We study the effect of surfactants on the dynamics of a drop-interface coalescence using full three-dimensional direct numerical simulations. We employ a hybrid interface-tracking/level-set method, which takes into account Marangoni stresses that arise from surface-tension gradients, interfacial and bulk diffusion and sorption kinetic effects. We validate our predictions against the experimental data of Blanchette and Bigioni (Nat. Phys., vol. 2, issue 4, 2006, pp. 254–257) and perform a parametric study that demonstrates the delicate interplay between the flow fields and those associated with the surfactant bulk and interfacial concentrations. The results of this work unravel the crucial role of the Marangoni stresses in the flow physics of coalescence, with particular attention paid to their influence on the neck reopening dynamics in terms of stagnation-point inhibition, and near-neck vorticity generation. We demonstrate that surfactant-laden cases feature a rigidifying effect on the interface compared with the surfactant-free case, a mechanism that underpins the observed surfactant-induced phenomena.

The breakup of an interface into a cascade of droplets and their subsequent coalescence is a generic problem of central importance to a large number of industrial settings such as mixing, separations and combustion. We study the breakup of a liquid jet introduced through a cylindrical nozzle into a stagnant viscous phase via a hybrid interface-tracking/level-set method to account for the surface tension forces in a three-dimensional Cartesian domain. Numerical solutions are obtained for a range of Reynolds ($Re$) and Weber ($We$) numbers. We find that the interplay between the azimuthal and streamwise vorticity components leads to different interfacial features and flow regimes in $Re$–$We$ space. We show that the streamwise vorticity plays a critical role in the development of the three-dimensional instabilities on the jet surface. In the inertia-controlled regime at high $Re$ and $We$, we expose the details of the spatio-temporal development of the vortical structures affecting the interfacial dynamics. A mushroom-like structure is formed at the leading edge of the jet inducing the generation of a liquid sheet in its interior that undergoes rupture to form droplets. These droplets rotate inside the mushroom structure due to their interaction with the prevailing vortical structures. Additionally, Kelvin–Helmholtz vortices that form near the injection point deform in the streamwise direction to form hairpin vortices, which, in turn, trigger the formation of interfacial lobes in the jet core. The thinning of the lobes induces the creation of holes which expand to form liquid threads that undergo capillary breakup to form droplets.

We study the effect of surfactant on the dynamics of a bubble bursting through an interface. We perform fully three-dimensional direct numerical simulations using a hybrid interface-tracking/level-set method accounting for surfactant-induced Marangoni stresses, sorption kinetics and diffusive effects. We select an initial bubble shape corresponding to a large Laplace number and a vanishingly small Bond number in order to neglect gravity, and isolate the effects of surfactant on the flow. Our results demonstrate that the presence of surfactant affects the dynamics of the system through Marangoni-induced flow, driving motion from high to low concentration regions, which is responsible for the onset of a recirculation zone close to the free surface. These Marangoni stresses rigidify the interface, delay the cavity collapse and influence the jet breakup process.

We study the effect of insoluble surfactants on the wave dynamics of vertically falling liquid films. We use three-dimensional numerical simulations and employ a hybrid interface-tracking/level-set method, taking into account Marangoni stresses induced by gradients of interfacial surfactant concentration. Our numerical predictions for the evolution of the surfactant-free, three-dimensional wave topology are validated against the experimental work of Park & Nosoko (AIChE J., vol. 49, 2003, pp. 2715–2727). The addition of surfactants is found to influence significantly the development of horseshoe-shaped waves. At low Marangoni numbers, we show that the wave fronts exhibit spanwise oscillations before eventually acquiring a quasi-two-dimensional shape. In addition, the presence of Marangoni stresses is found to suppress the peaks of the travelling waves and preceding capillary wave structures. At high Marangoni numbers, a near-complete rigidification of the interface is observed.

In chemical process engineering, surrogate models of complex systems are often necessary for tasks of domain exploration, sensitivity analysis of the design parameters, and optimization. A suite of computational fluid dynamics (CFD) simulations geared toward chemical process equipment modeling has been developed and validated with experimental results from the literature. Various regression-based active learning strategies are explored with these CFD simulators in-the-loop under the constraints of a limited function evaluation budget. Specifically, five different sampling strategies and five regression techniques are compared, considering a set of four test cases of industrial significance and varying complexity. Gaussian process regression was observed to have a consistently good performance for these applications. The present quantitative study outlines the pros and cons of the different available techniques and highlights the best practices for their adoption. The test cases and tools are available with an open-source license to ensure reproducibility and engage the wider research community in contributing to both the CFD models and developing and benchmarking new improved algorithms tailored to this field.