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By combining the developments in acoustics, hydrodynamics and chemical kinetics, a new promising device is entering the market: the cavitation reactors, used for processing of suspensions, emulsions and for intensification of chemical processes in solutions. These devices are can be used either separately (in laboratory test-benches) or in industrial mixing processes. In today’s market, two main types of cavitation reactors are available: the ultrasonic cavitation reactors and the hydrodynamic cavitation reactors. The latter are more popular due to simpler design, reliability and reasonable cost.

The modern cavitation reactor allows to continuously disperse (atomize a solid component), homogenize (further atomization of a fraction and increasing the uniformity of its distribution in a liquid), disintegration (breaking of complex substances into components), deagglomeration (destruction of particle agglomerates), as well as produce stable emulsions on industrial scale.

Any cavitation reactor is based on initiation of cavitation processes in the medium pumped through the reactor. Local low pressure due to the change of flow rate (hydrodynamic cavitation) or passing of a powerful sound wave (acoustic cavitation) cause intensive formation of cavities, which then collapse, generating shockwaves. In the hydrodynamic mixer, the process occurs when the liquid mix passes through specially profiled nozzles. In hydrodynamic reactors of advanced design, nozzle geometry is variable, facilitating control of the flow parameters depending of the liquid properties and the required result.

Beside geometric parameters of the cavitation reactor proper, it efficiency significantly depends on operating pressure in the reactor and the temperature of the liquid (emulsion or suspension). For instance, if the pressure of the liquid passing through the reactor is increased from 5 to 15 bar, the cavitation process is tens of times more intensive. It should be noted that the maximum intensity of the reaction process with increase of the pressure shifts towards elevated temperatures. It has been experimentally proven, that the optimal cavitation occurs when the liquid is heated to 65% of its boiling temperature at the current operating pressure.

In the process of operation, the internal surface of the mixing chamber and the nozzles of the cavitation reactor come under a significant loads, therefore, the responsible manufacturers of such devices, such as GlobeCore, use super strong materials, stable to both impact loads and abrasion. If the liquids to be processed are chemically active, the chemical stability of the reactor’s construction material is a factor.

The cavitation reactor made by GlobeCore as a part of the biodiesel production line is used to make the processed feedstock more uniform. Under the stress of cavitation shock waves, the molecular bounds of the biofeedstock are broken, and the particle size decreases to 1 – 8 micron. Processing in hydrodynamic mixer also increases the area of application of bacteria, intensifying biogas production by 30 – 50%.

The GlobeCore cavitation reactors are versatile in terms of processed media, compact and reliable, and hold a leading place in the world market in terms of price to quality ratio.

The combination of and technical developments in the field of acoustics, hydrodynamics and chemical kinetics result in new promising devices in the technology market. One of them is the cavitation reactor capable of producing suspensions, emulsions and intensifying chemical processes in solutions. It can either be used separately (in laboratory equipment) or as a part of industrial production lines. In today’s market, there are two types of cavitation reactors: ultrasonic cavitation reactors and hydrodynamic cavitation reactors. The latter are more popular  due to simplicity of design, reliability and affordability.

A modern cavitation reactor performs continuous dispersion (grinding of the solid component), homogenization (additional grinding of one fraction and its homogeneous distribution in a liquid medium), disintegration (breaking of complex substances into constituent parts) and deagglomeration (breaking up of particle aggregates). It helps to commercially receive emulsion resistant to stratification.

The principle of operation of any cavitation reactor is the initiation of cavitation processes in a solution pumped through the reactor. The drop of local pressure with a slowing current (hydrodynamic cavitation) or a powerful acoustic wave (acoustic cavitation) cause cavitation bubbles to appear. The bubbles rapidly collapse, generating shock waves. In the hydrodynamic cavitation reactor the process occurs when the mixture passes through special nozzles. The geometry of the nozzles may vary, controlling the fluid flow, acheiving the necessary rheological properties and the desired result.

Apart from geometry, the performance of a cavitation reactor depends on the operating pressure in the reactor and the temperature of the fluid (emulsion slurry). For example, by increasing the pressure of the pumped fluid from 5 to 15 bar, the cavitation processes occurs at least ten times more intensively. It is worth noting that the maximum intensity of the cavitation processes is achieved not only by the increase of pressure but also by raising the temperature. Experiments show that optimum cavitation effect occurs upon heating the liquid to 65% of its boiling point

In operation, the inner surface of the mixing chamber and the nozzle of the  cavitation reactor undergo tremendous stress. GlobeCore make their reactors of heavy-duty, impact and abrasion resistant materials. If the liquid is chemically active, the cavitation reactor is made of chemically resistant materials.

GlobeCore cavitation reactors are used for continuous biodiesel production, making the material more homogeneous. Under the influence of cavitation shocks, the complex molecular bonds are broken, and the particle size is reduced to 1-8 micron. This dramatically increases the surface of the particles of biological material coated with bacteria and, as a result, intensifies biogas production by 30-50%

GlobeCore Cavitation reactors are versatile, compact and reliable, they have the highest quality at the best price, putting GlobeCore equipment in the leading position in the global market.

Non-freezing liquid for cars is a product of mass use.  It is not possible to do without it in the cold season, because this substance allows to keep car windshields clean, thereby providing good visibility to the driver and improving road safety.

Today the market of automobile goods is quite diverse, so you can find antifreeze of both domestic and foreign production without any problem.  We should note that the composition of antifreeze should always include alcohol, detergent additives, aromatics and dyes.  When choosing antifreeze it is recommended to remember two simple rules.

First, before buying the product check its smell.  If it is too sharp, then it most likely means that the liquid is made from methanol.  This substance is hazardous to human health.  If the odor resembles that of acetone, it has to deal with isopropyl alcohol.  It is less toxic, but under certain circumstances may also irritate the mucous membranes of your respiratory tract and eyes.

Second, to determine forgery you need to pay attention to product price.  Self-made antifreezes are usually significantly cheaper than branded ones.  It will not hurt to examine containers: cheap plastic bottles might mean problems.

The proper way is to purchase the fluid in a specialized automotive store before the onset of the cold season.

Acquisition of a non-certified product can lead to the fact that you’ll get substance including methyl alcohol.  It is easily miscible with many conventional solvents and water and is relatively inexpensive.  But remember – this substance is poisonous!

In case of contact with the human body, methanol attacks its nervous and vascular systems and causes vision disorders.  A dose of more than 30 g can be lethal.  When using methyl-based antifreeze, there is a risk of involuntary inhalation of its vapors getting into the passenger compartment through the vents.  If this happens, a person may feel sick; that will be expressed in severe headache, dizziness and general weakness.

In many countries, the use of methanol for the production of antifreeze is prohibited by law, but it does not stop the unscrupulous smart dealers rushing for easy money.

The quality of brake fluid affects the reliability of the braking system and road safety.  This substance transmits energy from master brake cylinder to wheel cylinder.

Vehicle braking is characterized by friction forces between the brake rotor and brake pads.  This releases a certain amount of heat which is transmitted to brake fluid through service elements of the brake system.  Therefore, boiling point and viscosity are very important parameters of this substance.

Besides, it must meet a number of other requirements:

• Minimal impact on the rubber parts of the brake system.
• Good corrosion resistance.
• Good lubricating properties.
• Stable operating properties at low and high temperatures.

The composition of brake fluids

Mineral brake fluid is composed of alcohol and castor oil.  They do not meet current standards regarding boiling point and viscosity index.

The composition of glycol brake fluids include polyglycols and their esters.  These fluids have a high boiling point and good viscosity.  At the same time, they possess a significant disadvantage, because they can absorb moisture from the atmosphere.

Silicone brake fluids are produced from silicon-organic polymers.  Their positive properties include: a wide range of operating temperatures, low hygroscopicity and inertness to various materials.  Their main drawback is low lubricity.

Mixing of brake fluids

You can still find two alternative views as to whether it is possible to mix brake fluid or not.  The answer is both yes and no.  The point is that mixing is allowed only when both liquids have the same basis.  Such information can usually be found on product label.  If for any reason there is no label, it is better not to take the risk.  Before mixing it is also necessary to evaluate the operating temperature of the fluid.

It is also worth mentioning that silicone brake fluid cannot be combined with fluids with a different basis, as well as mineral fluid cannot be mixed with glycol-based fluid.

Using special fluid for cleaning a car windshield in the cold season is common for the vast majority of drivers.  The popular name of this liquid is “antifreeze”.  This product is in great demand with the onset of cold weather, when the temperature drops below zero.  Antifreeze if often quite pricey, so many drivers are interested in the composition of this liquid and the possibility of its production at home. Let’s consider these questions in more detail.

In fact, the notion of “non-freezing liquid for windshield wash” refers to simple alcohol with some additives.  But it is not as simple as that.  There are different types of alcohol, and therefore alcohol-based products will differ in their properties.

In general, the composition of frost resistant fluids can be represented by the following components:

• Alcohol;
• Surface-active agents (surfactants);
• Water;
• Aromatic and coloring agents.

Let us consider the degree of influence of each of the components on the specific properties of antifreeze liquid for windshield washer.

Alcohols

In theory, several types of alcohol may be used for non-freezing liquid production:

• Ethyl.  It is considered to be the safest for human health.  At the same time, the price of ethanol is rather high;
• Methyl.  This alcohol is quite toxic; it does not have any pronounced odor and is banned in many countries for use in the manufacture of antifreeze;
• Isopropyl.  This alcohol features very pungent odor and is relatively cheap.  It is often used as the basis for production of counterfeit windshield washer fluid.

Surfactants

Surfactants are mandatory components of non-freezing liquids.  They are necessary to remove dirt, soot and oil traces from the glass.  All of these substantially impair visibility, so it is impossible to do without surfactants.  However, it is not necessary to use them in large quantities to get a good result.

Aromatics

We have already mentioned that alcohols with a sharp unpleasant odor are used for the production of antifreeze.  Aromatic substances are required to give the desired smell to the liquid: citrus fruit, apples, etc.

Dyes

Dyes give the liquid the desired hue for identification of individual product brands.

Water

Water deserves special attention.  Quality production requires the use of distilled water.

Concentrate or liquid?

Retail network offers two forms of antifreeze: antifreeze concentrate and ready liquid meant for a specific temperature.  The concentrate must be diluted with water before use, while the ready liquid can be immediately poured into a car wash liquid tank.

Antifreeze production

If you know the recipe, you are halfway there.  All the necessary components are mixed in a certain proportion, and then antifreeze can be poured into a washer tank.  But while making antifreeze at home, you should remember that the properties of this product can be very different from the standard.  It all depends on the starting components.

If you have decided to produce antifreeze in large volumes, i.e. to start your own business, it does not hurt to clarify a few points.  Firstly, you need to obtain permits for the production of products such as windshield fluid.  Antifreeze contains alcohol, but not all substances of this class may be permitted for use in the production of washing liquid.  This is primarily due to the fact that some alcohols pose a hazard to human health.  Secondly, you need to select quality equipment which will produce high quality antifreeze that can compete with existing products.  Mixing equipment is essential during the preparation of antifreeze for windshield washer.

GlobeCore offers hydrodynamic (inline) USB-type mixing plants.  They have proven themselves in industrial use as cost-effective, accurate and sustainable means of production of high-quality antifreeze liquids with optimal cost.  The achievable cost savings and increase of production profitability, compared to conventional technology of mixing the components in mixing vessels, can accelerate the return on investment up to 60% per year and provide a return on the project in one year or less.

Windshield washer liquid made by these plants is stable and does not separate for a long time, which makes it competitive in the automotive product market.

In cold weather, car windscreen washer system requires the use of special liquids.  The thing is that if you pour plain water, it will simply freeze.  Ice crystals cause damage to washer system; besides, water will form frozen drops and stains on the glass, which will significantly worsen visibility for the driver.

When should one use non-freezing liquid?

In such conditions non-freezing liquid for windscreen washer becomes the only salvation for drivers.  It has an excellent property: remains liquid even in extreme cold.

Different kinds of antifreeze have different freezing temperature thresholds.  In practice, it can vary from -5°C to -50°C.  The exact figure depends on the concentration of alcohol.  For example, if the product contains 70% of isopropyl alcohol, then such washer liquid will not freeze even at -30°C.

In the first place, when choosing antifreeze, one should take into account the geographical features of the region where the vehicle is used.

Product quality and range

Manufacturers often use a mixture of alcohols in the production of antifreeze.   Such measures are necessary to obtain the best quality of fluid characteristics.

Each of the alcohols used in washer fluid has a certain degree of negative impact on human health. Methyl alcohol is considered the most poisonous.  Just 5 grams of this substance causes blindness.

In order to improve aesthetic properties, manufacturers add special flavors to antifreeze liquid.

Today, the range of windscreen washer fluid is quite wide.  To see it, you can visit any specialized store.

What is the best buy?

Wholesale buying of antifreeze requires adherence to certain rules.  Firstly, it is necessary to make sure that the product is of a good quality.  Many manufacturers try to save on packaging in order to reduce costs.  At wholesale purchase it is necessary to foresee this issue and thoroughдн inspect the containers before making a deal.

Plastic bottles and cans are the most reliable packaging.  But storage of the product in cans has a certain disadvantage, which is the loss of some properties.  If containers are exposed to direct sunlight or high humidity, it can cause their deformation and loss of sealing.  Consequently, it can lead to evaporation of alcohol, and washer liquid will lose its properties.  Increased attention is also required when pouring the liquid into the washing tank.  Care should be taken so that the lid is firmly closed; otherwise there is a possibility of alcohol evaporation and decrease of freezing temperature threshold.

Odorless antifreeze liquid

Pursuit of profit leads to the fact that some unscrupulous manufacturers produce windscreen-washing liquid, containing methyl alcohol.  It is very dangerous to human health.

If the use of antifreeze is accompanied by ailment, nausea, tearing, then surely you bought a product with methyl alcohol.  For this very reason the production and sale of non-freezing liquid containing methyl is banned in many countries worldwide.

How to choose good windscreen washer liquid?

In fact, the choice of windscreen washer liquids is enormous, even among low-cost products.  However, the price as the sole criterion is unacceptable.  Your optimal choice is a product which contains isopropyl alcohol and ethanol.

When checking the quality of liquid, you need to remember a few simple rules:

• Poor quality antifreeze is usually much cheaper;
• n case if there’s poor or no odor, such washer liquid is likely to contain methanol.  Isopropyl alcohol is characterized by odor, which resembles acetone. Isopropyl-based antifreeze is usually flavored.

In some areas the cold period can last for up to eight months.  Sub-zero temperatures are recorded even in October.  This fact makes a small antifreeze production business quite promising.

Why do we need non-freezing liquids?

One important area of antifreeze liquid us is cleaning of car windscreens (windscreen cleaners). Another is cooling of the engine.

In the cases described above, antifreeze liquids have different functions, and their composition is also different.

Water is not suitable for cooling car engines, because it is subject to freezing at sub-zero temperatures.  Subsequent heating of ice in the system leads to expansion and damage of engine parts.  Antifreeze is a different story.  Even in the bitter cold, it has a consistency that is absolutely not harmful for engine system components.  Usually it looks like fine crumbs or slurry.  Antifreeze is poured into a radiator and an expansion tank.

A clean car windscreen is not a luxury in the cold season, but rather a way of ensuring road safety.  After all, ice crust substantially worsens the view and it is virtually impossible for a driver to objectively assess the current situation on the road in such circumstances.  Shampoos or other detergents are often added to antifreeze in order to keep windscreens clean.

What is non-freezing liquid made of?

Antifreeze and windscreen washer fluids are made on the basis of alcohol, glycol and glycerin.

Shady manufacturers of antifreeze often use methyl alcohol.  It is relatively cheap and allows a good profit margin.  But the whole problem is that this substance is rather toxic and can affect a human body not only after ingestion, but also after inhalation of high concentrations of its vapors.

Isopropyl alcohol is not as volatile and it forms a film on the glass which stays longer.  However, it has specific pungent odor that can even break through the odor of fragrances added to antifreeze.

Glycols have the ability to increase freezing resistance of the product in which they are used as an additive.  Such substances (e.g., ethylene glycol) can ensure a liquid state even when the temperatures drops to – 60°C.

Given the above, as well as taking in account the experience of entrepreneurs engaged in the production of antifreeze, we can name the most commonly used components.  These include: isopropyl alcohol, ethylene glycol, flavoring agents (to remove unpleasant odors), water, surfactants (to remove contaminants from the surface of the glass) and dyes.

Water must be absolutely pure, without any sediment.  There is no stringent standard for antifreeze color, but it is better to give it a light blue hue.  Also you will need plastic containers or bottles for bottling and labels.

What about the technology?

Production of antifreeze or other non-freezing liquid does not require any deep knowledge in chemistry.  The overall antifreeze production technology can be formulated as the following sequence of operations:

• water purification;
• mixing of the components;
• heating of the mixture;
• filling the product in plastic containers;
• labeling;
• transportation.

This technology is the same both for the production of windshield washer fluid and antifreeze.  The only difference is the composition of additives.

Antifreeze production line structure

You need the following equipment for the production of non-freezing liquids:

• Reactor for heating and cooling of the mixture;
• USB-type plant, providing high-quality blending of the components for antifreeze liquid;
• Storage tank for automobile liquids;
• Compressor or pump;
• Equipment for bottling;
• Capping machine;
• Labeling device;
• Piping system.

Certainly each type of equipment is important, but particular attention should be paid to the USB-type plant manufactured by GlobeCore.  It ensures high-quality mixing of two to five initial components.  The advantages of this equipment include: precise control of dosage of each component, significant reduction of mixing cycle duration and no need to use mixing tanks for homogenization of the final product.  During the process of mixing in an in-line mixer, the flow rate of each component is continuously adjusted in order to obtain the finished product with stable quality according to the predetermined recipe.  The resulting non-freezing fluid does not break into individual components and has a long shelf life.

Theoretical payback period is calculated according to the specific conditions of your future production.  It could be three months, six months or a year.  This time interval can be reduced due to versatility of this equipment.  The same line allows the production of three types of liquids: antifreeze, windscreen washer liquid and shampoo. The wider the range, the better the sales of the finished products.

Final cost of the antifreeze production line depends on the degree of its automation and production capacity.