ABSTRACT
Microfluidic devices, allowing superior control over the spatial and temporal distribution of chemical substances and high process reproducibility, are nowadays essential in various research areas and industrial fields where the traditional "macroscopic" approach was no longer able to keep up with the increasing demands of high-end applications. In the present work, internal mixing of droplets formed by a flow-focusing X-junction at constant flow rates of both phases for three different channel heights (i.e. 20, 40 and 60 µm) was investigated and characterised. Both experimental methods and 3D CFD simulations were employed in order to resolve governing factors having an impact on internal mixing and homogenization time of model tracers inside of droplet reactors. Additionally, the influence of channel height on internal mixing was experimentally studied for continuous preparation of iron oxide nanoparticles by co-precipitation reaction. Since the initial nucleation phase is strongly affected by mixing and spatial distribution of all reactants, the final particle size and particle size distribution (PSD) can be used as direct indicators of mixing performance. It has been demonstrated that the smallest 20 µm channels provided narrower PSD and smaller particle mean size compared to higher channels.
ABSTRACT
Droplet-based microfluidic devices are now more than ever used for the synthesis of nanoparticles with low polydispersity and well-defined properties suitable for various industrial applications. Very small reaction volumes (microlitre to femtolitre) and short diffusion lengths, provide superior mixing efficiency and heat transport. Both play the dominant role in case of ultra-fast chemical reactions triggered upon reactant mixing, e.g. preparation of colloidal silver by reduction of silver salt. The high sensitivity of these systems to process variables makes otherwise more straightforward batch-wise production prone to suffer from inconsistency and poor reproducibility, which has an adverse effect on the reliability of production and further particle utilisation. This work presents a rigorous description of microfluidic droplet formation, reactant mixing, and nanoparticle synthesis using CFD simulations and experimental methods. The reaction mixture inside of droplets was homogenized in less than 40 milliseconds, which has been confirmed by simulations. Silver nanoparticles produced by droplet-based microfluidic chip showed superior to batch-wise preparation in terms of both particle uniformity and polydispersity.
