Numerical simulation and performance study of three-dimensional variable angle baffle micromixer

Xinkun Chen; Bao Song; Xiaoyu Li; Jixu Zou; Xueye Chen

doi:10.1515/ijcre-2024-0191

Article

Numerical simulation and performance study of three-dimensional variable angle baffle micromixer

Xinkun Chen , Bao Song , Xiaoyu Li , Jixu Zou and Xueye Chen

Published/Copyright: March 3, 2025

Published by

Become an author with De Gruyter Brill

Submit Manuscript Author Information

From the journal International Journal of Chemical Reactor Engineering Volume 23 Issue 1

Abstract

In microfluidic systems, micromixers are of utmost importance for achieving efficient mixing. However, current micromixers still have deficiencies in mixing efficiency, which restricts their widespread application in fields such as biotechnology, chemical synthesis, and environmental analysis. This paper focuses on the influence of variable-angle baffles on the mixing efficiency of micromixers. By altering the geometric configurations of baffles, the mixing efficiency of solutions is enhanced. Specifically, the impacts of baffle direction, quantity, and height are explored. Additionally, groups of three baffles are utilized to investigate the effect of staggered heights on mixing. Through COMSOL simulations, it is found that the 45-degree structural baffle is highly conducive to solution mixing. An increment in baffle number prolongs the fluid mixing path, thereby augmenting the efficiency. Similarly, a rise in baffle height intensifies the fluid disturbance and elevates the mixing efficiency. Notably, setting a group of baffles to 0.15–0.05–0.1 mm is particularly advantageous for enhancing the mixing efficiency, as this configuration optimizes the fluid flow regime and promotes chaotic convection, thus significantly improving the micromixer’s performance.

Keywords: variable angle baffle; numerical simulation; mixing efficiency; micromixer

Corresponding author: Xueye Chen, College of Transportation, Ludong University, Yantai 264025, Shandong, China, E-mail: xueye_chen@126.com

Funding source: Ludong University introduced talents and started funding project

Award Identifier / Grant number: LD22065

Funding source: Yantai Science and Technology Innovation Development Plan Key Basic Research Projects

Award Identifier / Grant number: 2023JCYJ048

Funding source: Young Taishan Scholars Program of Shandong Province of China

Award Identifier / Grant number: tsqn202103091

Funding source: Special Supporting Funds for Leading Talents above Provincial Level in Yantai

Award Identifier / Grant number: 220-20230002

Funding source: Shandong Natural Science Foundation

Award Identifier / Grant number: ZR2024ME052

Research ethics: Not applicable.
Informed consent: Not applicable.
Author contributions: Conceptualization: X.K.C., B.S. Methodology: Y.X.L.,X.Y.C. Investigation: X.K.C., X.Y.C. Visualization: B.S., X.K.C. Supervision: X.Y.C. Writing – original draft: X.K.C. Writing – review & editing: Y.X.L, X.Y.C.
Use of Large Language Models, AI and Machine Learning Tools: No.
Conflict of interest: The authors declare no conflicts of interest.
Research funding: Yantai Science and Technology Innovation Development Plan Key Basic Research Projects (2023JCYJ048), Special Supporting Funds for Leading Talents above Provincial Level in Yantai (220-20230002), Young Taishan Scholars Program of Shandong Province of China (tsqn202103091), Ludong University introduced talents and started funding project (LD22065), Shandong Natural Science Foundation (ZR2024ME052).
Data availability: The data that support the findings of this study are available on request from the corresponding author.

References

[1] N. T. Nguyen and Z. Wu, “Micromixers – a review,” J. Micromech. Microeng. vol. 15, no. 2, p. R1, 2004, https://doi.org/10.1088/0960-1317/15/2/r01.Search in Google Scholar

[2] Á. Ríos, M. Zougagh, and M. Avila, “Miniaturization through lab-on-a-chip: Utopia or reality for routine laboratories? A review,” Anal. Chim. Acta, vol. 740, pp. 1–11, 2012, https://doi.org/10.1016/j.aca.2012.06.024.Search in Google Scholar PubMed

[3] C. Y. Lee and L. M. Fu, “Recent advances and applications of micromixers,” Sensor. Actuator. B Chem., vol. 259, pp. 677–702, 2018, https://doi.org/10.1016/j.snb.2017.12.034.Search in Google Scholar

[4] G. Cai, L. Xue, H. Zhang, and J. Lin, “A review on micromixers,” Micromachines, vol. 8, no. 9, p. 274, 2017, https://doi.org/10.3390/mi8090274.Search in Google Scholar PubMed PubMed Central

[5] X. Chen and T. Li, “A novel passive micromixer designed by applying an optimization algorithm to the zigzag microchannel,” Chem. Eng. J., vol. 313, pp. 1406–1414, 2017, https://doi.org/10.1016/j.cej.2016.11.052.Search in Google Scholar

[6] S. Zhang, X. Chen, Z. Wu, and Y. Zheng, “Numerical study on stagger Koch fractal baffles micromixer,” Int. J. Heat Mass Transfer, vol. 133, pp. 1065–1073, 2019, https://doi.org/10.1016/j.ijheatmasstransfer.2019.01.009.Search in Google Scholar

[7] D. Jing and S. Yi, “Electroosmotic flow in tree-like branching microchannel network,” Fract, vol. 27, no. 6, pp. 1950095–23, 2019, https://doi.org/10.1142/s0218348x19500956.Search in Google Scholar

[8] Z. Wu and X. Chen, “Numerical simulation of a novel microfluidic electroosmotic micromixer with Cantor fractal structure,” Microsyst. Technol., pp. 1–8, 2019 (Microsystem Technologies), https://doi.org/10.1007/s00542-019-04311-8.Search in Google Scholar

[9] R. H. Liu, R. Lenigk, and P. A. Grodzinski, “Acoustic micromixer for enhancement of DNA biochip systems,” J. Nanolithogr. MEMS, MOEMS, vol. 2, no. 3, pp. 178–185, 2003, https://doi.org/10.1117/1.1582467.Search in Google Scholar

[10] D. Nouri, A. Zabihi-Hesari, and M. Passandideh-Fard, “Rapid mixing in micromixers using magnetic field,” Sensor Actuator Phys., vol. 255, pp. 79–86, 2017, https://doi.org/10.1016/j.sna.2017.01.005.Search in Google Scholar

[11] Y. Deng, T. Zhou, Z. Liu, Y. Wu, S. Qian, and J. G. Korvink, “Topology optimization of electrode patterns for electroosmotic micromixer,” Int. J. Heat Mass Transfer, vol. 126, pp. 1299–1315, 2018, https://doi.org/10.1016/j.ijheatmasstransfer.2018.06.065.Search in Google Scholar

[12] X. Chen and Z. Wu, “Design and numerical simulation of a novel microfluidic electroosmotic micromixer with three electrode pairs,” J. Chem. Technol. Biotechnol., vol. 94, no. 6, pp. 1991–1997, 2019, https://doi.org/10.1002/jctb.5982.Search in Google Scholar

[13] Z. Wu and X. Chen, “Numerical simulation of a novel microfluidic electroosmotic micromixer with Cantor fractal structure,” Microsyst. Technol., vol. 25, no. 8, pp. 3157–3164, 2019, https://doi.org/10.1007/s00542-019-04311-8.Search in Google Scholar

[14] X. Chen, T. Li, H. Zeng, Z. Hu, and B. Fu, “Numerical and experimental investigation on micromixers with serpentine microchannels,” Int. J. Heat Mass Transfer, vol. 98, pp. 131–140, 2016, https://doi.org/10.1016/j.ijheatmasstransfer.2016.03.041.Search in Google Scholar

[15] X. Chen and Z. Zhao, “Numerical investigation on layout optimization of obstacles in a three-dimensional passive micromixer,” Anal. Chim. Acta, vol. 964, pp. 142–149, 2017, https://doi.org/10.1016/j.aca.2017.01.066.Search in Google Scholar PubMed

[16] X. Chen, Z. Zhang, D. Yi, and Z. Hu, “Numerical studies on different two-dimensional micromixers basing on a fractal-like tree network,” Microsyst. Technol., vol. 23, no. 3, pp. 755–763, 2017, https://doi.org/10.1007/s00542-015-2742-x.Search in Google Scholar

[17] W. Han, W. Li, and H. Zhang, “A comprehensive review on the fundamental principles, innovative designs, and multidisciplinary applications of micromixers,” Phys. Fluids, vol. 36, no. 10, 2024, https://doi.org/10.1063/5.0238393.Search in Google Scholar

[18] R. R. Gidde, P. M. Pawar, B. P. Ronge, A. B. Shinde, N. D. Misal, and S. S. Wangikar, “Flow field analysis of a passive wavy micromixer with CSAR and ESAR elements,” Microsyst. Technol., vol. 25, no. 3, pp. 1017–1030, 2019, https://doi.org/10.1007/s00542-018-4071-3.Search in Google Scholar

[19] J. Ter Schiphorst, et al., “Photoresponsive passive micromixers based on spiropyran size-tunable hydrogels,” Macromol. Rapid Commun., vol. 39, no. 1, p. 1700086, 2018, https://doi.org/10.1002/marc.201700086.Search in Google Scholar PubMed

[20] S. Zhang, X. Chen, Z. Wu, and Y. Zheng, “Numerical study on Koch fractal baffle micromixer,” Fractals, vol. 27, no. 03, p. 1950026, 2019, https://doi.org/10.1142/s0218348x19500269.Search in Google Scholar

[21] X. Chen, J. Zhai, and X. Chen, “A novel micromixer based on coastal fractal for manufacturing controllable size liposome,” Phys. Fluids, vol. 36, no. 11, 2024, https://doi.org/10.1063/5.0239840.Search in Google Scholar

[22] M. Bayareh, M. N. Ashani, and A. Usefian, “Active and passive micromixers: a comprehensive review,” Chem. Eng. Process. Intensif. p. 107771, 2019, https://doi.org/10.1016/j.cep.2019.107771.Search in Google Scholar

[23] W. Han, et al., “A critical review of on-line oil wear debris particle detection sensors,” J. Mar. Sci. Eng. vol. 11, no. 12, p. 2363, 2023, https://doi.org/10.3390/jmse11122363.Search in Google Scholar

[24] S. Xiong and X. Chen, “Numerical simulation of three-dimensional passive micromixer based on the principle of Koch fractal,” Int. J. Chem. React. Eng., vol. 19, no. 5, pp. 465–472, 2021, https://doi.org/10.1515/ijcre-2021-0020.Search in Google Scholar

[25] W. Han, W. Li, and H. Zhang, “Insight into mixing performance of bionic fractal baffle micromixers based on Murray’s Law,” Int. Commun. Heat Mass Tran., vol. 157, p. 107843, 2024, https://doi.org/10.1016/j.icheatmasstransfer.2024.107843.Search in Google Scholar

Received: 2024-09-19

Accepted: 2025-02-16

Published Online: 2025-03-03

You are currently not able to access this content.

Articles in the same Issue

https://doi.org/10.1515/ijcre-2024-0191

Keywords for this article

variable angle baffle; numerical simulation; mixing efficiency; micromixer