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Microfluidic devices may provide significant technological advancement in the production of micro and nanoparticles of interest in the pharmaceutical sector, for instance, particles used as drug carriers (Yeh et al., 2013). Indeed, microfluidics enables their production with precise control of the dimensional distribution, not achievable with conventional beaker methods. The particle size is crucial for the optimal operation, thus representing a key target along with the generation frequency. The device geometry, properties, and flow rates of the fluids are the main parameters that affect the generation process. In this work, we investigate the production of alginate droplets in an X-shaped microdevice (Tomasi Masoni et al., 2022). More specifically, we feed an alginate solution in sunflower oil working in the dripping regime. Experimental visualizations are carried out for different flow rates and concentrations of the surfactant to comprehend their effect on droplet formation. Interestingly, we identify operating conditions that prevent the formation of satellite droplets to preserve a narrow dimensional distribution.

The T-shaped micro-junction is among the most used geometry in microfluidic applications, and many design modifications of the channel walls have been proposed to enhance mixing. In this work, we investigate through numerical simulations the introduction of one pair of small rectangular cavities in the lateral walls of the mixing channel just downstream of the confluence region. The aim is to preserve the simple geometry that has contributed to spread the practical use of the T-shaped micro-junction while suggesting a modification that should, in principle, work jointly with the vortical structures present in the mixing channel, further enhancing their efficiency in mixing without significant additional pressure drops. The performance is analyzed in the different flow regimes occurring by increasing the Reynolds number. The cavities are effective in the two highly-mixed flow regimes, viz., the steady engulfment and the periodic asymmetric regimes. This presence does not interfere with the formation of the vortical structures that promote mixing by convection in these two regimes, but it further enhances the mixing of the inlet streams in the near-wall region of the mixing channel without any additional cost, leading to better performance than the classical configuration.

This work is aimed at investigating the mixing process of highly viscous paints, used to colour leathers in the tanning industry, through Computational Fluid Dynamics (CFD). In particular, a mixing tank is fed with a master liquid and different liquid pigments and then stirred by Cowles impellers in order to obtain a paint of a uniform colour. The typical dynamic viscosity of the liquids in this process is µ ~ O(0.1-10) Pa·s, while the Cowles rotational speed is usually very high, i.e. 3000-5000 rpm. The numerical model is based on the solution of the unsteady Reynolds-Averaged Navier–Stokes (RANS) equations for continuity, momentum and species mass fractions, the latter being used to describe the different components. The impeller motion is modelled through the Sliding Deforming Mesh (SDM) approach, using rotating (unstructured) meshes in the impeller region and a static (structured) mesh in the remainder of the tank. The master liquid and coloured pigments are assumed to stratify within the tank at initial time and the steady rotational speed is then imposed abruptly to the impellers. The level of homogeneity in the stirred tank is evaluated through the analysis of component concentration fields over time. In particular, such local concentrations can be used to determine the mixture colour in different regions of the tank, and hence predict the degree of homogeneity at different times; this is accomplished by defining a proper homogeneity indicator based on the spatial variance of the estimated colour. The proposed numerical model provides an efficient method to investigate the colour of the mixture and to evaluate an appropriate mixing time. The methodology gives also important indications for the tank design, especially useful in the case of non-conventional impellers, high rotation rates and viscous fluids.

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.