Mixing sensitivity to the inclination of the lateral walls in a T-mixer

One of the simplest geometries for micro-mixers has a T-shape, i.e., the two inlets join perpendicularly the mixing channel. The cross-sections of the channels are usually square/rectangular, as straight walls facilitate experimental and modeling analysis. On the contrary, this work investigates through Computational Fluid Dynamics the effect of a cross-section with lateral walls inclined of an angle α as such an inclination may stem from different microfabrication techniques. Considering water as operating fluid, the same mixing performance as square/rectangular cross-sections is obtained for inclinations α≤3°; this indicates the maximum admissible error on the perpendicularity of the walls in the manufacturing process. Above this value, the presence of inclined walls delays the onset of the engulfment regime at higher Reynolds numbers, and for α≥23°the mixing is hampered dramatically, as the flow is unable to break the mirror symmetry and enter in the engulfment regime. At low Reynolds numbers, the mixing is moderately improved for α≥10°, because the vortex regime presents a lower degree of symmetry than that of T-mixers with straight walls

Unsteady flow regimes in arrow-shaped micro-mixers with different tilting angles

Two arrow-shaped micro-mixers, obtained from the classical T-shaped geometry by tilting downward the inlet channels, are considered herein. The two configurations, having different tilting angle values, have been chosen since they show significantly different flow topologies and mixing performances at low Reynolds numbers. In the present paper, we use both experimental flow visualizations and direct numerical simulations to shed light on the mixing behavior of the two configurations for larger Reynolds numbers, for which the mixers present unsteady periodic flows, although in laminar flow conditions. The tilting angle influences the flow dynamics also in the unsteady regimes and has a significant impact on mixing. The configuration characterized by the lower tilting angle, i.e., α = 10°, ensures a better global mixing performance than the one with the larger angle, i.e., α = 20°

Effect of stratification on the mixing and reaction yield in a T-shaped micro-mixer

The effect of a small density difference, i.e., lower than 12%, between the two miscible liquid streams fed to a T-shaped junction is investigated experimentally and through numerical simulations. Micron-resolution particle image velocimetry (micro-PIV) experiments provided detailed support to the numerical analysis of how stratification influences flow features in different flow regimes. From dimensional analysis, we find that gravitational and inertial fluxes balance each other at a distance L=d/Ri from the confluence along the mixing channel, where d is the hydraulic diameter and Ri is the Richardson number. In general, at distances |y|≪L, the influence of gravity can be neglected, while at |y|≫L the two fluids are fully segregated; in particular, at the confluence, the flow field is the same as the one that we obtain assuming that the two inlet fluids are identical. Thus, in the segregated regime, the contact region separating the two fluids of the inlet streams remains vertical at distances |y|≪L along the mixing channel while it becomes progressively horizontal at |y|≈L. In the vortex regime as well, near the confluence the flow field presents a mirror symmetry, with a very small resulting degree of mixing; however, as we move down the mixing channel, when |y|>L, gravity becomes relevant, leading to a symmetry breaking that promotes convection and enhances mixing. When we further increase the Reynolds number, in the engulfment regime, the degree of mixing becomes much larger due to the mixing induced by the flow instability at the confluence and thus the successive stratification appears to have a small effect on the flow topology, with a degree of mixing that continues to grow very slowly in the mixing channel, similar to what happens in the case of identical inlet fluids. As expected, the onsets of the vortex and engulfment regimes occur at values of the Reynolds number Re that hardly depend on the density difference between the two inlet fluids, provided that Re is defined in terms of the fluid properties of a homogeneous fluid mixture. Finally, the reaction yield along the mixing channel is computed both from numerical and experimental data. In agreement with theoretical predictions, we found that the reaction yield depends on the Damköhler number and the kinetic constant, while it is independent of the density ratio, at least within the range of the investigated conditions

Influence of the inlet conditions on the degree of mixing of a t-shaped micro-mixer

Paper presented at the 9th International Conference on Heat Transfer, Fluid Mechanics and Thermodynamics, Malta, 16-18 July, 2012.The degree of mixing of a T-shaped micro-mixer depends strongly on the inlet flow conditions. Specifically, through a series of numerical simulations, we compared the case where the flow at the micro-mixer confluence is fully developed with that when it is not, and found that in the former case engulfment occurs at smaller Reynolds number, with a different flow pattern and with much larger mixing efficiencies than in the latter case. In particular for fully developed flow conditions the engulfment shows S-shaped morphology, whereas for non- fully developed inlets a symmetry breaking occurs, leading to a C-shaped engulfment pattern. This is characterized by much lower mixing efficiencies.dc201

An Overview of Flow Features and Mixing in Micro T and Arrow Mixers

An overview of the mixing performances of micro T mixers operating with a single fluid is presented. The focus is on the relationship between the flow features and mixing. Indeed, T mixers are characterized by a variety of regimes for increasing Reynolds numbers; they are briefly described, in particular in terms of the three-dimensional vorticity field, which can explain the different mixing performances. The effects of changes in the aspect ratio of the channels are also reviewed. The role of instability and sensitivity analyses in highlighting the mechanisms of the onsets of the different regimes is then described. These analyses also suggest possible geometrical modifications to promote mixing. We focus on that consisting of the downward tilting of the inlet channels (arrow mixers). Arrow mixers are interesting because the onset of the engulfment regime is anticipated at lower Reynolds numbers. Hence, the mixing performances of arrow mixers with varying Reynolds number are described

A study on the effect of flow unsteadiness on the yield of a chemical reaction in a t micro-reactor

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

Influence of the inlet conditions on the degree of mixing of a t-shaped micro-mixer

Paper presented at the 9th International Conference on Heat Transfer, Fluid Mechanics and Thermodynamics, Malta, 16-18 July, 2012.The degree of mixing of a T-shaped micro-mixer depends strongly on the inlet flow conditions. Specifically, through a series of numerical simulations, we compared the case where the flow at the micro-mixer confluence is fully developed with that when it is not, and found that in the former case engulfment occurs at smaller Reynolds number, with a different flow pattern and with much larger mixing efficiencies than in the latter case. In particular for fully developed flow conditions the engulfment shows S-shaped morphology, whereas for non- fully developed inlets a symmetry breaking occurs, leading to a C-shaped engulfment pattern. This is characterized by much lower mixing efficiencies.dc201

Influence of cross-sectional geometry on mixing in a T-shaped micro-junction

Microfluidics is gaining increasing interest in the field of chemical engineering, as miniaturization may lead to a significant intensification of chemical processes. Since the flow is laminar, achieving a good mixing of reactants is one of the main challenges. The simplest geometry is constituted by a T-shaped mixer in which the two inlets join perpendicularly the mixing channel. The inlet cross section is usually square while the mixing channel cross-section is a rectangle as straight walls facilitate experimental and modelling analysis. The present work, on the contrary, is aimed at investigating through Computational Fluid Dynamics the effect of a cross-section with lateral inclined walls, to emulate a microfabrication technology based on laser machining. The presence of inclined walls is found to hamper mixing at high Reynolds numbers as the flow is unable to break the mirror symmetry and thus to undergo the engulfment regime. However, at low Reynold numbers the mixing is improved because the vortex regime presents a lower degree of symmetry with respect to that of T-mixers with straight walls

Optimally Managing Chemical Plant Operations: An Example Oriented by Industry 4.0 Paradigms

Updating industrial facilities to increase the level of automation and digitalization to match Industry 4.0 paradigms has become essential for many companies. Following such a trend, this paper presents a real-time optimization algorithm that plays a central role in a larger project framework devoted to highly interconnecting different network components of an Italian chemical industrial site. The proposed methodology aims at best managing the production rates of various products to fulfill a sales plan organized to satisfy numerous client requests. The considered model takes into account both batch and continuous processes as well as salable and non-storable products. The algorithm structure relies on the use of a non-linear optimization scheme and on the concepts of batch scheduling. Different features of the proposed methodology have been tested on real plant data, showing how the predicted forecast always improved the initial operation plan by considering both aspects of feasibility and economic nature. The use of the proposed algorithm assures the basis for fully integrating the control systems and the selling department of the facility in a more interactive and responsive manner

Mixing Improvement in a T-Shaped Micro-Junction through Small Rectangular Cavities

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