Design of single-wave-based curved and rectangular serpentine microchannels for mixing applications: a CFD study

Mixing performance of a fractal-like tree network micromixer based on Murray’s law

Discrete element method study of effects of the impeller configuration and operating conditions on particle mixing in a cylindrical mixer

This work aims to find the optimum value of blade height ratio (R) for improving mixing performance and energy consumption of a Triple-Blade Concentric Double-Helix Static Mixer. In this study, mixing of two fluids at different concentrations subjected to laminar flow conditions is numerically analyzed by using finite element-based Computational Fluid Dynamics simulations. Different values of the R parameter are considered in a wide range of Reynolds numbers (Re = 200–1000). This analysis then carried out an in-depth study of R's effect on mixing performance, strength segregation, mixing index, helicity, velocity profile, pressure drop, pumping power, and efficiency. The findings showed that a blade height ratio of R = 2/3 gave the highest mixing index (MI), with the maximum value of 0.99 at a Re number of 600, which showed the best mixing performance in the channel. Helicity visualization also showed complex helicity patterns with increased vortex interactions for the 2/3 configuration. This geometry gave an improvement in MI by about 17.85% over Triple-Blade Concentric Single-Helix Static Mixer (TB-CSH-SM) with R = 0 at Re = 600. It is also important to mention that increasing the R value leads to an increase in pressure drop and, consequently, an increase in pumping energy consumption. Although R = 2/3 gives the best mixing performance, the energy consumption is relatively higher than that for R = 0, which has the lowest power input but a lower MI. The investigation concludes that R = 2/3 represents a balanced solution since it realizes an optimum mixing performance with a moderate energy consumption and hence is suitable for applications requiring an efficient compromise between mixing quality and energy consumption.

Flow and mixing analysis of non-Newtonian fluids in straight and serpentine microchannels

Scientific research and development in the field of microfluidics and nanofluidics technology has witnessed a rapid expansion in recent years. Microfluidic and nanofluidic systems are finding increasing application in wide spectrum of biomedical and engineering fields, including oil and gas technology. Fluid flow characterization in porous geologic media is an important factor for predicting and improving oil and gas recovery. By developing understanding about the propagation of hydraulic fracturing fluid constituents in irregular micro- and nano-structures, and their multiphase interaction with reservoir fluids (e.g. mixing of supercritical CO2 with oil or gas) we can significantly improve efficiency of the current oil and gas (O&G) extraction process and reduce associated environmental impacts. In present paper, mixing of hydraulic fracturing fluid constituents in three dimensional serpentine microchannel system is simulated in CFD environment and results are used to evaluate mixing efficiency for different fracturing fluid compositions. In addition, pressure drop along the length of serpentine micro-channel is evaluated. Serpentine micro-channels considered in this study consist of periodic symmetrical and asymmetrical proppant particles, placed on both sides of the channel over the full length of the channel, to simulate realistic geometrical constraints usually seen in geological fractures. The fluid flow is characterized as a function of the proppant particle radius by varying size of adjacent proppant particles. Further, the flow is characterized by varying distance between adjacent proppant particles. Overall, this study will be primarily helpful to gain fundamental understanding of fracturing fluid mixing in micro-fractures, similar to real geologic media. In addition, this study will provide an insight into variations of fracturing fluid mixing efficiency, and pressure drop in micro-fracture systems as a function of geometry of the proppant particles at different flow rates.

Parametric study on mixing of two fluids in a three-dimensional serpentine microchannel

Chaotic vortex micromixer utilizing gas pressure driving force

In this study, Y-shaped micromixers with mixing chamber design optimized as rotation and chaotic advection in the fluid domain increase with the chamber. Motivated by the advantages of Y-shaped mixers, a parametric study was performed for inlet angles (α, β), inlet channel eccentricities (x-ecc, z-ecc) and length scale ratios (L1/L2, D1/D2, and Vsp). z-eccentricity is introduced in addition to x-eccentricity to create a design that further enhances the swirl and chaotic advection inside mixing chamber for the first time. The results reveal that the maximum mixing efficiency can be achieved for Reynolds number of 81 and α, β, x-ecc, z-ecc, D1/D2, and L1/L2 values of 210°, 60°, 20 μm, 20 μm, 1.8, and 4, respectively. In addition, the proposed Y-shaped micromixer leads to a lower pressure drop (at least 50% reduction for all Reynolds numbers) in comparison to competing design. The maximum reduction in pressure drop is 72% less than the curved-straight-curved (CSC) (Re = 81) with mixing efficiency of 88% and pressure drop of 9244.4 Pa. Overall, an outstanding mixing efficiency was offered over a wide range of Reynolds numbers with distinctly low pressure drop and a compact micromixer design, which could be beneficial for a wide variety of applications where volume and pumping power are limited.

A novel passive micromixer, called a trapezoidal-zigzag micromixer (TZM), is reported. A TZM is composed of trapezoidal channels in a zigzag and split–recombine arrangement that enables multiple mixing mechanisms, including splitting–recombining, twisting, transversal flows, vortices, and chaotic advection. The effects of geometric parameters of the TZM on mixing performance are systematically investigated by the Taguchi method and numerical simulations in COMSOL Multiphysics. The number of mixing units, the slope angle of the trapezoidal channel, the height of the constriction element, and the width ratio between the middle-trapezoidal channel and the side-trapezoidal channel are the four parameters under study. The mixing performance of the TZM is investigated at three different Reynolds number (Re) values of 0.5, 5, and 50. The results showed that a TZM with six mixing units, a trapezoidal slope angle of 75°, a constricting height of 100 µm, and a width ratio of 0.5 has the highest mixing efficiency. This optimal TZM has a mixing efficiency greater than 85% for Re values from 0.1 to 80. In particular, for Re ⩽ 0.9 and Re ⩾ 20, the mixing efficiency of the optimal TZM is greater than 90%. The proposed TZM has a higher mixing efficiency and a smaller footprint than previously reported micromixers.

Sample mixing is difficult in microfluidic devices because of laminar flow. Micromixers are designed to ensure the optimal use of miniaturized devices. The present study aims to design a chaotic-advection-based passive micromixer with enhanced mixing efficiency. A serpentine-shaped microchannel with sinusoidal side walls was designed, and three cases, with amplitude to wavelength (A/λ) ratios of 0.1, 0.15, and 0.2 were investigated. Numerical simulations were conducted using the Navier–Stokes equations, to determine the flow field. The flow was then coupled with the convection–diffusion equation to obtain the species concentration distribution. The mixing performance of sinusoidal walled channels was compared with that of a simple serpentine channel for Reynolds numbers ranging from 0.1 to 50. Secondary flows were observed at high Reynolds numbers that mixed the fluid streams. These flows were dominant in the proposed sinusoidal walled channels, thereby showing better mixing performance than the simple serpentine channel at similar or less mixing cost. Higher mixing efficiency was obtained by increasing the A/λ ratio.

Static mixers have been widely used in marine research fields, such as marine control systems, ballast water treatment systems, and seawater desalination, due to their high efficiency, low energy consumption, and broad applicability. However, the turbulent mixing process and fluid–wall interactions involving complex structures make the mixing transport characteristics of static mixers complex and nonlinear, which affect the mixing efficiency and stability of the fluid control device. Here, the modeling and design optimization of the two-phase flow mixing and transport dynamics of a static mixer face many challenges. This paper proposes a modeling and problem-solving method for the two-phase flow transport dynamics of static mixers, based on the lattice Boltzmann method (LBM) and large eddy simulation (LES). The characteristics of the two-phase flow mixing dynamics and design optimization strategies for complex component structures are analyzed. First, a two-phase flow transport dynamics model for static mixers is set up, based on the LBM and a multiple-relaxation-time wall-adapting local eddy (MRT-WALE) vortex viscosity coupling model. Using octree lattice block refinement technology, the interaction mechanism between the fluid and the wall during the mixing process is explored. Then, the design optimization strategies for the flow field are analyzed under different flow rates and mixing element configurations to improve the mixing efficiency and stability. The research results indicate that the proposed modeling and problem-solving methods can reveal the dynamic evolution process of mixed-flow fields. Blade components are the main driving force behind the increased turbulent kinetic energy and induced vortex formation, enhancing the macroscopic mixing effect. Moreover, variations in the flow velocity and blade angles are important factors affecting the system pressure drop. If the inlet velocity is 3 m/s and the blade angle is 90°, the static mixer exhibits optimized overall performance. The quantitative analysis shows that increasing the blade angle from 80° to 100° reduces the pressure drop by approximately 44%, while raising the inlet velocity from 3 m/s to 15 m/s lowers the outlet COV value by about 70%, indicating enhanced mixing uniformity. These findings confirm that an inlet velocity of 3 m/s combined with a 90° blade angle provides an optimal trade-off between mixing performance and energy efficiency.

Numerical analysis of vortex T micromixer with diffuser plates and obstacles

PurposeThis study aims to propose the increase of heat dissipation requirements of modern electronic equipment and the fast development of micro-scale manufacturing technologies. The heat transfer mechanism is studied in-depth, especially for its pattern of secondary flow caused by the repeated inversion of centrifugal force. Effects of η on the frictional pressure drop and average Nusselt number are studied and the performance of such microchannel heat sink with various bend amplitudes is comprehensively evaluated. These results can provide important insight into the optimal design of this novel design configuration for microelectronics cooling.Design/methodology/approachA three-dimensional model based on the finite volume approach and SIMPLEC algorithm is performed to test an innovative serpentine microchannel, which behaves differently from conventional serpentine microchannel due to the significant effect of centrifugal force inversion.FindingsThe effect of centrifugal force significantly influences the flow and thermal fields which are responsible for the enhancement in heat transfer coefficient. The number, size and intensity of vortices increase with increasing Re, and the vortices are reformed at every change of the geometry in a periodic fashion. The serpentine microchannel studies more effectively at larger bend amplitude. Pressure fluctuations and temperature variation are greater with increasing bend amplitude.Practical implicationsSeveral techniques have been developed to augment single-phase convective heat transfer in channels. One technique is to use a serpentine channel that enhances the heat transfer due to flow mixing and periodic interruption of thermal boundary layers. This technique has been applied to micro-heat exchangers, thermal regenerators and mini/microreactors.Social implicationsThe optimal design of this novel design configuration for microelectronics cooling can be attained. It will become an effective cooling technology for solving the increasing of heat dissipation requirements of modern electronic equipment.Originality/valueThe flow and heat transfer characteristics are first presented for the circular serpentine microchannel made up of alternate U-bends without interposed straight segments. The present study first examines the effect of such centrifugal force inversion on velocity contour, pressure distribution and temperature distribution. The patterns of secondary flow along the flow passage caused by the repeated inversion of centrifugal force are further studied in depth. The effect of bend amplitude on the flow and heat transfer is explored and the performance of such microchannel heat sink has been comprehensively evaluated.

Chemical bioreactions play a significant role in many of the microfluidic devices, and their applications in biomedical science have seen substantial growth. Given that effective mixing is vital for initiating biochemical reactions in many applications, micromixers have become increasingly prevalent for high-throughput assays. In this research, a numerical study using the finite element method was conducted to examine the fluid flow and mass transfer characteristics in novel micromixers featuring an array of pillars. The study utilized two-dimensional geometries. The impact of pillar configuration on mixing performance was evaluated using concentration distribution and mixing index as key metrics. The study explores the effects of pillar array design on mixing performance and pressure drop, drawing from principles such as contraction–expansion and split-recombine. Two configurations of pillar arrays, slanted and arrowhead, are introduced, each undergoing investigation regarding parameters such as pillar diameter, gap size between pillar groups, distance between pillars, and vertical shift in pillar groups. Subsequently, optimal micromixers are identified, exhibiting mixing efficiency exceeding 99.7% at moderate Reynolds number (Re = 1), a level typically challenging for micromixers to attain high mixing efficiency. Notably, the pressure drop remains low at 1102 Pa. Furthermore, the variations in mixing index over time and across different positions along the channel are examined. Both configurations demonstrate short mixing lengths and times. At a distance of 4300 μm from the inlet, the slanted and arrowhead configurations yielded mixing indices of 97.2% and 98.9%, respectively. The micromixers could provide a mixing index of 99.5% at the channel’s end within 8 s. Additionally, both configurations exceeded 90% mixing indices by the 3 s. The combination of rapid mixing, low pressure drop, and short mixing length positions the novel micromixers as highly promising for microfluidic applications.

A microfluidic-based gas sensor was chosen as an alternative method to gas chromatography and mass spectroscopy systems because of its small size, high accuracy, low cost, etc. Generally, there are some parameters, such as microchannel geometry, that affect the gas response and selectivity of the microfluidic-based gas sensors. In this study, we simulated and compared 3D numerical models in both simple and serpentine forms using COMSOL Multiphysics 5.6 to investigate the effects of microchannel geometry on the performance of microfluidic-based gas sensors using multiphysics modeling of diffusion, surface adsorption/desorption and surface reactions. These investigations showed the simple channel has about 50% more response but less selectivity than the serpentine channel. In addition, we showed that increasing the length of the channel and decreasing its height improves the selectivity of the microfluidic-based gas sensor. According to the simulated models, a serpentine microchannel with the dimensions W = 3 mm, H = 80 µm and L = 22.5 mm is the optimal geometry with high selectivity and gas response. Further, for fabrication feasibility, a polydimethylsiloxane serpentine microfluidic channel was fabricated by a 3D printing mold and tested according to the simulation results.