• Cavitation flow in an ARHCR is studied combining flow visualization and CFD. • Cavitation is characterized by the periodic motion of CGUs. • Cavitation development process shows high periodicity from flow visualization. • Vortex cavitation is generated at the vortex center of CGUs. • Sheet cavitation is induced in the flow separation region of downstream CGUs.

Hydrodynamic cavitation (HC) has been widely considered a promising technique for industrial-scale process intensifications. The effectiveness of HC is determined by the performance of hydrodynamic cavitation reactors (HCRs). The advanced rotational HCRs (ARHCRs) proposed recently have shown superior performance in various applications, while the research on the structural optimization is still absent. The present study, for the first time, identifies optimal structures of the cavitation generation units of a representative ARHCR by combining genetic algorithm (GA) and computational fluid dynamics, with the objectives of maximizing the total vapor volume, $V_{\mathit{vapor}}$ , and minimizing the total torque of the rotor wall, ${\overrightarrow{M}}_z$ . Four important geometrical factors, namely, diameter (D), interaction distance (s), height (h), and inclination angle (θ), were specified as the design variables. Two high-performance fitness functions for $V_{\mathit{vapor}}$ and ${\overrightarrow{M}}_z$ were established from a central composite design with 25 cases. After performing 10,001 simulations of GA, a Pareto front with 1630 non-dominated points was obtained. The results reveal that the values of s and θ of the Pareto front concentrated on their lower (i.e., 1.5 mm) and upper limits (i.e., 18.75°), respectively, while the values of D and h were scattered in their variation regions. In comparison to the original model, a representative global optimal point increased the $V_{\mathit{vapor}}$ by 156% and decreased the ${\overrightarrow{M}}_z$ by 14%. The corresponding improved mechanism was revealed by analyzing the flow field. The findings of this work can strongly support the fundamental understanding, design, and application of ARHCRs for process intensifications.

Hydrodynamic cavitation is a powerful tool for the enhancement of various processing applications. This study utilizes continuous hydrodynamic cavitation (CHC) for the inactivation of pathogens in milk for the first time. The thermal characteristics, inactivation performance, damage on the nutritional composition, product safety, and cost of the advanced rotational hydrodynamic cavitation reactor at pilot scale were comprehensively investigated. The inactivation results demonstrated that 5.89, 5.53, and 2.99 ± 0.08 log reductions of Escherichia coli, Staphylococcus aureus, and Bacillus cereus were achieved, respectively, at a final treatment temperature of 70 °C for 1-2 s. Moreover, the detrimental effect of CHC on the nutritional composition of milk, including mineral, fat, protein, and vitamin contents, was similar to that of high-temperature short-time method. The change in the concentrations of general bacteria and E. coli, as well as the pH value and acidity of the CHC treated milk stored at 5 °C for 14 days was found to be close to that of low-temperature long-time pasteurized milk. The cost of the present CHC treatment was $0.00268/L with a production rate of 4.2 L/min. CHC appears to be a remarkable method for the continuous processing of milk, as well as other liquid foods with high nutrition and "fresh-picked" flavor, due to its high efficacy, good scalability, high production capacity, and low operating and equipment costs.

Hydrodynamic cavitation is a promising technique for water disinfection. In the present paper, the disinfection characteristics of an advanced hydrodynamic cavitation reactor (ARHCR) in pilot scale were studied. The effects of various flow rates (1.4-2.6 m3/h) and rotational speeds (2600-4200 rpm) on the removal of Escherichia coli (E. coli) were revealed and analyzed. The variation regularities of the log reduction and reaction rate constant at various cavitation numbers were established. A disinfection rate of 100% was achieved in only 4 min for 15 L of simulated effluent under 4200 rpm and 1.4 m3/h, with energy efficiency at 0.0499 kWh/L. A comprehensive comparison with previously introduced HCRs demonstrates the superior performance of the presented ARHCR system. The morphological changes in E. coli were studied by scanning electron microscopy. The results indicate that the ARHCR can lead to serious cleavage and surface damages to E. coli, which cannot be obtained by conventional HCRs. Finally, a possible damage mechanism of the ARHCR, including both the hydrodynamical and sonochemical effects, was proposed. The findings of the present study can provide strong support to the fundamental understanding and applications of ARHCRs for water disinfection.