Abstract Summary (Max 250 words)
Predicting the performance of high-pressure homogenization (HPH) remains a significant challenge in CFD due to the complex coupling of high-shear turbulence and transient cavitation. While cavitation has an essential impact on droplet breakup and cell lysis in food and biotech applications, its stochastic nature often complicates process control and energy efficiency. This study presents a numerical and experimental framework to characterize these cavitation-driven mixing dynamics. The CFD modeling approach utilizes a multiphase mixture formulation incorporating the Schnerr-Sauer and Zwart-Gerber-Belamri mass transfer models to map vapor volume fractions and macroscopic flow behavior across varying orifice geometries. To ensure numerical reliability, simulations were validated against high-speed shadow-graphic images, enabling a direct comparison between predicted cavitation zones and experimental flow regimes. The study systematically investigates the influence of pressure gradients and flow rates on local stress fields. These CFD-derived insights are correlated with macroscopic process parameters, specifically droplet size distributions and protein release yields from cell disruption. By evaluating the advantages and limitations of different cavitation models, this work provides a robust tool for the digital twin-based design of HPH systems. The results offer the mixing community a deeper understanding of how to bridge the gap between microscopic phase-change phenomena and industrial-scale process optimization.
