Volume 8, Manuscript ID
es20250005, p. 01-10, 2025
Doi: https://doi.org/10.32435/envsmoke-2025-0005
Environmental
Smoke, e-ISSN: 2595-5527
“A leading multidisciplinary peer-reviewed journal”
Full Article:
AN
EXPERIMENTAL AND NUMERICAL ANALYSIS OF DIFFERENT SPECIAL-SHAPED CAVITY
CIGARETTE FILTER RODS FOR TYPICAL SMOKE STREAM ADSORPTION
Zhi Huang1 (https://orcid.org/0000-0001-9980-986X); Hua Liu1 (https://orcid.org/0000-0003-0358-8455); Kangzhong Shi2; Jiuyi Liu3 (https://orcid.org/0000-0002-1860-7666); Ying Zhao2,* (https://orcid.org/0000-0002-1751-2243); Qun Yin2 (https://orcid.org/0000-0003-1804-2682); Mengdie Cai3,* (https://orcid.org/0000-0002-7605-4895); Lisheng Guo3 (https://orcid.org/0000-0003-0272-6254); Song Sun3 (https://orcid.org/0009-0006-9876-5221)
1China Tobacco Chongqing Industrial Company
Limited, Nanan 400060, Chongqing, China
2Eastman Shuangwei Fibers Company Limited,
Hefei 230601, Anhui, China
3School of Chemistry and Chemical Engineering,
Anhui University, Hefei, Anhui 230601, China
*Corresponding authors: zhaoy@esfcl.com (Y. Zhao); caimengdie1987@163.com (M. Cai)
Submitted on: 19 Mar. 2025
Accepted on: 27 Apr. 2025
Published on: 01 Aug. 2025
License:
https://creativecommons.org/licenses/by/4.0/
Abstract
Cigarette
filter rods, as an essential component of cigarettes, effectively filter and
trap harmful substances in the smoke. With the continuous application of
advanced manufacturing technologies in filter rod production, various forms of
filter rods have been developed. Inhere, understanding the adsorption of the
smoke stream on filter rods is beneficial for reducing the toxic effect of
smoking on human health and controlling the design of filter rods. Different
filter rods with special-shape cavities are chosen to investigate the influence
of hollow structure on the interception efficiency of cigarettes through the
DRIFTS technique. The results showed that the interception efficiency of the
C-shaped filter rod for most typical flue gas is comparable to that of normal
filter rod, and much higher than that of the Square-shaped cavity filter rod.
Combined with the Computational Fluid Dynamics flow field simulation results,
it can be seen that the gas flow in the C-shaped area exhibits a swirling
effect from the small to the large end of the C-shaped cross-section in the
hollow area, providing theoretical basis and experimental support for the
development of efficient filter materials, which will help to improve the
safety of tobacco products and reduce the harm of smoking to human health.
Keywords: Acetate
fiber. Special-shaped cavity filter rod. Smoke stream components. Interception.
1 Introduction
According to the investigation from the World Health Organization, by
2030, the consumption of tobacco will remain high, and more than 500 million
people alive today will die from a variety of diseases caused by tobacco (CHAN;
WRIGHT; XIAO, 2022; JHA, 2009). The situation will probably occur because more
than 4000 toxic compounds such as nicotine, tar, particulate matter (PM), and
gaseous compounds in cigarette smoke are released through different chemical
reactions during the burning process of tobacco (DENG; YANG; LI, 2017; LI;
HECHT, 2022; WEN; GU; TANG, 2022).
Among
them, mainstream smoke with harmful substances is adsorbed by smokers and
continues to accumulate in the body, which can increase the potential risk of
illnesses such as lung cancer, chronic obstructive pulmonary disease,
angiocardiopathy, cerebrovascular disease, etc (THUN; HENLEY; CALLE, 2002).
Even though exposed for a short period, passive smokers, which included
pregnant women, infants, and children, also inevitably inhale smoke (ADAM;
MCAUGHEY; MOCKER, 2010). The process leads to harmful consequences such as
respiratory tract injury, increased blood viscosity, and damage to the lining
of the blood vessels.
Therefore,
the reduction of toxic substances in mainstream smoke is of vital significance
(ZENG; LIU; JIANG, 2023). Nevertheless, research on this topic remains limited.
In the field of commercial cigarettes, a cellulose acetate (CA) filter tip is
the most mature and widely used material to filter mainstream smoke (XU; DU;
ZHENG, 2022).
With the increasingly diverse
needs of consumers, a variety of special filter rods such as grooved filter
rods, particle filter rods, fragrant thread filter rods, gel filter rods, and
special-shaped cavity filter rods have been gradually developed (HUANG; LIU;
ZHOU, 2024). The special-shaped cavity filter rod is a new type of filter rod
made by using a special process to form visible patterns at the ends. The
cavity shape can be designed into various shapes such as circle, triangle,
star-shaped, heart-shaped, square-shaped and other within a filter, and it has
the dual functions of pattern design anti-counterfeiting and smoke regulation,
so it has been widely used in cigarette products (PENG; OUYANG; CAO, 2023).
However, as a novel filter
variant, cavity sharp cellulose acetate filter rods have the potential to
improve the smoking experience while effectively removing harmful components
from smoke when compared to conventional cellulose acetate filters (WAN JIQIANG,
2022). This unique and attractive appearance of hollow-shaped filter also can
have various segments within a filter. It is available to differentiate
cigarette brands strategically.
Meanwhile, Hubei Tobacco
Industrial Co., Ltd. developed a hollow-core filtered cigarette with lower
resistance to draw, which effectively reduces the release of tar and carbon
monoxide (SONG; BENOWITZ; BERMAN, 2017).
As a new type of filter rod form,
the current research on the special-shaped cavity filter rods mainly focuses on
aspects such as filter rod structure design and production process, and the
influence on the main physical and chemical indicators and sensory quality of
cigarettes still needs to be further studied in-depth. In view of this, this
article intends to make a comparison between the more common circular cavity
filter rods and the normal solid filter rods in the market. By using infrared
thermal imaging technology and in-situ DRIFTS technology, the influence rules
of the two types of filter rods on the three-dimensional temperature field, the
release of mainstream smoke, and the interception efficiency of harmful
substances are investigated.
In this study, computational
fluid dynamics (CFD) analysis was carried out using ANSYS Fluent software
(version Fluent 2022 R1) to simulate the changes in pressure and velocity
within the cavity filter. As the flue gas was considered an incompressible fluid,
a pressure-based solver was employed for these simulations. The simulation
results further explain the impact of differences in smoke stream retention
efficiency between C-shaped filter rod, square-shaped filter, and normal solid
filter. The findings of this study have practical implications for industries
involved in cigarette filter design and manufacturing. By understanding the
retention efficiency of different smoke stream components and the flow dynamics
within cigarette filters, manufacturers can improve product performance,
enhance filtration efficiency, and meet regulatory standards more effectively.
2 Material and Methods
Materials
The chemicals used in the
experiments, including phenol and acetone, were purchased from Sinopharm
Chemical Reage, nt Co.,
Ltd. Deionized water (resistivity of 18.2 MΩ) was purified by using a Millipore
system. Gases used in the study were Argon (Ar,
99.99+%) and the compressed air (20 vol% O2/N2).
The C-sharp, square-shaped, and
normal solid cellulose acetate filter rods used in this study were obtained
from Eastman Shuangwei Fibers Company Limited (Figure
1). The degree of acetyl substitution of cellulose acetate is between 2.0
and 2.7. Its molecular formula is [C6H7O2 (OCH3)x(OH)3-x], n = 200-400).
It is widely used as a commercial cigarette filter tow (cigarette cellulose
acetate tow) with a radius of 4 mm, and a length of 20 mm.
Figure
1. The schematic diagram of
C-sharp, square-shape, and normal solid cellulose acetate filter rod. Source:
The authors, based on experimental materials.
Infrared
thermal imaging test
The three-dimensional temperature gradient of
the filter stick during cigarette burning was observed and recorded by the
Forward Looking Infrared (FLIR) thermal imaging system with a THERMACAM 25
camera and the THERMACAM Reporter 2000 software. The distance between the
camera and the object was fixed from 10 cm to 50 cm.
In-situ
DRIFTS measurements
To elucidate adsorption on the surface of the
CO and typical low-carbon aldehydes and ketones, in-situ DRIFTS measurements
were performed on a Bruker IFS 66v/s FTIR spectrometer equipped with a
self-built setup and a DRIFTS cell. As shown in Figure S1, the setup consists
of a detection system, a reaction system, and a coupling reaction gas-dosing
system. In the gas-dosing system, mass flow controllers were used to control
the 20 vol% O2/N2 compressed air which carried SR vapor
from the saturator containing typical acetone and.
The water vapor was supplied and regulated to
the cell via a by-pass line. The relative humidity in
the cell was determined using an electronic hygrometer fixed in the by-pass line. The reaction system consists of a praying
mantis DRIFTS accessory (Harrick Scientific) and a reaction cell (HVC, Harrick
Scientific). The reaction cell is equipped with a sample cup with retaining
plates in it and covered by a dome fitted with three windows. Cooling water was
circulated through a coil surrounding the base of the dome to facilitate the
reaction at room temperature.
Computational
Fluid Dynamics (CFD)
The numerical models were constructed using
unstructured tetrahedral grids and analyzed with Fluent 16.2 (ANSYS, Inc.,
Canonsburg, Pennsylvania, USA). Simulations utilized a pressure-based solver
with a coupled velocity-pressure coupling algorithm.
The discretization of turbulence kinetic
energy, turbulence dissipation rate, energy equations, and spatial momentum
employed a second-order upwind scheme. The SST k-ω model was used to evaluate
turbulence effects in the hollow region of the C-shaped, square-shape, and
normal solid filter rod and the external environment.
In the solid filter rod region, the model
accounted for the fibrous characteristics of the filter using a porous medium
and laminar flow model. The porous medium had a viscous resistance coefficient
of 2.07×109 m-2, an inertial resistance coefficient of
3.81×104 m-1, and a porosity of 0.889.
The filter rod model's inlet, shown in the
blue area of Figure
2, used a velocity inlet boundary to maintain a flow rate of 17.5 ml/s with
air as the fluid. The solid filter rod region and the hollow region were connected with sharing nodes, indicated by the green
area. The boundary of the external environment, marked in red, used a pressure
outlet boundary with a gauge pressure of 0 Pa. All other boundaries were
no-slip walls, shown in gray.
Figure
2. C-shaped filter rods simulation model.
3 Results
and Discussion
Figure
3 shows the infrared thermal imaging of
various types of cellulose acetate filter rods in both the same combustion and
absorption states, providing a direct visualization of the temperature field
distribution of the flue gas for these different types. In Figure
3a, the infrared thermal imaging shows C-shaped filter rods with a
distinct C-shaped area indicating higher temperatures within the cavity
compared to the solid area. Meanwhile, Figure
3b displays an infrared thermal image of a standard normal solid
filter rod, revealing a circular temperature field distribution consistent with
the cross shape of the filter rod. However, Figure
3c shows a similar circular temperature field distribution, which is
totally different from the square-shaped hollow filter rod structure.
Figure
3. The infrared thermal
images for a burning cigarette using a) a C-shaped filter rod; b) a normal
solid filter rod; and c) a square-shaped
filter rod.
The infrared thermal imaging results show
that the C-shaped filter rods reveal different temperature distribution
characteristics during the puffing process due to their unique cavity
structures. Within these special-shaped filter rods, the smoke tends to flow
through the hollow parts preferentially, resulting in the temperature of this
area being significantly higher than that of other parts. The surface area of
the C-shaped filter rod is large, which may increase the contact area between
the smoke and the C-shaped filter rod, thereby improving the filtration effect.
In contrast, the normal filter rod shows a relatively uniform temperature
distribution. The differences in temperature distribution further indicate that
the geometric shape of the filter rod has a significant impact on the flow path
of the smoke and its heat conduction characteristics.
Diffuse Fourier-transform
infrared spectroscopy (DRIFTS) is an in-situ
technology to characterize the adsorption states of molecule on materials
surface (ALALWAN; ALMINSHID, 2020; GUO; GAO; GAO, 2023; SHI; GUO; ZHANG, 2021). Therefore, the in-situ DRIFTS technique was used to
test the adsorption characteristics of typical smoke substances over different
samples, such as CO, H2O, acetone, phenol, and nicotine (Figure
4-9). First, as a typical harmful substance in the smoke stream, CO is chosen
as a probe molecule to study the adsorption characteristic of cellulose
acetate filter. Figure
4 displays the in-situ
DRIFTS differential spectra of CO on the cellulose acetate filter surface at
room temperature. The band at 2159 cm-1 is
assigned to CO stretching (vCO), which indicates CO adsorption on the
surface of the cellulose acetate filter after exposure to the CO stream (KAFTAN; KUSCHE; LAURIN, 2017; PFERREIRA-APARICIO; RODRIGUEZ-RAMOS; ANDERSON,
2000). The intensity of the band
becomes stronger with the adsorption time prolonging until it reaches CO
adsorption equilibrium around 10 min. The saturated adsorption capacity
of a normal solid filter rod is slightly higher than that of a C-shaped filter
rod, followed by the square-shaped filter rod.
Figure
4. DRIFTS spectra of CO
adsorption over a) C-shaped filter rod; b) normal solid filter rod; and c)
square-shape filter rod.
Figure
5 shows that the normalized adsorption amounts
of CO by different filter rods vary with adsorption time. Notably, the
adsorption of CO by different filter rods gradually increases as the adsorption
time prolongs until it reaches saturation. In the initial stage, the red curve
of the normal filter rod rises relatively quickly, indicating a high initial
adsorption rate for CO. The C-shaped filter rod comes next, and the
square-shaped filter rod rises more slowly, suggesting a relatively low initial
adsorption rate. This means the normal filter rod can adsorb
more CO in a short time, while the square-shaped filter rod takes longer to
achieve a similar adsorption amount.
Figure
5. Interception
efficiency comparison of different filter rods.
When saturation is finally reached, the normal filter rod
has the highest normalized adsorption amount, followed by the C-shaped filter
rod, and the square-shaped filter rod has the lowest. This shows that the
normal filter rod has the strongest saturation adsorption capacity for CO,
while the square-shaped filter rod has the weakest. These differences indicate
that the hollow shape and structure of filter rods have a significant impact on
their ability and rate to adsorb CO. Different
structures may lead to variations in the contact area, contact mode with CO,
and the internal flow field, thus affecting the adsorption performance.
In Figure
6, it is seen that, the peak at ∼3580 cm−1
is considered as H2O molecular adsorbing on cellulose acetate
filters (CHOE; LADEMANN; DARVIN, 2016) and signals around ∼3500 and ∼3400 cm−1
are identified as H2O adsorbing on HO-* (H2O···HO-*) and
* -OH
groups interacting with H-bond (*-OH···H-), respectively (GUO; CHEN; SUN, 2018).
Figure
6. DRIFTS spectra of H2O
adsorption over a) C-shaped filter rod; b) normal solid filter rod; and c) square-shape filter rod.
With the increase in H2O
adsorption time of the cellulose acetate filter rod in typical flue gas, the
adsorption capacity increases and reaches saturation in approximately 10 min.
The saturated H2O adsorption capacity of a normal solid filter rod
is slightly higher than that of a C-shaped filter rod, The saturated H2O
adsorption capacity of a square-shaped filter is lowest.
In addition, the in-situ DRIFTS was also applied to study the influences of
acetone exposure on different cellulose acetate filter samples (Figure
7). As for both three cellulose acetate filters, the bands at 3010,
2920 and 1350 cm-1 are ascribed to CH3 stretching peaks (ZAKI; HASAN; PASUPULETY, 2001), while the bands around 1710 and 1445 cm-1
are assigned to C=O absorption stretching peaks, all these characteristic infrared absorption peaks are
assigned to the acetone absorbed on the surface of filters (CANO-CASANOVA; MEI; MUL, 2020). The adsorption intensity of the band
becomes stronger with the adsorption time prolonging until it reaches the
acetone adsorption equilibrium around 8 min. With the increase in acetone
adsorption time of the cellulose acetate filter rod in typical flue gas, the
adsorption capacity increases and reaches saturation in approximately 10 min.
The saturated adsorption capacity of a C-shaped filter rod is slightly higher
than that of a normal solid filter rod, much higher than that of a square-shape
filter rod.
Figure
7. DRIFTS spectra of acetone
adsorption over a) C-shaped filter rod; b) normal solid filter rod; and c) square-shape filter rod.
Figure
8 shows the DRIFTS spectra of phenol adsorption over different cellulose
acetate filters. The DRIFTS spectra of phenol typically show characteristic
peaks corresponding to various functional groups. According to Sambeth et al., in the 1,650–1,200 cm−1 range,
the bands indicate the presence of an aromatic group (1,633 and 1,494 cm−1)
and phenoxy species (1,265 cm−1) (D’ALESSANDRO; THOMAS; SAMBETH, 2012). The bands at 1,633 and 1,494 cm−1
are assigned to the aromatic group (ALLAHKARAMI; DEHGHAN MONFARED; SILVA, 2023). With the increase in
phenol adsorption time of the cellulose acetate filter rod in typical flue gas,
the adsorption capacity increases and reaches
saturation in approximately 10 min. The saturated
adsorption capacity of a normal solid filter rod is slightly higher than that
of a C-shaped filter rod. The square-shaped filter rod exhibits the lowest phenol
adsorption.
Figure
8. DRIFTS spectra of phenol
adsorption over a) C-shaped filter rod; b) normal solid filter rod; and c)
square-shape filter rod.
Figure
9 presents DRIFTS spectra of nicotine adsorption on C-shaped, normal solid,
and square-shaped filter rods. The study examines absorbance changes at
specific time intervals (0, 2, 4, 6, 8, and 10 minutes), focusing on
characteristic nicotine vibrational modes (e.g., C-H, C=N, and N-H stretching) (HUA; LU; ZHENG,
2017). It
is observable that the peaks at 3300-3500 cm−1 are assigned to the
N-H stretching of the amino group in nicotine (GARRIGUES;
PéREZ-PONCE; GARRIGUES, 1998). The bands in the range of 2750-3000 cm−1 corresponded to
the C-H stretching of nicotine’s alkyl groups. The bands at 1600-1700 cm−1
respected to C=N Stretching of nicotine (ILIC;
JOVIC-JOVICIC; BANKOVIC, 2019).
Figure
9. DRIFTS spectra of nicotine
adsorption over a) C-shaped filter rod; b) Normal solid filter; and c)
square-shaped filter rod.
The nicotine adsorption capacity of all the filter rods demonstrates a
time-dependent enhancement pattern, progressively increasing with exposure
duration until reaching saturation equilibrium within approximately 10 minutes.
The C-shaped filter rod exhibits the highest adsorption, likely due to
increased surface area or specific surface interactions, while the normal solid
filter demonstrates slower but consistent adsorption kinetics.
The square-shaped filter rod may display the lowest adsorption capacity,
which is influenced by its surface properties. This analysis provides critical
insights into the impact of filter morphology on nicotine adsorption, offering valuable
guidance for optimizing filtration system design.
As shown in Figure
10, as the C-shaped filter rod maintains the same absorption resistance as
the normal solid filter rod, it exhibits a similar typical smoke stream
interception efficiency as the normal solid filter rod. Its interception
efficiency for various typical flue gases, including CO, H2O and
phenol, is only slightly lower than that of the normal solid filter rod.
Furthermore, the acetone interception efficiency of C-shaped filter rods is
even higher than that of normal solid filters. Importantly, the reduction of
the actual filling area has minimal impact on its
adsorption effect.
Figure
10. Comparison of typical smoke stream interception
efficiency over C-shaped filter rod, normal solid filter rod and square-shape
filter rod.
To further investigate the effects of hollow
shapes, the computational fluid dynamics (CFD) model for the smoke flow in a
grooved filter was developed in order to study the flow field distribution in
different filters with their characteristic hollow shapes (AFKHAMI; BROWN; SABOGAL-PAZ, 2023). By means of the developed model, the smoke
flow in the grooved filter at an average velocity of the ISO smoking regime was
simulated, and the distribution of the velocity of cigarette smoke in the
grooved filter was obtained (SONG; LIU; SUN, 2024).
The internal flow field distribution diagram
of C-shaped and square-shaped filter rod are depicted in Figure
11(a) and (b). The results of the CFD flow field simulation show that there
is a swirling flow effect from the small end to the large end inside the
C-shaped filter rod. The swirling flow effect enhances the contact time and
contact area between the smoke and the filter rod material, which is helpful in
improving its adsorption performance for smoke components.
Figure
11. Internal flow field
distribution diagram of (a) C-shaped filter and b) square-shape filter rod.
Although the effective adsorption area of the
C-shaped filter rod is smaller than that of the common filter rod, through the
characteristics of the flow field, it finally achieves a smoke interception
efficiency similar to that of the common filter rod.
4 Conclusions
Cigarette often produces a range of toxic and harmful substances when
it is heated without burning. Efficiently reducing the
content of these species in smoke, has a positive
significance for the tobacco industry. As a key trapping material, filter rods
can reduce the concentration of these harmful substances in smoke. Despite
this, it is important to modify the filter rod in order to
efficiently improve its adsorption and retention characteristics.
Therefore, in this paper, we have
systematically studied and explored the interception effects of different
special-shaped filter rods on the components of cigarette smoke and deeply
analyzed the temperature field distribution and adsorption characteristics of
the special-shaped filter rods through CFD flow field simulation, infrared
thermal imaging technology, and in-situ DRIFTS technology. The research results
show that the geometric shape of the special-shaped filter rods significantly
affects the smoke flow path, temperature field distribution, and the adsorption
efficiency of smoke components:
1) Through infrared thermal imaging technology, it is
found that C-shaped filter rods show different temperature distribution
characteristics during the puffing process due to their unique cavity
structures, for the C-shaped filter rod, the smoke tends to flow through the
hollow parts preferentially, resulting in the temperature of this area being
significantly higher than that of other parts. In contrast, the common filter
rod shows a relatively uniform temperature distribution. The differences in
temperature distribution further indicate that the geometric shape of the
filter rod has a significant impact on the flow path of the smoke and its heat
conduction characteristics.
2) The adsorption behaviors of typical smoke components
(CO, H₂O, acetone, phenol, and nicotine) are studied by using the in-situ
DRIFTS technology. The results show that there are obvious differences in the
interception effects of different special-shaped filter rods on the smoke
components. Due to its larger surface area and complex flow field path, the
C-shaped filter rod exhibits relatively high interception efficiencies for
acetone and nicotine.
However, the common filter rod is more effective in
intercepting CO and H₂O. The hollow structure of the rice-shaped filter rod
causes most of the smoke components to directly pass through the hollow area,
reducing the contact opportunities with the filter rod material, and resulting
in the lowest interception efficiency.
3) The results of the CFD flow field simulation show that
there is a swirling flow effect from the small end to the large end inside the
C-shaped filter rod. The swirling flow effect enhances the contact time and
contact area between the smoke and the filter rod material, which is helpful in
improving its adsorption performance for smoke components. Although the
effective adsorption area of the C-shaped filter rod is smaller than that of
the common filter rod, through the characteristics of the flow field, it
finally achieves a smoke interception efficiency similar to
that of the common hollow filter rod.
Based on the above research, this study
verifies the potential of special-shaped filter rods, especially the C-shaped
filter rod, in smoke filtration and interception. Although the C-shaped filter
rod does not have an advantage in terms of the adsorption area, through
reasonable geometric design and flow field optimization, it can significantly
improve the smoke filtration effect.
CREDIT AUTHORSHIP CONTRIBUTION
STATEMENT
Zhi Huang: Resources, Writing – original draft. Hua Liu: Conceptualization, Methodology, Data curation. Kangzhong Shi: Methodology, Investigation, Data curation. Jiuyi Liu: Software, Formal
analysis, Data curation. Ying Zhao: Data curation, Writing – original draft.
Qun Yin: Software, Methodology, Investigation, Data curation, Mengdie Cai: Resources, Writing
– review & editing, Supervision. Lisheng Guo:
Investigation, Software. Song Sun: Writing – review & editing, Supervision.
DECLARATION OF INTEREST
The authors disclose
that they have no known competing financial interests or personal relationships
that could have appeared to influence the study reported in this manuscript.
FUNDING SOURCE
This
work is supported by Higher Education Natural Science Foundation of Anhui
Province (KJ2021A0029 and KJ2021A0027), Distinguished Young Research Project of
Anhui Higher Education Institution (022AH020007), Chongqing China Tobacco
Industry Co., LTD. Science and technology project "Chongqing China Tobacco
'Tianzi' medium branch special type filter rod
structure-activity relationship Study" (GY202208).
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