Chaotic-flow-driven mixing in T- and V-shaped micromixers

Abstract

T- and V-shaped (or arrow-shaped) micromixers enable the control of rapid chemical reactions by permitting accelerated mixing. Their mixing performance has been extensively investigated at moderate flow rates, which correspond to Reynolds numbers of the order of several hundreds. However, this operating range does not align with the recent applications of microreactors in organic synthesis. Therefore, this study examined mixing times in T- and V-shaped micromixers with 250-µm-wide channels at high flow rates (Reynolds numbers of up to 1500). The progress of mixing between an acidic solution and a basic solution containing a pH-sensitive fluorescent molecule was visualized by fluorescence microscopy imaging. An image analysis of 200 frames for each condition helped evaluate the degree of mixing and its stability over time under chaotic flow. The performance and stability of the V-shaped micromixer were significantly enhanced when the flow-rate ratio was changed from 1:1 to 1:2. The difference in momentum between the two inlet streams suppressed the undesirable alternation of the flow patterns at the junction. The effects of the choice of fluids (in the lower- and higher-flow-rate sides) on the reaction selectivity were explored through a numerical analysis. It was clarified that the substrate-side flow rate has to be set lower than that of the reactant side in the competing consecutive reaction system. Moreover, a short mixing time of 1 ms was achieved using the V-shaped micromixer at a flow-rate ratio of 1:2 and Re of 1500. These findings provide practical guidelines for the design and operation of microreactor systems.