Characterization of the oil water two phase flow in a novel microchannel contactor equipped with helical wire static mixer.

This study investigates an oil/water two-phase system to assess the potential efficacy of a novel passive mixer in enhancing the liquid-liquid interfacial area within a micro-channel contactor. In this system, two fluids are introduced into a microchannel with a diameter of 800 μm and a length of 20 cm, which is equipped with a stainless-steel helical wire measuring 250 μm in diameter. Throughout the experiments, both fluids are supplied at equal flow rates, and the dominant forces, including attachment and detachment forces, are examined. The results reveal a critical Weber number of 3.8 × 10³, at which the first detachment occurs. A comparison between microchannels with and without the passive micromixer demonstrates that greater slug breakup occurs in the system incorporating the helical wire micromixer. This innovative configuration results in a significant reduction in slug/droplet size compared to a microchannel without a barrier, decreasing from approximately 600 μm to 390 μm at a flow rate of 0.8 mL/min. Additionally, a flow map is presented, illustrating three distinct flow regimes: flow contains long slug, Slug-droplet flow, and droplet flow regimes, with the droplet flow regime covering the largest area. The findings indicate that the implementation of this innovative passive mixer substantially increases the interfacial area, providing significant advantages for mass transfer applications.