R*_max. The droplet non-coalescence is more likely to happen as the Ca increases or the R*_max decreases. Furthermore, the critical value Ca_c for droplet non-coalescence reduces as the R*_max decreases. The ion transportation causes uneven distribution of ions and thus strengthens the F_E, resulting in the non-coalescence. These results provide significant guidance for efficient demulsification of water-in-oil emulsion.     

Coalescence dynamics of two droplets of different viscosities in T-junction microchannel with a funnel-typed expansion chamber

The coalescence behavior of two droplets with different viscosities in the funnel-typed expansion cham-ber in T-junction microchannel was investigated experimentally and compared with droplet coalescence of the same viscosity.Four types of coalescence regimes were observed:contact non-coalescence,squeeze non-coalescence,two-droplet coalescence and pinch-off coalescence.For droplet coalescence of different viscosities,the operating range of non-coalescence becomes narrowed compared to the droplet coalescence of same viscosity,and it shrinks with increasing viscosity ratio η of two droplets,indicating that the difference in the viscosity of two droplets is conducive to coalescence,especially when 1 ＜ η＜ 6.Furthermore,the influences of viscosity ratio and droplet size on the film drainage time (Tdr) and critical capillary number (Cac) were studied systematically.It was found that the film drainage time declined with the increase of average droplet size,which abided by power-law relation with the size dif-ference and viscosity ratio of the two droplets:Tdr ～ (ld)0.25±0.04 and Tdr ～ (η)-0.1±002.For droplet coales-cence of same viscosity,the relation of critical capillary number with two-phase viscosity ratio and dimensionless droplet size is Cac =0.48λ0.26l-2.64,while for droplet coalescence of different viscosities,the scaling of critical capillary number with dimensionless average droplet size,dimensionless droplet size difference and viscosity ratio of two droplets is Cac =0.11 η-0.07ls-2.23ld0.16.     

Non-coalescence behavior of neutral droplets suspended in oil under a direct current electric field

The excessive electric field gives rise to droplet non-coalescence and droplet chains in the electric dehydrator, which severely deteriorates oil–water separation efficiency and even leads to short circuit. To reveal the underlying mechanism of droplet non-coalescence, dynamic behavior of two neutral droplets in silicone oil under a direct current electric field is investigated by using high-speed photography. The experimental results show that there exists a critical electric field strength above which two droplets will bounce off after the contact. The critical electric field strength of droplet non-coalescence is affected by the initial separation distance between droplets, the radius of droplet, and the surfactant concentration. Whether the non-coalescence behavior occurs in the electric field is determined by the competition of electric force and capillary force, which dominates the evolution of tiny connection channel.     

新型静电聚结器中水滴聚结特性研究

传统电脱水器采用裸电极,含水率较高时在高强电场作用下容易发生击穿现象,今设计了包覆绝缘层的高压电极并加工了新型静电聚结器,可有效避免击穿现象的发生。采用水/原油乳状液为实验介质,并利用显微高速摄像系统结合图像处理技术对水滴的聚结规律进行了观察和分析,探索了电场强度、流量、含水率等因素对水滴聚结特性的影响。结果表明:包覆绝缘层的高压电极可有效防止电击穿现象的发生,增加电场强度有助于油水分离,但高于临界场强后容易导致液滴破碎;含水率为10%、20%、30%时,最优电场强度不同,分别是372、320和204 kV m 1;含水率10%和30%乳化物液滴粒径增大倍数明显大于含水率20%的工况;电场作用时间影响液滴聚结效果,高强电场在低流量下具有很显著的作用;随着流量的增加电场作用降低,但高强电场在高流量下依然使液滴粒径明显增大。     

电场作用下双液滴聚合特性

乳状液破乳分离是目前高含水期油田开采过程中难以解决的技术问题，电场破乳方法具有高效清洁等优点，是解决该问题的有效手段。采用数值模拟与试验验证相结合的方法研究电脱水过程中阶跃、斜坡电场诱导下双液滴的聚合与分离特性。结果表明，在斜坡电场作用下，界面张力引起的泵吸作用大于电场力引起的颈缩作用，有利于液滴聚并，且液滴发生二次乳化现象的概率降低。而施加阶跃电场时，一定范围内能够达到液滴破乳的目的，但液滴在聚并过程中易发生二次乳化现象。从电场对连续相影响的角度分析发现，阶跃电场不仅对液滴具有驱动作用，对连续相的影响也较为明显，阶跃电场会增大连续相内湍流作用，不利于电脱水过程。因此，采用斜坡信号诱导液滴聚合能够降低二次乳化现象发生的概率。     

Transient and steady-state deformations and breakup of dispersed-phase droplets of immiscible polymer blends in steady shear flow

Transient and steady-state deformations and breakup of viscoelastic polystyrene droplets dispersed in viscoelastic high-density polyethylene matrices were observed in a simple steady shear flow between two transparent parallel disks. By separately varying the elasticities of the individual blend components, the matrix shear viscosity, and the viscosity ratio, their effects on the transient deformation, steady-state droplet size, and the breakup sequence were determined. After the startup of a steady shear flow, the viscoelastic droplet initially exhibits oscillations of its length in the flow direction, but eventually stretches preferentially in the vorticity direction. We find that at fixed capillary number, the oscillation amplitude decreases with increasing droplet elasticity, while the oscillation period depends primarily on, and increases with, the viscosity ratio. At steady-state, the droplet length along the vorticity direction increases with increasing capillary number, viscosity ratio, and droplet elasticity. Remarkably, at a viscosity ratio of unity, the droplets remain in a nearly undeformed state as the capillary number is varied between 2 and 8, apparently because under these conditions a tendency for the droplets to widen in the vorticity direction counteracts their tendency to stretch in the flow direction. When a critical capillary number, Ca_c, is exceeded, the droplet finally stretches in the vorticity direction and forms a string which becomes thinner and finally breaks up, provided that the droplet elasticity is sufficiently high. For a fixed matrix shear stress and droplet elasticity, the steady-state deformation along the vorticity direction and the critical capillary number for breakup both increase with increasing viscosity ratio.     

Movement of dispersed droplets of W/O emulsion in a uniform DC electrostatic field:Simulation on droplet coalescence☆

Considering the droplet coalescence, the motion of a group of dispersed droplets in W/O emulsion in a DC electric field is simulated. The simulation demonstrates the evolutions of droplet number, size as wel as its distribution, local concentration distribution and droplet size-velocity relation with the applied time of electric field. The sim-ulated average droplet size is roughly consistent with the experimental value. The simulated variation of droplet number with time under several applied voltages shows that increasing voltage is more effective for raising the rate of droplet coalescence than extending exerting time. However, with the further raise of applied voltage, the improvement in droplet coalescence rate becomes less significant. The evolution of simulated droplet size–velocity relationship with time shows that the inter-droplet electric repulsion force is very strong due to larger electric charge on the droplet under higher applied voltage, so that the magnitude and the direction of droplet velocity become more random, which looks helpful to droplet coalescence.     

Interfacial phenomena and droplet size of particle stabilized emulsions in oscillatory shear

Production of particle stabilized oil in water emulsions has been investigated both theoretically and experimentally under oscillatory shear conditions using different stabilizing particles (SPs). The investigation included analysis of the interaction between particles interfacial stability and droplets breakage and coalescence. For hydrophobic SPs, droplets maintained their sizes as determined by torque balance (TB) without significant breakage or coalescence. For the more hydrophilic SPs, larger droplets formed that broke by eddies in the inertial subrange. At higher fluid shear stresses, loss of the SPs occurred during droplet formation leading to near bare droplet surface and coalescence to much larger sizes with subsequent fragmentation by capillary instabilities. The final droplet size in both cases was very different from TB model predictions. A modeling approach is proposed that combined both TB and droplet breakage and coalescence mechanisms. Comparison between the experimental results and the models predictions showed satisfactory agreement. © 2016 American Institute of Chemical Engineers AIChE J, 62: 2902–2911, 2016     

Development of polymer blend morphology during compounding in a twin-screw extruder. Part I: Droplet dispersion and coalescence—a review

The theoretical and experimental data on the breakup of droplets are reviewed. Several factors influence development of droplets: flow type and its intensity, viscosity ratio, elasticity of polymers, composition, thermodynamic interactions, time, etc. For Newtonian systems undergoing small, linear deformation, both the viscosity ratio and the capillary number control deformability of drops. On the other hand, the breakup process can be described by the dimensionless breakup time and the critical capillary number. Drops are more efficiently broken in elongational flow than in shear, especially when the viscosity ratio λ ? 3. The drop deformation and breakup seems to be more difficult in viscoelastic systems than in Newtonian ones. There is no theory able to describe the deformability of viscoelastic droplet suspended in a viscoelastic or even Newtonian medium. The effect of droplets coalescence on the final morphology ought to be considered, even at low concentration of the dispersed phase, ?_d ? 0.005. Several drop breakup and coalescence theories were briefly reviewed. However, they are of little direct use for quantitative prediction of the polymer blend morphology during compounding in a twin-screw extruder. Their value is limited to serving as general guides to the process modeling.     

Droplet splitting in multi-furcating microchannel: A three-dimensional numerical simulation study

This work investigates the splitting of a droplet in a multi-furcating microfluidic channel for a two-phase system employing 3D simulation. The simulations were performed using an explicit volume of fluid (VOF) method and have been validated using experimental data taken from the literature. The width ratio of the branch channel to the main channel is set to 0.25 for five branches of the multi-furcating microchannel, as it is the width ratio at which multiple splitting takes place. Simulations have been carried out at different oil velocities (V_o) ranging from 0.12 to 0.22 m/s and at different water velocities (V_w) ranging from 0.002 to 0.10 m/s. Oil fraction data in the main channel has been recorded and compared with the homogenous model. The average difference between the homogeneous model and the 3D simulations is 22.68%. Analysis of dimensionless droplet length in ±0°, ± 40°, and 90° branch channels has been done. α (length of the droplet in branch channel/width of the main channel) increases up to a flow rate ratio of 0.38, and then decreases, whereas β (length of the droplet in the main channel/width of the main channel) increases with an increase in flow rate ratio. A flow pattern map has been developed to identify the various droplet breakup regimes at the junction. Frequency (counts per unit time) of droplet generation increases with capillary number for all the branch channels except for the 0° branch channel, where the regime is that the droplet passes through three branch channels. The volume distribution ratio (λ) decreases at first, then increases with an increase in capillary number for 0°:90° and 40°:90° angle branch channels for the regime where the droplet passes through five branch channels. For the regime where the droplet passes through three branch channels, the trend is likely linear with λ = 0.3 ± 0.04. The dimensionless mother droplet length increases with an increase in capillary number for V_o = 0.13 and 0.16 m/s, but for V_o = 0.19 and 0.22 m/s, the dimensionless mother droplet length becomes constant after capillary number = 0.26 and 0.30 respectively. The droplet breakup time (t) for regime (a), where the droplet passes through three branch channels, is 0.002 s; for regime (b), where the droplet passes through five branch channels, it is 0.001 s; and for regime (c), where multi-furcation and coalescence of the droplet occurs, it is 0.0005 s. Multiple splitting is a topic covered in this paper that can be applied to upcoming microfluidic platform-based devices.     

Electro-coalescence of an aqueous droplet at an oil-water interface

The coalescence of an aqueous droplet at an oil-water interface under an electric field has been investigated, with a view to quantify conditions that give rise to secondary droplet formation. Two patterns of drop-interface coalescence may occur: complete coalescence and partial coalescence. The former is obviously the desirable pattern for industrial coalescers. However in practice, the process of coalescence could actually produce smaller droplets, which become more difficult to remove, and hence undesirable. This is caused by either necking, due to extensive elongation of the droplet, or reaction to a fast and energetic coalescence and is referred to as partial coalescence. The volume of the droplets formed in this way has been analyzed as a function of the initial droplet size, electric field strength and the distance between the droplet and the interface. The expansion speed of the neck connecting the droplet and interface at the beginning of the pumping process has also been quantified. These results are useful in optimizing the electro-coalescence process.     

非均匀电场下乳化油中液滴变形动力学行为

外加电场下液滴的变形动力学行为是乳化液电脱水机理研究的重要内容。基于Cahn-Hilliard方程的相场方法,建立了液滴在非均匀电场下的仿真模型,研究了电场作用下乳化液中液滴在形变、移动和聚结过程中电荷密度和电场力的分布规律,以及流场和电场的耦合作用。仿真分析了液滴粒径、电场强度以及电场非均匀系数对液滴运动行为的影响。利用实验室小型脱水系统开展了乳化液脱水实验,并通过高速摄像机对乳化液中液滴的运动行为进行了观测与分析。研究结果表明,在非均匀电场中液滴表面的极化电荷分布不均,由液滴中部向两端逐渐增大,在靠近电场集中方向处的电荷密度和Maxwell应力值最大;在一定范围内增大电场强度、电场非均匀系数或液滴粒径,可使液滴形变量增大,液滴向电场集中区域的移动速度以及液滴间的聚结速度增加。     

微流控技术中液滴聚并的研究进展

随着微流控技术的发展，在微通道内精确调控液滴行为的研究受到越来越多的关注。详细介绍了引发液滴聚并的方式，包括主动聚并和被动聚并。主动聚并是指施加电场、磁场、温度场等引起液滴融合，被动聚并是指通过改变通道结构或改变通道壁面润湿性促进聚并发生。此外，综述了液滴聚并动力学研究进展，例如：液膜排出时间和临界毛细管数。最后对聚并过程中的流场研究做了简要介绍。对液滴聚并的后续机理研究、探索高效的聚并方式和聚并的实际应用具有重要的指导意义。     

直流脉冲电场下液滴-界面聚并行为

为了深入探究直流脉冲电场下液滴-界面聚并行为,针对去离子水作为分散相、葵花油作为连续相的体系,分别改变电场参数（电场强度、频率、波形）和物性参数（界面张力、电导率、液滴粒径、固体颗粒）进行显微实验研究,得到了液滴-界面聚并机制及各参数的影响规律。实验结果表明,液滴-界面存在完全聚并和不完全聚并两种机制,决定因素是泵吸和颈缩过程的相互作用。电场强度增大,不完全聚并程度增大,而电场频率的作用则相反,这与电场力大小和液滴稳定程度有关。随表面活性剂浓度增大,二次液滴急剧增大,超过临界胶束浓度后,小幅减小。随电导率和SiO₂浓度增大,不完全聚并程度均先增大后减小,而随液滴粒径增大,不完全聚并程度持续增大。大部分工况下,液滴在直流稳恒电场下不完全聚并程度高于直流脉冲电场。为脉冲静电破乳机理的深入探讨及高效紧凑脉冲电脱盐脱水设备的研发奠定了理论基础。     

Prediction of average droplet size in flowing immiscible polymer blends

The paper is focused on calculation of the average droplet size in immiscible blends during their steady flow. Available theoretical and experimental results of studies of the droplet breakup and coalescence are utilized to derive the equations describing dynamic equilibrium between the droplet breakup and coalescence. New expression for the coalescence efficiency, reliably reflecting recent theoretical results, is proposed. The equation for the average steady droplet size, controlled by the stepwise breakup mechanism and coalescence of droplets with not very different sizes, is derived for blends containing up to 10–20 vol % of the droplets. For blends with above approximate 20 vol % of the droplets, the breakup by the Tomotika mechanism and coalescence in highly polydisperse system is modeled. Results of the derived equations are compared with experimental data; qualitative agreement is found for the dependence of the droplet size on the amount of the dispersed phase. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134, 45250.     

Morphology evolution and dynamics of droplet coalescence on superhydrophobic surfaces

In this work, the coalescence of two equal‐sized water droplets on superhydrophobic surfaces (SHSs) is experimentally investigated. The morphologies of droplet coalescence are observed from side‐view and bottom‐view using high‐speed camera system. The related morphology evolution and dynamics of droplet coalescence are explored. The dynamic behaviors of droplet coalescence on SHSs can be decomposed into liquid bridge growth, contact line evolution, and droplet jumping. The liquid bridge radius is proportional to the square root of time, whereas the dimensionless prefactor is decreased from 1.18 to 0.83 due to the transition of interface curvature. The retraction velocity of the contact line shows limited dependence on initial droplet radii as the retraction dynamics considered here are governed by the capillary–inertial effect. The coalesced droplet finally departs the substrate with a dimensionless jumping velocity of around 0.2. A heuristic argument is made to account for the nearly constant dimensionless jumping velocity. © 2018 American Institute of Chemical Engineers AIChE J, 64: 2913–2921, 2018     

Numerical simulation of a falling droplet surrounding by air under electric field using VOF method: A CFD study

This is a numerical study of a falling droplet surrounding by air under the electric field modeled with finite volume method by means of CFD. The VOF method has been employed to model the two-phase flow of the present study. Various capillary numbers are investigated to analyze the effects of electric field intensity on the falling droplet deformation. Also, the effects of electric potential on the heat transfer coefficient have been examined. The obtained results showed that by applying the electric field at a capillary number of 0.2 the droplet tends to retain its primitive shape as time goes by, with a subtle deformation to an oblate form. Intensifying the electric field to a capillary number of 0.8 droplet deformation is almost insignificant with time progressing; however, further enhancement in capillary number to 2 causes the droplet to deform as a prolate shape and higher values of this number intensify the prolate form deformation of the droplet and result in pinch-off phenomenon. Ultimately, it is showed that as the electric potential augments the heat transfer coefficient increases in which for electric potential values higher than 2400 V the heat transfer coefficient enhances significantly.     

Numerical simulation of a falling droplet surrounding by air under electric field using VOF method: A CFD study

This is a numerical study of a falling droplet surrounding by air under the electric field modeled with finite volume method by means of CFD. The VOF method has been employed to model the two-phase flow of the present study. Various capillary numbers are investigated to analyze the effects of electric field intensity on the falling droplet deformation. Also, the effects of electric potential on the heat transfer coefficient have been examined. The obtained results showed that by applying the electric field at a capillary number of 0.2 the droplet tends to retain its primitive shape as time goes by, with a subtle deformation to an oblate form. Intensifying the electric field to a capillary number of 0.8 droplet deformation is almost insignificant with time progressing; however, further enhancement in capillary number to 2 causes the droplet to deform as a prolate shape and higher values of this number intensify the prolate form deformation of the droplet and result in pinch-off phenomenon. Ultimately, it is showed that as the electric potential augments the heat transfer coefficient increases in which for electric potential values higher than 2400 V the heat transfer coefficient enhances significantly.     

Coalescence of Water Droplets in Crude Oil Emulsions: Analytical Solution

In petroleum refineries, water is used in desalting units to remove the salt contained in crude oil. Typically, 7 % of the volume of hot crude oil is water, forming a water‐and‐oil emulsion. The emulsion flows between two electrodes and is subjected to an electric field. The electrical forces promote the coalescence of small droplets of water dispersed in crude oil, and these form bigger droplets. This paper calculates the forces acting on the droplets, highlighting particularly the mechanisms proposed for droplet–droplet coalescence under the influence of an applied electric field. Moreover, a model is developed in order to calculate the displacement speed of the droplets and the time between droplet collisions. Thus, it is possible to simulate and optimize the process by changing the operational variables (temperature, electrical field, and water quantity). The main advantage of this study is to show that it is feasible to increase the volume of water recycled in desalting processes, thus reducing the use of freshwater and the generation of liquid effluents in refineries.     

Microencapsulation of hydrophilic solid powder as fire retardant agent with epoxy resin by droplet coalescence method

To give water resistance to Bistetrazol–diammonium (BHT–2NH₃) as a fire retardant agent, microencapsulation with epoxy resin was tried by the droplet coalescence method. In this method, two kinds of epoxy resin droplets were prepared; one is the larger epoxy resin droplet containing BHT–2NH₃ as a core material and the other the smaller droplets containing Imidazole as a gelation agent. The larger epoxy resin droplets were made to coalesce with the many smaller droplets during the microencapsulation process to prepare microcapsules. In the experiment, the agitation velocities for preparation of the droplets and for coalescence were mainly changed. With increase in the impeller speed, the content of core material increased, became maximum because of increase in the coalescence frequency, and then decreased because of breakup of droplets. With increase in the impeller speed, the leakage ratio of core material decreased, became minimum, and then increased. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008.