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• The Mod-DI can destroy the symmetry flow field and induce more vortices. • The mixing time of the system could be shortened by equipping the Mod-DI. • The Mod-DI system reaches dynamic equilibrium before the Trad-DI system. • The intensification mechanism is due to the formation of metastable flow field. Process intensification is important for achieving efficient fluid mixing. In this study, the process intensification mechanism of mixing was investigated based on the evolution of sub-steady flow pattern. The results showed that the modified dual impeller (Mod-DI) could eliminate the isolation zone and symmetry of the flow pattern, which always appears in the traditional dual impeller (Trad-DI) system. Furthermore, the mixing time (t m) and dynamic equilibrium time (t de) of the Mod-DI system were significantly shorter than those of the Trad-DI system, which could be attributed to the enhancement of fluid flow fluctuations caused by the loss of stability of sub-steady flow field. In the presence of baffles, t m and t de could be further reduced. The shortening of time was at the expense of increasing power consumption. Overall, the intensification mechanism of the Mod-DI is mainly since the formation of sub-steady flow field, which enhances the instability of the fluid flow. [ABSTRACT FROM AUTHOR]

[Display omitted] A practical hyperchaotic circuit has been designed, which has further been successfully applied to the manganese metal electrolysis system, replacing the traditional direct current power to alter the dynamic system of electrolysis process. The results illustrate that the hyperchaotic current can significantly suppress the electrochemical oscillation. Therefore, the growth of manganese (Mn) dendrites in the cathode can be significantly suppressed by the ultra − wide chaotic current fluctuation because of the regulation of electronic dynamic system. In addition, the distribution of manganese dendrites is quantified for the first time through image analysis, processing, and calculation. Besides, the hyperchaotic current can also considerably improve the current efficiency with 2 % increasing and reduce the energy consumption about 0.3 kW·h/kg simultaneously. It also demonstrates some advantages of chaotic current electrodeposition technology by conducting a larger-scale chaotic current electrolysis experiment. [ABSTRACT FROM AUTHOR]