Microchannel reactive distillation for the conversion of aqueous ethanol to ethylene

Here we demonstrate the proof-of-concept for microchannel reactive distillation for alcohol-to-jet application:combining ethanol/water separation and ethanol dehydration in one unit operation.Ethanol is first distilled into the vapor phase,converted to ethylene and water,and then the water co-product is condensed to shift the reaction equilibrium.Process intensification is achieved through rapid mass transfer-ethanol stripping from thin wicks using novel microchannel architectures-leading to lower residence time and improved separation efficiency.Energy savings are realized with integration of unit operations.For example,heat of condensing water can offset vaporizing ethanol.Furthermore,the dehydration reaction equilibrium shifts towards completion by immediate removal of the water byproduct upon formation while maintaining aqueous feedstock in the condensed phase.For aqueous ethanol feedstock(40%_w),71% ethanol conversion with 91% selectivity to ethylene was demonstrated at 220℃,600psig,and 0.28 h^(-1) wt hour space velocity.2.7 stages of separation were also demonstrated,under these conditions,using a device length of 8.3 cm.This provides a height equivalent of a theoretical plate(HETP),a measure of separation efficiency,of ^(3).3 cm.By comparison,conventional distillation packing provides an HETP of ^(3)0 cm.Thus,9,1 × reduction in HETP was demonstrated over conventional technology,providing a means for significant energy savings and an example of process intensification.Finally,preliminary process economic analysis indicates that by using microchannel reactive distillation technology,the operating and capital costs for the ethanol separation and dehydration portion of an envisioned alcoholto-jet process could be reduced by at least 35% and 55%,respectively,relative to the incumbent technology,provided future improvements to microchannel reactive distillation design and operability are made.

Overall Assessment of Heat Transfer for a Rarefied Flow in a Microchannel with Obstacles Using Lattice Boltzmann Method

The objective of this investigation is to assess the effect of obstacles on numerical heat transfer and fluid flow momentum in a rectangular microchannel(MC).Two distinct configurations were studied:one without obstacles and the other with alternating obstacles placed on the upper and lower walls.The research utilized the thermal lattice Boltzmann method(LBM),which solves the energy and momentum equations of fluids with the BGK approximation,implemented in a Python coding environment.Temperature jump and slip velocity conditions were utilized in the simulation for the MC and extended to all obstacle boundaries.The study aims to analyze the rarefaction effect,with Knudsen numbers(Kn)of 0.012,0.02,and 0.05.The outcomes indicate that rarefaction has a significant impact on the velocity and temperature distribution.The presence of nine obstacles led to slower fluid movement inside the microchannel MC,resulting in faster cooling at the outlet.In MCs with obstacles,the rarefaction effect plays a crucial role in decreasing the Nusselt number(Nu)and skin friction coefficient(Cf).Furthermore,the study demonstrated that the obstacles played a crucial role in boosting fluid flow and heat transfer in the MC.The findings suggest that the examined configurations could have potential applications as cooling technologies in micro-electro-mechanical systems and microdevice applications.

Molecular dynamics simulation of the flow mechanism of shear-thinning fluids in a microchannel

Shear-thinning fluids have been widely used in microfluidic systems,but their internal flow mechanism is still unclear.Therefore,in this paper,molecular dynamics simulations are used to study the laminar flow of shear-thinning fluid in a microchannel.We validated the feasibility of our simulation method by evaluating the mean square displacement and Reynolds number of the solution layers.The results show that the change rule of the fluid system's velocity profile and interaction energy can reflect the shear-thinning characteristics of the fluids.The velocity profile resembles a top-hat shape,intensifying as the fluid's power law index decreases.The interaction energy between the wall and the fluid decreases gradually with increasing velocity,and a high concentration of non-Newtonian fluid reaches a plateau sooner.Moreover,the velocity profile of the fluid is related to the molecule number density distribution and their values are inversely proportional.By analyzing the radial distribution function,we found that the hydrogen bonds between solute and water molecules weaken with the increase in velocity.This observation offers an explanation for the shear-thinning phenomenon of the non-Newtonian flow from a micro perspective.

Applying the Shearlet-Based Complexity Measure for Analyzing Mass Transfer in Continuous-Flow Microchannels

Continuous-flow microchannels are widely employed for synthesizing various materials,including nanoparticles,polymers,and metal-organic frameworks(MOFs),to name a few.Microsystem technology allows precise control over reaction parameters,resulting in purer,more uniform,and structurally stable products due to more effective mass transfer manipulation.However,continuous-flow synthesis processes may be accompanied by the emergence of spatial convective structures initiating convective flows.On the one hand,convection can accelerate reactions by intensifying mass transfer.On the other hand,it may lead to non-uniformity in the final product or defects,especially in MOF microcrystal synthesis.The ability to distinguish regions of convective and diffusive mass transfer may be the key to performing higher-quality reactions and obtaining purer products.In this study,we investigate,for the first time,the possibility of using the information complexity measure as a criterion for assessing the intensity of mass transfer in microchannels,considering both spatial and temporal non-uniformities of liquid’s distributions resulting from convection formation.We calculate the complexity using shearlet transform based on a local approach.In contrast to existing methods for calculating complexity,the shearlet transform based approach provides a more detailed representation of local heterogeneities.Our analysis involves experimental images illustrating the mixing process of two non-reactive liquids in a Y-type continuous-flow microchannel under conditions of double-diffusive convection formation.The obtained complexity fields characterize the mixing process and structure formation,revealing variations in mass transfer intensity along the microchannel.We compare the results with cases of liquid mixing via a pure diffusive mechanism.Upon analysis,it was revealed that the complexity measure exhibits sensitivity to variations in the type of mass transfer,establishing its feasibility as an indirect criterion for assessing mass transfer intensity.The method presented can extend beyond flow analysis,finding application in the controlling of microstructures of various materials(porosity,for instance)or surface defects in metals,optical systems and other materials that hold significant relevance in materials science and engineering.

A comprehensive review on microchannel heat sinks for electronics cooling

The heat generation of electronic devices is increasing dramatically,which causes a serious bottleneck in the thermal management of electronics,and overheating will result in performance deterioration and even device damage.With the development of micro-machining technologies,the microchannel heat sink(MCHS)has become one of the best ways to remove the considerable amount of heat generated by high-power electronics.It has the advantages of large specific surface area,small size,coolant saving and high heat transfer coefficient.This paper comprehensively takes an overview of the research progress in MCHSs and generalizes the hotspots and bottlenecks of this area.The heat transfer mechanisms and performances of different channel structures,coolants,channel materials and some other influencing factors are reviewed.Additionally,this paper classifies the heat transfer enhancement technology and reviews the related studies on both the single-phase and phase-change flow and heat transfer.The comprehensive review is expected to provide a theoretical reference and technical guidance for further research and application of MCHSs in the future.

Effect of boundary slip on electroosmotic flow in a curved rectangular microchannel

The aim of this study is to numerically investigate the impact of boundary slip on electroosmotic flow(EOF) in curved rectangular microchannels. Navier slip boundary conditions were employed at the curved microchannel walls. The electric potential distribution was governed by the Poisson–Boltzmann equation, whereas the velocity distribution was determined by the Navier–Stokes equation. The finite-difference method was employed to solve these two equations. The detailed discussion focuses on the impact of the curvature ratio, electrokinetic width, aspect ratio and slip length on the velocity. The results indicate that the present problem is strongly dependent on these parameters. The results demonstrate that by varying the dimensionless slip length from 0.001 to 0.01 while maintaining a curvature ratio of 0.5 there is a twofold increase in the maximum velocity. Moreover, this increase becomes more pronounced at higher curvature ratios. In addition, the velocity difference between the inner and outer radial regions increases with increasing slip length. Therefore, the incorporation of the slip boundary condition results in an augmented velocity and a more non-uniform velocity distribution. The findings presented here offer valuable insights into the design and optimization of EOF performance in curved hydrophobic microchannels featuring rectangular cross-sections.

Gas microchannel plate-pixel detector for X-ray polarimetry

POLAR-2 is a gamma-ray burst(GRB)polarimeter that is designed to study the polarization in GRB radiation emissions,aiming to improve our knowledge of related mechanisms.POLAR-2 is expected to utilize an on-board polarimeter that is sensitive to soft X-rays(2-10 keV),called low-energy polarization detector.We have developed a new soft X-ray polari-zation detector prototype based on gas microchannel plates(GMCPs)and pixel chips(Topmetal).The GMCPs have bulk resistance,which prevents charging-up effects and ensures gain stability during operation.The detector is composed of low outgassing materials and is gas-sealed using a laser welding technique,ensuring long-term stability.A modulation factor of 41.28%±0.64% is obtained for a 4.5 keV polarized X-ray beam.A residual modulation of 1.96%±0.58% at 5.9 keV is observed for the entire sensitive area.

Numerical Simulation of Droplet Generation in Coaxial Microchannels

In this study,numerical simulations of the pinching-off phenomena displayed by the dispersed phase in a continuous phase have been conducted using COMSOL Multiphysics(level-set method).Four flow patterns,namely“drop flow”,“jet flow”,“squeeze flow”,and“co-flow”,have been obtained for different flow velocity ratios,channel diameter ratios,density ratios,viscosity ratios,and surface tension.The flow pattern map of two-phase flow in coaxial microchannels has been obtained accordingly,and the associated droplet generation process has been critically discussed considering the related frequency,diameter,and pinch-off length.In particular,it is shown that the larger the flow velocity ratio,the smaller the diameter of generated droplets and the shorter the pinch-off length.The pinch-off length of a droplet is influenced by the channel diameter ratio and density ratio.The changes in viscosity ratio have a negligible influence on the droplet generation pinching frequency.With an increase in surface tension,the frequency of generation and pinch-off length of droplets decrease,but for small surface tension the generation diameter of droplet increases.

Different efficiency toward the biomimetic aerobic oxidation of benzyl alcohol in microchannel and bubble column reactors: Hydrodynamic characteristics and gas–liquid mass transfer

The selective aerobic oxidation of benzyl alcohol to benzaldehyde has attracted considerable attention because benzaldehyde is a high value-added product. The rate of this typical gas–liquid reaction is significantly affected by mass transfer. In this study, CoTPP-mediated(CoTPP: cobalt(II) mesotetraphenylporphyrin) selective benzyl alcohol oxidation with oxygen was conducted in a membrane microchannel(MMC) reactor and a bubble column(BC) reactor, respectively. We observed that 83% benzyl alcohol was converted within 6.5 min in the MMC reactor, but only less than 10% benzyl alcohol was converted in the BC reactor. Hydrodynamic characteristics and gas–liquid mass transfer performances were compared for the MMC and BC reactors. The MMC reactor was assumed to be a plug flow reactor,and the dimensionless variance was 0.29. Compared to the BC reactor, the gas–liquid mass transfer was intensified significantly in MMC reactor. It could be ascribed to the high gas holdup(2.9 times higher than that of BC reactor), liquid film mass transfer coefficient(8.2 times higher than that of BC reactor), and mass transfer coefficient per unit interfacial area(3.8 times higher than that of BC reactor). Moreover,the Hatta number for the MMC reactor reached up to 0.61, which was about 15 times higher than that of the BC reactor. The computational fluid dynamics calculations for mass fractions in both liquid and gas phases were consistent with the experimental data.

Effects of channel wall wettability on gas-liquid dynamics mass transfer under Taylor flow in a serpentine microchannel

The wall wettability of microchannels plays an important role in the gas-liquid mass transfer dynamics under Taylor flow.In this study,we regulated the contact angle of the wall surface through surface chemical grafting polymerization under controlled experimental conditions.The dynamic changes of CO_(2)bubbles flowing along the microchannel were captured by a high-speed video camera mounted on a stereo microscope,whilst a unit cell model was employed to theoretically investigate the gas-liquid mass transfer dynamics.We quantitatively characterized the effects of wall wettability,specifically the contact angle,on the formation mechanism of gas bubbles and mass transfer process experimentally.The results revealed that the gas bubble velocity,the overall volumetric liquid phase mass transfer coefficients(kLa),and the specific interfacial area(a)all increased with the increase of the contact angle.Conversely,gas bubble length and leakage flow decreased.Furthermore,we proposed a new modified model to predict the gas-liquid two-phase mass transfer performance,based on van Baten’s and Yao’s models.Our proposed model was observed to agree reasonably well with experimental observations.

Study on liquid–liquid two-phase mass transfer characteristics in the microchannel with deformed insert

In this work, the liquid-liquid two-phase mass transfer characteristics in the microchannel with deformed insert were studied. The experiment used di-(2-ethylhexyl) phosphoric acid/kerosene-Cu^(2+)as the mass transfer evaluation system. The effects of some key factors such as the total flow velocity,channel inner diameter, channel length, insert diameter, extractant concentration on the extraction efficiency and mass transfer coefficient were systematically investigated. Compared with a simple microreactor, the liquid-liquid mass transfer enhancement effect of the insert was quantitatively analyzed. The study found that the regular deformation of the insert could cause fluid interface deformation and promote flow state chaos, effectively increasing the mass transfer rate. And the enhancement effect of the insert was more significant at high flow velocities. The highest mass transfer coefficient in the microchannel with deformed insert was 7.886 s^(-1), the enhancement factor could reach 4.17. And only needed 0.095 s to approach the extraction equilibrium. The deformed center insert exhibited an effective liquid-liquid mass transfer enhancement effect, which can be used as a micro-chemical process enhancement method to be applied in the fields of higher throughput mass transfer and chemical synthesis,and at the same time provide ideas for development and structural optimization of microreactors.

Liquid-liquid two-phase flow in a wire-embedded concentric microchannel: Flow pattern and mass transfer performance

In this work, flow pattern and mass transfer of liquid-liquid two-phase flow in a wire-embedded concentric microchannel are studied using toluene-water system. Droplet flow, slug flow, oval flow and annular flow are observed in the wire-embedded concentric microchannel. The effects of embedded wires and physical properties on flow patterns are investigated. The embedded wire insert is conducive to the formation of annular flow. The flow pattern distribution regions are distinguished by the Caaq(capillary number)±We_(org)(Weber number) flow pattern map. When Weorg<0.001, slug flow is the main flow pattern, and when Weorg>0.1, annular flow is the main flow pattern. Oval flow and droplet flow are between We_(org)= 0.001-0.1, and oval flow is transformed into droplet flow with the increase of Caaq. The effect of flow rate, phase ratio, initial acetic acid concentration, insert shape and flow patterns on mass transfers are studied. Mass transfer process is enhanced under annular flow conditions, the volumetric mass transfer coefficient is up to 0.36 s^(-1) because of the high interfacial area and interface renewal rate of annular flow.

Microchannel reactors for Fischer-Tropsch synthesis:Experimental investigation and mathematical modeling

The Fischer-Tropsch synthesis is a significant technology for converting coal,natural gas,and biomass into synthetic fuels.In recent years,the use of microchannel reactors for the Fischer-Tropsch synthesis has attracted significant attention.Fischer-Tropsch synthesis experiments were carried out in a microchannel reactor and the influences of reaction conditions on the experimental results were investigated in this study.Based on the experimental data,a dynamic multi-component pseudo-homogeneous variable-volume flow model of microchannel reactors for the Fischer-Tropsch synthesis was built to determine the pressure-,velocity-,conversion-and(component-wise)concentration-distributions in reaction channels.The model takes into account the combined effects of gas volume expansion caused by the frictional pressure drop and gas volume contraction caused by reaction consumption.A novel effective method for calculating the pressure and superficial gas velocity values in microchannel reactors was proposed in the model.Besides that,two sets of experimental data were selected from references to evaluate the validity and accuracy of the model.The reaction performances in the microchannels were analyzed carefully based on the calculated results.

Experimental and Numerical Analysis of the Influence ofMicrochannel Size and Structure on Boiling Heat Transfer

Computational fluid dynamics was used and a numerical simulation analysis of boiling heat transfer in microchannels with three depths and three cross-sectional profiles was conducted.The heat transfer coefficient and bubble generation process of three microchannel structures with a width of 80μm and a depth of 40,60,and 80μm were compared during the boiling process,and the factors influencing bubble generation were studied.A visual test bench was built,and test substrates of different sizes were prepared using a micro-nano laser.During the test,the behavior characteristics of the bubbles on the boiling surface and the temperature change of the heated wall were collected with a high-speed camera and a temperature sensor.It was found that the microchannel with a depth of 80μm had the largest heat transfer coefficient and shortest bubble growth period,the rectangular channel had a larger peak heat transfer coefficient and a lower frequency of bubble occurrence,while the V-shaped channel had the shortest growth period,i.e.,the highest frequency of bubble occurrence,but its heat transfer coefficient was smaller than that of the rectangular channel.

Numerical study on the hydrodynamics behavior of a central insert microchannel

In this work, the computational fluid dynamics method is used to study the liquid hydrodynamics behavior in the microchannel without central insert(MC1) and the central insert microchannel(MC2), respectively. The maximum deviation between simulation and experiment is 24%. The formations of flow patterns are explained based on contours and force analysis where the flow pattern maps are established by two-phase flow rate. The effects of aqueous phase viscosity and two-phase flow rate on the characteristic sizes of each flow pattern are also explored. Specifically, four unconventional flow patterns are found in MC2, namely the unique droplet flow, the unique slug flow, the unique coarse annular flow and the unique film annular flow. Though the insert occupies part of the channel, the pressure difference in the channel is significantly reduced compared with MC1. Moreover, the insert significantly changes the formation velocity range of each flow pattern, greatly broadens the formation range of annular flow and also has an important influence on the characteristic size of the flow pattern. The organic-phase dimensionless axial size(Lo/W) and the dimensionless radial size(Do/W) of the droplet(slug) are negatively related to the aqueous-phase viscosity(μa) and flow rate(ua). The Do/W of the annular is negatively correlated with μaand positively correlated with organic-phase flow rate(uo). This study provides direct numerical evidence that the insert is key to the formation of bicontinuous phase flow pattern, as well as further strengthens our understanding of the flow characteristics and optimization design of insert microchannels.

Simulation of gas–liquid two-phase flow in a flow-focusing microchannel with the lattice Boltzmann method

A lattice Boltzmann method for gas–liquid two-phase flow involving non-Newtonian fluids is developed. Bubble formation in a flow-focusing microchannel is simulated by the method. The influences of flow rate ratio, surface tension,wetting properties, and rheological characteristics of the fluid on the two-phase flow are analyzed. The results indicate that the flow pattern transfers from slug flow to dry-plug flow with a sufficiently small capillary number. Due to the presence of three-phase contact lines, the contact angle has a more significant effect on the dry-plug flow pattern than on the slug flow pattern. The deformation of the front and rear meniscus of a bubble in the shear-thinning fluid can be explained by the variation of the capillary number. The reduced viscosity and increased contact angle are beneficial for the drag reduction in a microchannel. It also demonstrates the effectiveness of the current method to simulate the gas–liquid two-phase flow in a microchannel.

Bionic microchannels for step lifting transpiration

Those various cross-sectional vessels in trees transfer water to as high as 100 meters,but the traditional fabrication methods limit the manufacturing of those vessels,resulting in the non-availability of those bionic microchannels.Herein,we fabricate those bionic microchannels with various cross-sections by employing projection micro-stereolithography(PμSL)based 3D printing technique.The circumradius of bionic microchannels(pentagonal,square,triangle,and five-pointed star)can be as small as 100μm with precisely fabricated sharp corners.What's more,those bionic microchannels demonstrate marvelous microfluidic performance with strong precursor effects enabled by their sharp corners.Most significantly,those special properties of our bionic microchannels enable them outstanding step lifting performance to transport water to tens of millimeters,though the water can only be transported to at most 20 mm for a single bionic microchannel.The mimicked transpiration based on the step lifting of water from bionic microchannels is also achieved.Those precisely fabricated,low-cost,various cross-sectional bionic microchannels promise applications as microfluidic chips,long-distance unpowered water transportation,step lifting,mimicked transpiration,and so on.

Study on an improved rotating microchannel separator in the intensification for demulsification and separation process

An improved rotating microchannel(IRM) separator was further explored in the intensification for demulsification and separation process. Oil-in-water(O/W) emulsion system of 2-ethylhexyl phosphoric acid-2-ethylhexyl ester(P507)–water without emulsifier was employed to evaluate the performance of the new equipment. In this experiment, the influence on demulsification separation process was explored by changing the geometrical structure and channel height of the microchannel and combining the liquid–liquid two-phase flow pattern, and the correlation general graph between demulsification efficiency and dimensionless parameters was established. The total demulsification effect of the IRM and the separation capacity of the clear organic phase recovered from demulsification are significantly improved. In addition, the liquid–liquid two-phase flow pattern of the clear organic phase after demulsification and the remaining emulsion in the IRM are observed and recorded by high-speed photography. The separation ability of organic phase from the upper outlet can be significantly improved when the total demulsification rate of IRM is up to 90%. There are 3 types and 6 kinds of flow patterns observed. The results demonstrated that the suitable demulsification performance is obtained when the liquid–liquid two-phase inside the IRM is in a parallel pattern. Finally, the relation map between total demulsification efficiency and the universal flow is drawn, which provides a basis for the accurate control of the IRM device.

Computer simulation of Cu:AlOOH/water in a microchannel heat sink using a porous media technique and solved by numerical analysis AGM and FEM

Extensive improvements in small-scale thermal systems in electronic circuits,automotive industries,and microcomputers conduct the study of microsystems as essential.Flow and thermic field characteristics of the coherent nanofluid-guided microchannel heat sink are described in this perusal.The porous media approximate was used to search the heat distribution in the expanded sheet and Cu:γ-AlOOH/water.A hybrid blend of Boehme copper and aluminum nanoparticles is evaluated to have a cooling effect on the microchannel heat sink.By using Akbari Ganji and finite element methods,linear and non-linear differential equations as well as simple dimensionless equations have been analyzed.The purpose of this study is to investigate the fluid and thermal parameters of copper hybrid solution added to water,such as Nusselt number and Darcy number so that we can reach the best cooling of the fluid.Also,by installing a piece of fin on the wall of the heat sink,the coefficient of conductive heat transfer and displacement heat transfer with the surrounding air fluid increases,and the efficiency of the system increases.The overall results show that expanding values on the NP(series heat transfer fluid system maximizes performance with temperatures)volume division of copper,as well as boehmite alumina particles,lead to a decrease within the stream velocity of the Cu:AlOOH/water.Increasing the volume fraction of nanoparticles in the hybrid mixture decreases the temperature of the solid surface and the hybrid nanofluid.The Brownian movement improves as the volume percentage of nanoparticles in the hybrid mixture grows,spreading the heat across the environment.As a result,heat transmission rates rise.As the Darcy number increases,the thermal field for solid sections and Cu:AlOOH/water improves.

Growth behavior of CVD diamond in microchannels of Cu template

Deposition of diamond inside the trenches or microchannels by chemical vapor deposition （CVD） is limited by the diffusion efficiency of important radical species for diamond growth （H, CH3） and the pore depth of the substrate template. By ultrasonic seeding with nanodiamond suspension, three-dimensional （3D） penetration structure diamond was successfully deposited in cylindrical microchannels of Cu template by hot-filament chemical vapor deposition. Micro-Raman spectroscopy and scanning electron microscopy （SEM） were used to characterize diamond film and the effects of microchannel depth on the morphology, grain size and growth rate of diamond film were comprehensively investigated. The results show that diamond quality and growth rate sharply decrease with the increase of the depth of cylindrical microchannel. Individual diamond grain develops gradually from faceted crystals into micrometer cluster, and finally to ballas-type nanocrystalline one. In order to modify the rapid decrease of diamond quality and growth rate, a new hot filament apparatus with a forced gas flow through Cu microchannels was designed. Furthermore, the growth of diamond film by new apparatus was compared with that without a forced gas flow, and the enhancement mechanism was discussed.