Steering of Liquid Mixing Speed in Interdigital Micro Mixers – From Very Fast to Deliberately Slow Mixing

Very fast mixing in the range of milliseconds as well as deliberately slow mixing was realized by specially adjusted interdigital micro mixers made of glass or stainless steel. The corresponding micro mixers are presented including experimental and theoretical investigations of the respective mixing process. Fast mixing was realized by combination of flow multilamination by interdigital microstructured feeding structures with geometric focusing. Details on the microfabrication, achievable throughputs and hydrodynamics are discussed. To prevent clogging of microsized feeding structures in the case of precipitation reactions, mixing was deliberately slowed down by separating the reactant solutions at the outlet by additional layers of inert liquids.     

Laminar Fluid Mixing in Micromixers: Description of Pull-Push Effects

A numerical study was performed on laminar mixing of fluids by means of embedded microbarriers against the flow direction in two three-dimensional T-micromixers. Two microchannels with different obstacle arrangements were considered, and the effect of volumetric flow rate Q on two-stream pull-push motion was investigated. With increasing Q and distance of the barriers to the sidewalls K, different vortices and fluid movement patterns develop in the two micromixers. Maximum mass transfer is obtained for the micromixer with smaller K value. With decreasing K, pull-push movement strongly affects fluid merging, and the quality of mixing increases. Moreover, the effect of fluid tortuosity was studied, and a direct relationship between hydrodynamic fluid tortuosity and mass transfer was found.     

Mixing in Sub‐micron Ducts

This paper considers a class of fluidic devices, anticipated to become important in the near future, where characteristic channel dimensions are in the range 0.1 to 1.0 microns. Typical current applications of microfluidics have device sizes of 10 to 100 micron, this is sufficiently small to force laminar flow but not so small that molecular diffusion is a dominant factor. In the smaller devices contemplated here, diffusion is important and existing mixing strategies and correlations are no longer applicable. Novel results and interesting complexities are discussed for reactive, single and two phase flows in sub‐micron channels.     

Simulation of Droplet Generation by Mixing Nozzles

In various chemical processes thorough homogeneous mixing is of great importance. Due to their small characteristic dimensions, micromixers have a great potential to achieve fast and uniform mixing. However, in the field of powder synthesis from precipitation processes the use of standard micromixers is severely limited because of rapid clogging of the microchannels. As an alternative, mixing nozzles which are less susceptible to fouling can provide a sufficient mixing quality. The flow field and fluid distribution inside multi‐fluid droplets during droplet formation is simulated. Depending on the geometry and flow rates, complex velocity fields and flow distributions are found and the impact on the mixing efficiency is qualitatively deduced. Furthermore, we point out how the tendency of fouling can be further reduced with the help of improved nozzle geometries.     

Computational study of convective–diffusive mixing in a microchannel mixer

Scalar mixing due to convection and diffusion in a microchannel mixer is studied using CFD. A method is developed to quantitatively measure the effect of false diffusion on scalar decay rate. This method computes an average false diffusivity from a given numerical solution and it is not limited to any particular numerical scheme. It is found that a range of molecular diffusivity exist in which average false diffusion is smaller than molecular diffusion and scalar decay rates can be computed accurately with CFD in the mixer. This range of molecular diffusivity covers most of the liquid solutions encountered in chemical and biochemical engineering. When effective diffusivity is used, this range can be further expanded. The predicted mixing structures agree well with experimental results in literature. The classical lamellar structures of the baker's transformation are strongly affected by diffusion. The striation doubling process is destroyed by diffusion broadening at very early stage in the mixer. The optimal mixing is achieved at low Re when the mixing mechanism in the mixer is the baker's transformation. At higher Re, secondary flow is generated and the mixing mechanism is the competition of the kinematics of the baker's transformation and the dynamics of the cross sectional flow. Results show that the secondary flow hinders mixing and the scalar decays at lower exponential rates than when the mixing is due to the baker's transformation alone.     

Numerical and Experimental Study on Mixing in Chaotic Micromixers with Crossing Structures

Two chaotic micromixers (Models A and B) based on the split-and-recombine principle using multilayer microchannels are proposed and the mixing performance was analyzed numerically and experimentally for a wide range of Reynolds numbers. The fluid flow and mixing performance were numerically analyzed by solving Navier-Stokes equations. Micromixers were fabricated using a soft-lithography technique. As working fluids, water and a dye/water mixture were used. Quantitative and qualitative analyses were performed using confocal scanning microscopy and image processing techniques. The micromixers could enhance the mixing performance by expanding the interfaces between the working fluids to be mixed. The results confirm the superior mixing index of Model B compared to that of Model A.     

Utilization of Micromixers for Extraction Processes

The aim of the investigation was to evaluate the extraction performance of a mixer settler set‐up for miniplant technology using static micromixers as an alternative to conventional stirring apparatuses. A comprehensive experimental study was conducted at BASF AG to broaden the technology base for the “extraction” unit operation which is well established for miniplants in order to be utilized for microplant systems. The work proved that micromixers, or micromixer arrays, are highly efficient apparatuses for extraction purposes. The extraction efficiency was found to be a function of volume flow, which could be explained in light of the volume flow dependence of the mean droplet size and, hence, the specific surface area of the dispersions intermediately formed. At optimal flow conditions, one practical mixer settler stage was found to yield one theoretical plate for most systems investigated.     

Modeling of Mixing and Precipitation Using CFD and Population Balances

Simulations of particle size distributions in technical precipitation reactors require the consideration of turbulent mixing and precipitation kinetics. For that, spatially resolved population balances have to be evaluated. In turbulent flows these balances cannot be solved directly, instead either Reynolds averaging or Large Eddy Simulations have to be applied, while unresolved fluctuations need to be modeled. Reynolds averaging of the population balance leads to a turbulent growth dispersion term which has to be modeled. As no theoretically founded approach is available, an assumption was made in analogy to the turbulent diffusion, which improves the prediction of the size distribution shape compared to experiments.     

Characterization of mixing in an optimized designed T-T mixer with cylindrical elements

Passive micromixers are preferred over active mixers for many microfluidic applications due to their relative ease in integration into complex systems and operational flexibility. They also incur very low cost of manufacturing. However, the degree of mixing is comparatively low in passive mixers than active mixers due to the absence of disturbance in the flow by external forces and the inherent laminar nature of microchannel flows. Various designs of complex channel structures and three-dimensional geometries have been investigated in the past to obtain an efficient mixing in passive mixers. But the studies on mixing enhancement with simple planar geometries of passive mixers have been few and limited. The present work aims to investigate the possibility of mixing enhancement by employing simple planar type designs, such as T-mixer and T-T mixer with cylindrical elements placed in the mixing channel. The mixing performance has been evaluated in the Reynolds number range of 6 to 700. Numerical results have shown that T-T mixer with cylindrical elements performed significantly well and obtained very good mixing quality over basic T-mixer for the entire range of Reynolds number (6 to 700). The device has also shown better mixing as compared to basic T-T mixer and T-mixer with cylindrical elements. A larger pair of vortices formed in the stagnation area due to the presence of a cylindrical element in the junction. Cylindrical elements downstream caused significant enhancement in mixing due to splitting and recombining action. The size of the cylindrical element in the T-T mixer has been optimized to obtain better mixing performance of the device. Remarkable improvement in mixing quality by T-T mixer with cylindrical elements has been obtained at the expense of small rise in pressure drop as compared to other passive designs considered in this study. Therefore, the current design of T-T mixer with cylindrical elements can act as an effective and simple passive mixing device for various micromixing applications.     

An Analysis of Mixing in a Typical Experimental Set‐up to Measure Nnucleation Rates of Precipitation Processes

Mixing in a typical experimental setup to measure nucleation rates in precipitation processes was assessed. To determine these rates as a function of the driving force for concomitant polymorphs, it is necessary to perform these experiments at constant supersaturation. Therefore, the mixing time must be shorter than the time for the first nuclei to appear. For fast precipitation processes complete mixing has to be achieved within milliseconds. The mixing performance of a wide angle Y‐mixer was studied to see whether this is possible. An analysis of characteristic mixing times as a function of the average energy dissipation rate showed that turbulent dispersion of the feed streams determined the rate of the mixing process. The characteristic time for turbulent dispersion was of the same order as an arbitrarily set residence time in the Y‐mixer. However, CFD simulations of the flow showed large variation in the spatial distribution of the dissipation rate and revealed unsatisfying macromixing.     

CFD Modelling of Mixing Effects on the Course of Parallel Chemical Reactions Carried out in a Stirred Tank

Effects of turbulent mixing on the course of two fast parallel chemical reactions (neutralization of sodium hydroxide and hydrolysis of ethyl chloroacetate) carried out in a semibatch stirred tank reactor are experimentally investigated and numerically simulated. The flow pattern in the stirred tank is predicted using CFD and experimentally validated using Laser Doppler Anemometry. Mixing effects are modelled using three CFD based models. In the first and the second model the Beta probability distribution and the spiked distribution are used respectively; in the third model concentration fluctuations are neglected.     

A Dynamical Systems Approach to Mixing in Circulating Flows

Circulating flows are found in a variety of mixing equipment such as stirred tanks and airlift loop vessels. This paper presents a different route towards modeling the mixing in circulating flows. This route is based on an innovative use of Poincaré maps and suspended flows, concepts which are found in dynamical systems theory. The mixing model is developed for an arbitrary recirculating flow and uses a circulation time distribution function that is incorporated into the transport equations for an inert tracer injected into the flow system. Two cases are used to study the application of the mixing model in this work. The first case addresses the question of whether the mixing model can be used to study airlift vessels differing in scale and the second case highlights the application of the model to a standard stirred tank. In the first case, model predictions have been compared with experimental data obtained from two geometrically similar airlift systems of different volumes and good agreement is observed. A single parameter correlation for the mixing time is also proposed. In the second case, computational fluid dynamics was used to obtain the flow field of a standard stirred tank fitted with a six bladed Rushton turbine. From the flow field, the distribution of the circulation times is extracted and used to determine the tracer concentration profile in the stirred tank. Good agreement between the model predictions and published experimental data is observed thus indicating that the mixing model shows promise as a technique for studying the mixing in stirred tanks.     

Centrifugal Micromixery

We present a modular centrifugal micromixer comprising a mixing unit hosting a planar network of low‐aspect‐ratio microfluidic channels (“disk”), a fixed rotating drive (“player”) and contact‐free dispensers for the continuous feed of educts. The modular setup allows a simple fabrication and a child's play exchange of the mixing unit. High‐speed micromixing is powered by the Coriolis force at volume throughputs of up to milliliters per minute and microchannel! These outstanding characteristics are demonstrated by experiments and accompanying CFD‐simulations.     

CFD Investigation of the Mixing of Yield‐Pseudoplastic Fluids with Anchor Impellers

The study was carried out to simulate the 3D flow domain in the mixing of pseudoplastic fluids possessing yield stress with anchor impellers, using a computational fluid dynamics (CFD) package. The multiple reference frames (MRF) technique was employed to model the rotation of the impellers. The rheology of the fluid was approximated using the Herschel–Bulkley model. To validate the model, the CFD results for the power consumption were compared to the experimental data. After the flow fields were calculated, the simulations for tracer homogenization were performed to simulate the mixing time. The effects of impeller speed, fluid rheology, and impeller geometry on power consumption, mixing time, and flow pattern were explored. The optimum values of c/D (impeller clearance to tank diameter) and w/D (impeller blade width to tank diameter) ratios were determined on the basis of minimum mixing time.     

Suspension and Mixing Characterization of Intermittent Agitation Modes in DASGIP Bioreactors

Intermittent agitation strategies have been increasingly used for a range of process development applications, i.e., to modulate physical cues, to improve stem cell differentiation yields, and to control hydrodynamic shear stresses in microcarrier suspension; however, there is a distinct lack of characterization. Both continuous and intermittent agitation modes in relation to suspension and mixing dynamics within a DASGIP bioreactor were characterized. Suspension dynamics were found to be affected by microcarrier porosity and the degree of settling was found to be more pronounced at the top of the bioreactor. Mixing time characterization showed a marked improvement in mixing efficiency for intermittent agitation, with an overall dependence on the timing of tracer insertion.     

Novel Liquid‐Flow Splitting Unit Specifically Made for Numbering‐Up of Liquid/Liquid Chemical Microprocessing

A liquid‐flow splitting unit for dividing one main liquid stream into six substreams was developed without the need for active flow regulation. The tool has six fluid connectors that allow the numbering‐up of a respective number of microprocess devices for liquid or liquid/liquid processes. One such liquid/liquid process for which the current tool design and tests in particular have been conceived, is the forced precipitation of precious inorganic powders by the segmented flow tubular reactor (SFTR) technique. Such investigations were performed with six micromixers of impinging‐jet or interdigital separation layer type attached to the liquid‐flow splitting unit. Fluid equipartition is achieved via the action of the microdevices as flow resistors, thereby increasing the pressure drop of the system. Liquid splitting was carried out in a cylindrical liquid tank with one inlet and six outlet holes that also served for pulsation dampening. By CFD simulations the impact of two important geometric parameters of this tank, namely, the height at a given diameter and the position of the inlet hole, on the fluid splitting was studied. In addition, the influence of the injection direction with respect to the normal of the tank was analyzed. It turned out that in the presence of flow resistors (typically generating a pressure drop at about 60 mbar) this impact is negligible, i.e., principally, a large flexibility on design and operation is provided. Without these resistors, the before‐mentioned parameters in turn have a large impact that is discussed in detail. Experiments with a liquid‐flow splitting unit and six coupled impinging‐jet micromixers using water as liquid proved a reasonable fluid distribution with a standard and maximum deviation of the substream flow rates of 4 and 11 %, respectively. These deviations are mainly caused by different pressure drops (Δp) of the individual impinging‐jet mixers as a result of tolerances in the microfabrication method, die sinking μEDM manufacture. Already small differences in the microstructured outlet hole diameters (d = 300 μm) of the impinging‐jet mixer have a large influence due to the d^–4 ～ Δp dependence. Additionally, attaching specially adapted interdigital separation layer micromixers to the liquid‐flow splitting unit, a minimum/maximum (standard) deviation of the water distribution below 5 (2) % could be achieved. To obtain this improved result, it was necessary to optimize the choice of material, the design of the microstructure inside the mixer, and the fabrication process.     

Numerical characterisation of folding flow microchannel mixers

Micromixers have been considered in numerous recent studies with the aim of mixing different liquid streams for the common circumstance of non-inertial flow, i.e., in the Stokes flow regime. Under such conditions, the diffusion of momentum is dominant but the diffusion of species remains weak because the Schmidt number of liquids is large. Most mixers that have potential for application in the Stokes regime make use of a folding flow pattern that approximates the baker's transformation. In the work presented here, the general scaling of mixers of this type is developed from the exact equation for species transport and computations are made for a specimen mixer geometry to test the effectiveness of the resulting scaling. The scaling relation developed is found to give an excellent representation of the actual mixing characteristics of the specimen mixer over the entire range of Péclet number of practical interest. Finite volume computations are employed to solve the governing equations up to around Pe=10³. At higher Péclet numbers, where finite volume numerical solution becomes inaccurate with affordable mesh sizes, the species equation is solved using a Monte Carlo method instead. Finally, the scaling relation is used to develop the design relations needed to determine the number of mixing elements, the pressure drop incurred and the Péclet number of operation to achieve a given mixture uniformity within a specified mixing time.     

The Future of Mixing Research

This paper is the result of a plenary discussion session held at the 11^th European Conference on Mixing. Three perspectives on mixing research are explored: that of the industrialist, the equipment manufacturer, and the academic researcher. There was strong agreement that, while the one dimensional problems are reasonably well understood and many engineers thus perceive that mixing is simple, current practice actually requires us to address complex, multi‐dimensional problems with interactions between mixing, reaction, multi‐phase physics, surface phenomena, and transport phenomena. Understanding these multi‐scale, multi‐mechanism problems requires models which include interactions between the phenomena, and allow the effects of these interactions to emerge. Developing these models will require us to shift our perspective on mixing from one of equipment design to one of the mixing field as a fundamental physical mechanism.     

Mixing in High-Pressure Polymerization Reactors: A Combined Experimental and Modeling Approach

Mixing in low-density polyethylene (LDPE) reactors is crucial regarding process safety as well as process efficiency. The extreme process conditions of pressures up to 3000 bar make it difficult to get an insight into LDPE reactors. This problem is tackled by a combined experimental and modeling approach. A poly(methylmethacrylate) duplicate of a laboratory high-pressure reactor is set up to measure residence times and visualize flow lines. Experimental results are then compared to a computational fluid dynamics model.     

3种被动式微混合器的性能对比及压损分析

通过数值模拟的方法对3种不同结构的被动式微混合器进行了研究,同时对3种被动式微混合器的混合性能进行了对比,并进一步研究了微混合器的压力损失。结果显示,内肋形微混合器在5种速度条件下的混合性能要优于其他两种微混合器,而且随着流量越来越大,其压力损失也越来越大;内肋形微混合器的压力损失最大,Z形微混合器的次之,Y形微混合器的最小。