Mass transfer and size control of partially miscible fluid drops in a flow focusing microfluidic device

Abstract

We conducted laboratory experiments and numerical simulations to investigate the formation and evolution of drops formed by partially miscible two-phase fluid, n-butanol (the continuous phase) and water (the dispersed phase), in a flow focusing microfluidic system. We carefully calibrated the numerical model to obtain good agreement with experimental data in drop velocity and mass transfer, demonstrating the model's capability to capture realistic drop dynamics. Our detailed investigation of the numerical results allowed us to determine the mechanism of drop formation and obtain a relevant criterion in terms of the disperse-to-continuous flow ratio beyond which the tubing patterns would occur. Additionally, we found that the mass transfer between the two phases, specifically at the drop interface, strongly depends on the local distribution of dissolved concentration of the dispersed phase. To enhance mass transfer, we conducted numerical simulations on alternating curved channels, which allows for the lateral advection of the dispersed phase concentration in the continuous phase at the curved section. We found that this lateral movement enhances mass transfer at the drop interface. Through detailed investigation of numerical results, we addressed mechanisms of mass transfer enhancement in the curved channel. Overall, our findings provide insight into the mechanisms of drop formation and mass transfer in partially miscible two-phase fluids in microfluidic systems, which could be useful in designing and optimizing such systems for various applications.