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Mixing is a basic but challenging step to achieve in high throughput microfluidic applications such as organic synthesis or production of particles. A common approach to improve micromixer performance is to devise a single component that enhances mixing through optimal convection, and then sequence multiple such units back-to-back to enhance overall mixing at the end of the sequence. However, the mixing units are often optimized only for the initial non-mixed fluid composition, which is no longer the input condition for each subsequent unit. Thus, there is no guarantee that simply repeating a single mixing unit will achieve optimally mixed fluid flow at the end of the sequence. In this work, we analyzed sequences of 20 cylindrical obstacles, or pillars, to optimize the mixing in the inertial regime (where mixing is more difficult due to higher Peclet number) by managing their interdependent convection operations on the composition of the fluid. Exploiting a software for microfluidic design optimization called FlowSculpt, we predicted and optimized the interfacial stretching of two co-flowing fluids, neglecting diffusive effects. We were able to quickly design three different optimal pillar sequences through a space of 3220 possible combinations of pillars. As proof of concept, we tested the new passive mixer designs using confocal microscopy and full 3D CFD simulations for high Peclet numbers (Pe ≈ O(105–6)), observing fluid flow shape and mixing index at several cross-sections, reaching mixing efficiencies around 80%. Furthermore, we investigated the effect of the inter-pillar spacing on the most optimal design, quantifying the tradeoff between mixing performance and hydraulic resistance. These micromixer designs and the framework for the design in inertial regimes can be used for various applications, such as lipid nanoparticle fabrication which has been of great importance in vaccine scale up during the pandemic.

Microreactors are very attractive for intensifying chemical and biochemical reactions, as they enable a large heat transfer with high control of the operating conditions. These features allow improving the achievable reaction yield and selectivity. However, the mixing of reactants should be ensured, especially in simple designs, as the flow regime is laminar. This work aims at characterizing the flow regimes and degree of mixing in a X-shaped micromixer with two opposite inlets and at investigating how these regimes are affected by fluid properties. To this purpose we carry out numerical simulations of two different mixtures, i.e. Water-Water (W-W) and Water-Ethanol (W-E), for Reynolds numbers Re ⩽ 200 , to gain insight into the complex three-dimensional flow structures stemming from the impinging jets at the confluence. Besides, experimental flow visualizations from the W-W case provide a validation of the numerical model. The X-shaped reactor is observed to enable a superior mixing performance compared to T-, Y-, and Arrow-shaped microreactors, which are extensively employed.

Despite the very simple geometry and the laminar flow, T-shaped microreactors have been found to be characterized by different and complex steady and unsteady flow regimes, depending on the Reynolds number. In particular, flow unsteadiness modifies strongly the mixing process, however, little is known on how this change may affect the yield of a chemical reaction. In the present work, experiments and 3-dimensional numerical simulations are carried out jointly to analyze mixing and reaction in a T-shaped microreactor with the ultimate goal to investigate how flow unsteadiness affects the reaction yield. The onset of the unsteady asymmetric regime enhances the reaction yield by more than 30%, however, a strong decrease of the yield back to values typical of the vortex regime is observed when the flow undergoes a transition to the unsteady symmetric regime.

The effect of flow regimes on the reaction yield of a chemical reaction occurring in a T-shaped micro-reactor is investigated both experimentally and numerically by spanning different Reynolds and Damkohler numbers. The experimental set-up is arranged in order to get in-line information on both fluid dynamics and reaction progress along the mixing channel. Numerical simulations are performed using mesh-adaption cycles to well resolve the mixing between reactants; in this manner, the agreement between experiments and numerical simulations is very satisfactory. For the considered reaction involving two reagents different from water, despite flow regimes are coherent with the ones observed in case of water mixing, significant differences arise because stratification occurs due to the different density of the fluid streams. The dependency of reaction yield on both Reynolds and Damkohler numbers is strongly affected by the flow regimes. In the stratified regime, the reaction yield decreases with the Reynolds number, because the reduced residence time hampers the reaction progress, while in the engulfment regime, the Reynolds number has a positive effect on the yield, thanks to the enhanced mixing.