Contents

1. Introduction 2. Fluids 3. Physics of Microfluidic Systems 4. Microfabrication Technologies

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9. Liquid Handling 10.Microarrays 11.Microreactors 12.Analytical Chips 13.Particle-Laden Fluids a. Measurement Techniques b. Fundamentals of Biotechnology c. High-Throughput Screening

5. Flow Control 6. Micropumps 7. Sensors 8. Ink-Jet Technology

11. Microreactors

Jens Ducre and Roland Zengerle

11. Benefits of Miniaturization

h Transport phenomena
Well-predictable / reproducible in microstructures Intrinsic driving force
- No actuation required - Processes to large extent controlled by passive structures

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11. Microreactors

Jens Ducre and Roland Zengerle

11. Benefits of Miniaturization

h Fast diffusion
Ficks laws

Characteristic diffusion time Macro: l approx. 1 cm = 10-2 m

- t approx. 105 s

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- D approx. 10-9 m2 / s for solvated molecules

Micro: l approx. 100 m = 10-4 m

- t approx. 10 s

h Brownian motion
11. Microreactors Jens Ducre and Roland Zengerle

11. Diffusion Coefficient Fourier mass number

Particle diffusion / concentration

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11. Microreactors

Jens Ducre and Roland Zengerle

11. Benefits of Miniaturization

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11. Microreactors

Jens Ducre and Roland Zengerle

11. Benefits of Miniaturization

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11. Microreactors

Jens Ducre and Roland Zengerle

11. Benefits of Miniaturization

h Fast heat exchange
Fouriers law

Power associated with heat transport

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Characteristic time
- Same scale ~ l 2 as diffusion

Fourier number
- Heat diffusion / stored heat

11. Microreactors

Jens Ducre and Roland Zengerle

11. Thermal Conductivity

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11. Microreactors

Jens Ducre and Roland Zengerle

11. Microreactors
1. Micromixers 2. Heat Exchangers 3. Chemical Microreactors 4. Splitting of Flow 5. Fuel-Based Power Supplies
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11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Micromixers
h Mixing of two phases
Liquid liquid Liquid gas Gas gas Particles with fluids (suspensions)

h High accuracy
E.g. Bubble (gas, liquid) sizes

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h Mixing of reactants
Key step in chemical process engineering Fast response times Low dead volumes

11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Mixing of Reactants

h Speed depends on surface-to-volume ratio of interfaces

h Two consecutive processes h Generation of heterogeneous mixture

Time critical step
- Macroscopic time scales
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Finely dispersed structure Large surface-to-volume ratio to Enhanced diffusion

h Mixing on molecular level

Reaction kinetics Fast step, molecular time scales

11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Mixing in Macro- and Microdevices

h Macrodevices
Fast mixing by turbulences
- Shaking - Stirring

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h Microdevices
Laminar conditions Turbulences hard to induce Static mixing by diffusion enhanced by passive structures

11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Micromixers: Unique Features

h Ultrafast mixing as well as defined slow mixing by control over mixing time h Geometrically defined mixing processes by control over fluid layer thickness h Integrability of mixing units as parts of complex assembled systems
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h Generation of dispersions with small particle sizes and narrow size distributions h Synthesis of uniform-sized micro- to-nanoscale powder particles

11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Mixing Principles for Miscible and Immiscible Fluids

h Miscible fluids after contact
Miscible fluids mixed fast by means of diffusion due to small thickness of generated lamellae

h Immiscible fluids after contact

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Due to parabolic flow profile strong periodical velocity gradients generated at exit of each channel Velocity gradients lead to unstable flow configuration Thin fluid lamellae finally decompose into microdroplets or microbubbles surrounded by continuous phase
11. Microreactors

IMM Mainz

Jens Ducre and Roland Zengerle

11.1. Multilamination of Layers

IMM Mainz

h Fluids to be mixed introduced into mixing element as two counter-flows h Fluids stream into interdigital channel configuration h Periodical flow configuration consisting of lamellae of two fluids generated by means of slit-shaped interdigital channels h Stratified flow leaves device perpendicular to direction of feed flows
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11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Multi-Lamination of Sheaths

IMM Mainz

h Fluids to be mixed introduced into boreholes of mixer

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h Fluids entering single platelets divided into streams h From, e.g., three openings streams are guided through channel system to central position h These streams merge to fluid sheaths of small thickness h Alternating assembly of platelets results in alternating stack of sheaths of two different fluids h Mixing performed by interdiffusion within this multi-laminated sheath structure

11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Split and Recombine

h Caterpillar Mixer
Fluids to be mixed introduced into the device as two parallel streams By special surface shaping of channel walls, referred to as caterpillar structure, each fluid stream split into two substreams
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Four such substreams recombined to a multi-laminated fluid system Process repeated several times
IMM Mainz

11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Split and Reunify

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11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Moebius Mixer

h Two vertically stacked flows h Flow split in horizontal plane h Each subflow rotated by 90 h Rejoining of flows
Four lamellae

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11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Mixing by Lamination of Flow

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11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Mixing by Lamination of Flow

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11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Mixing by Lamination of Flow

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11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Mixing by Micro-Plumes

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11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Mixing by Micro-Plumes

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11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Low-Aspect Ratio Mixers

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Throughput: function of aspect ratio

11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Example: Drum Mixer on Bio-Disk

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11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Mixing by Hydrophobic Barriers

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11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Mixing by Hydrophobic Barriers

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11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Coanda-Effect Mixer

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11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Dispersions of Immiscible Fluids

IMM Mainz

h Liquid / liquid dispersions including emulsions

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h Gas / liquid dispersions including foams h Suspensions of nano-scale particles

11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Mixers for Liquid-Liquid Dispersion

h Liquid-liquid dispersion including emulsions h Production of small, regularly sized droplets h Droplets of narrow size distribution h Droplets of narrow size distribution
4 to 50 m Dependent on operating conditions

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IMM Mainz

11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Mixers for Liquid-Liquid Dispersion

h Critical parameters
Smaller droplets generated at higher volume flows Smaller droplets generated at higher ratios of flow rates Smaller droplets generated using mixing elements at smaller channel width

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IMM Mainz

11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Mixers for Liquid-Liquid Dispersion

h Critical parameters
Smaller droplets generated at higher volume flows Smaller droplets generated at higher ratios of flow rates Smaller droplets generated using mixing elements at smaller channel width
IMM Mainz

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11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Mixers for Liquid-Liquid Dispersion

h Critical parameters
Smaller droplets are generated at higher volume flows Smaller droplets are generated at higher ratios of flow rates Smaller droplets generated using mixing elements at smaller channel width

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IMM Mainz

11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Mixers for Gas-Liquid Dispersions

IMM Mainz

h Production of small, regularly sized bubbles h Under certain operating conditions, production of highly regular bubble trains
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h Formation of segmented (slug) and annular flow patterns, when combined with miniaturized residence time channels

11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Mixers for Gas-Liquid Dispersions

h Bubble sizes in model and real systems:

Diameter
- 50 to 500 m

Ratio of bubble length to diameter

- 1 to 4 - Typically 50 m
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IMM Mainz

Average bubble size deviation

11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Mixers for Suspension

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IMM Mainz

h Production of small micro-scale particles of uniform size h Model system: precipitation of copper oxalate
Particle size: 5 m

11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Active Mixers: Ultrasonic

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11. Microreactors

Jens Ducre and Roland Zengerle

11.1. Active Mixers: Chaotic Advection

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11. Microreactors

Jens Ducre and Roland Zengerle

11. Microreactors
1. Micromixers 2. Heat Exchangers 3. Chemical Microreactors 4. Splitting of Flow 5. Fuel-Based Power Supplies
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11. Microreactors

Jens Ducre and Roland Zengerle

11.2. Physics of Heat Exchange

h Heat transmission
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11. Microreactors

Jens Ducre and Roland Zengerle

11.2. Physics of Heat Exchange

h Heat transition

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11. Microreactors

Jens Ducre and Roland Zengerle

11.2. Convection and Heat Diffusion

h Convection
Collective transport of macroscopic volumes
- Buoyancy - Pumping

h Peclet number
Ratio convective / diffusive particle transport
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11. Microreactors

Jens Ducre and Roland Zengerle

11.2. Convection and Heat Diffusion

h Nuelt number
Ratio convective / diffusive heat transport Boundary region: wall / fluid Turbulences enhance heat transport

h Note

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Deviations from macro-theory Turbulence formation in wall layers

11. Microreactors

Jens Ducre and Roland Zengerle

11.2. Physics of Heat Exchange

h Newtons law of cooling

Temperature decay

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Characteristic time

11. Microreactors

Jens Ducre and Roland Zengerle

11.2. Heat Exchangers

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h Mixing and reaction devices often connected to heat transfer systems h Essential for effective heat management of reaction processes
11. Microreactors

IMM Mainz

Jens Ducre and Roland Zengerle

11.2. Flow Schemes

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11. Microreactors

Jens Ducre and Roland Zengerle

11.2. Co-Current Heat Exchanger

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11. Microreactors

Jens Ducre and Roland Zengerle

11.2. Counter-Current Heat Exchanger

h Power of heat transfer

With

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h Effective surface (cross section)

Required to establish given power P Measure for efficiency

11. Microreactors

Jens Ducre and Roland Zengerle

11.2. Crossed-Flow Heat Exchanger

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11. Microreactors

Jens Ducre and Roland Zengerle

11. Microreactors
1. Micromixers 2. Heat Exchangers 3. Chemical Microreactors 4. Splitting of Flow 5. Fuel-Based Power Supplies
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11. Microreactors

Jens Ducre and Roland Zengerle

11.3. Introduction
h Production of Chemicals
Contacting of phases
Liquid liquid Gas - gas Gas liquid Solid gas Solid liquid
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Contact on molecular level to enable reactions Controlled mixing of phases

- E.g. by microfabricated nozzles

h Important parameters
- Fast mixing - Uniform heat distribution
IMM Mainz

11. Microreactors

Jens Ducre and Roland Zengerle

11.3. Chemical Microreactors

h Objectives of miniaturization
Process intensification
- Running processes at more aggressive conditions, e.g. higher temperatures

Automated gathering of information

- Generation of comprehensive libraries
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High-quality chemicals
- Control of heat management - Uniform heat distributions

11. Microreactors

Jens Ducre and Roland Zengerle

11.3. Gas-Liquid Reactions

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11. Microreactors

Jens Ducre and Roland Zengerle

11.3. Gas-Liquid Reactions

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11. Microreactors

Jens Ducre and Roland Zengerle

11.3. Catalytic Gas Reactor

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11. Microreactors

Jens Ducre and Roland Zengerle

11. Microreactors
1. Micromixers 2. Heat Exchangers 3. Chemical Microreactors 4. Splitting of Flow 5. Fuel-Based Power Supplies
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11. Microreactors

Jens Ducre and Roland Zengerle

11.4. Throughput
h Usually pressure-driven flow (PDF)
EO-pumping strongly depends on
- Chemical to be transported - Interaction between surface and liquid - No universal transport mechanisms

Law of Hagen-Poisseuille
- I V ~ A2
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11. Microreactors

Jens Ducre and Roland Zengerle

11.4. Throughput
h Numbering up
Throughput IV,0 given N channels Channel radius r IV,0 ~ IV (r) N 2

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IMM Mainz

11. Microreactors

Jens Ducre and Roland Zengerle

11.4. Throughput: Flow Resistance

h Flow resistance
Single channel N channels in parallel

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h Ratio of flow resistances h Throughput

11. Microreactors

Jens Ducre and Roland Zengerle

11.4. Velocity and Residence Time

h Velocity profile

h Ratio of velocities
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h Minimum residence time

Center of channel

11. Microreactors

Jens Ducre and Roland Zengerle

11.4. Numbering-Up Concepts

h Numbering-up aims at an increase of throughput by parallel operation of a multitude of mixing units. h Feeding of these mixing units may be achieved by using a hierarchic distribution route, e.g. based on system / platelet / element. h When numbering up, the mixing conditions remain virtually the same, because mixing elements are simply added.

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IMM

11. Microreactors

Jens Ducre and Roland Zengerle

11.4. Numbering-Up Concepts

h Numbering up, hence, is advantageous, because the step from lab-scale processing to industrial processing is faster and more reliable.
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h As demonstrated in industrial case studies, simple combination of several micromixers paves the way to numbering-up.

IMM

11. Microreactors

Jens Ducre and Roland Zengerle

11.4. Numbering-Up: Problem

h Numbering up
Source often single stream

h Splitting up
Distribution of one source flow to multiple small streams

h Uniformity problem
Like electrical resistors in parallel Highest flow rate in channel with smallest flow resistance
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h Non-uniformity of resistances
Fabrication tolerances Flow patterns in flow splitter Backpressures caused by air pockets ...
11. Microreactors Jens Ducre and Roland Zengerle

11. Microreactors
1. Micromixers 2. Heat Exchangers 3. Chemical Microreactors 4. Splitting of Flow 5. Fuel-Based Power Supplies
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11. Microreactors

Jens Ducre and Roland Zengerle

11.5. Micro Fuel Cells

h A fuel cell operates like a battery in principle, producing electricity by electrochemically combining hydrogen and oxygen without combustion. h Unlike a battery, a fuel cell does not run down as long as fuel is supplied. The Micro Fuel Cell from Energy Related Devices is fueled by methanol or ethanol and is constructed with multiple layers of thin films. h The micro-fuel cell is like the cell of any living thing:
Input fuel is a hydrocarbon that is broken down catalytically, producing energy and harmless waste products of heat, carbon dioxide, and water vapor. The collection and energy distribution scheme of this microfuel cell system can be likened to the capillaries and veins in an animal.
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11. Microreactors

Jens Ducre and Roland Zengerle

11.5. Micro Fuel Cells

h The alcohol side of the film contains a catalyst that breaks the alcohol down into hydrogen ions and carbon dioxide. h This generates a negative electrical potential on the alcohol electrode. The hydrogen ions move through the film to the oxygen electrode on the air side of the cell. h The hydrogen ions combine with oxygen from the air to produce water vapor.
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h This produces a positive charge on the oxygen electrode. The oxygen and alcohol electrodes form the positive and negative terminals of the fuel cell; this is equivalent to the positive and negative terminals on a conventional battery.

11. Microreactors

Jens Ducre and Roland Zengerle

11.5. Advantages of Fuel Cells

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h Inexpensively manufacturable
Printing process similar to manufacture of computer chips

PNNL

h Environmentally responsible energy source

Non-polluting and does not involve use of toxic chemicals

h Instant refuel with methanol or ethanol

Safe, low-flammability, inexpensive, renewable, plant-based energy source

h Always On power source h Lightweight and compact size h 20 year estimated shelf-life
11. Microreactors Jens Ducre and Roland Zengerle

11.5. Microchannel Combustor / Evaporator

h Lightweight and compact sources of electric power and microclimate control
Carry-on power source for soldiers Thermal energy could drive electrical generation and provide the heating or cooling Combustion of hydrocarbon fuels produces highdensity thermal energy
- Energy density (W/kg or W/m3) of fuels factor of 100 greater than most advanced batteries
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Current heat generation

- Power transfer of 25 W / cm2

Low air-toxic emissions during operation

- Emissions of both NOx and CO reduced to below regulatory limits

Developing an approach to mass production

- Diffusion bonding of laminates for low cost fabrication

PNNL
Jens Ducre and Roland Zengerle

11. Microreactors

11.5. Microchannel Reactors for Automotive Fuel Processors

h Microchannel reactors reduce size of conventional reactors
Without lowering throughput

h Heat and mass transport limitations slow observed reaction rates in conventional reactors
Minimized in microchannel reactors

h Distance between heat generation and removal reduced

Tens of centimeters in conventional reactors Tens of microns in microchannel reactors
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h As distance shrinks, corresponding contribution of slow conduction and diffusion to heat exchange or catalyst surface is reduced. h Fast heat and mass transfer increases process efficiency, enabling process miniaturization without sacrificing productivity.

11. Microreactors

Jens Ducre and Roland Zengerle

11.5. Microchannel Reactors for Automotive Fuel Processors

h Fuel processor critical reactor technology for deployment of PEMbased fuel cells for automotive applications h Fuel processor produces hydrogen rich streams from gasoline or methanol in multi-step process
Fuel vaporizer Primary conversion reactor to produce synthesis gas Water gas shift reactor CO clean-up reactor
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h Conventional fuel processing technology based on fixed-bed reactors

Not scaling well with small modular nature of fuel cells

h Microchannel reactor-based fuel processors

Small, efficient, modular, lightweight and potentially inexpensive

h Based upon our results with other component investigations, we project a complete system volume of less than 9 liters to produce hydrogen at a sufficient rate and quality to produce 50-kW from a PEM fuel cell.

11. Microreactors

Jens Ducre and Roland Zengerle

11.5. Microchannel Reactors for Automotive Fuel Processors

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11. Microreactors

Jens Ducre and Roland Zengerle