Fast oil-in-water emulsification in microchannel using head-on impinging configuration: Effect of swirl motion

Liquid-liquid dispersion by head-on impingement in a cross-slot microfluidic device to form oil-in-water emulsion is experimentally investigated at broad range of flow rate conditions. Reynolds number based on the continuous aqueous phase flow is changed from 1000 to 7000 and the oil dispersed volume fraction varies between 3% and 30%. The flow patterns are observed in the vicinity of impinging region to characterize the effect of Reynolds number and oil volume fraction on the water-oil interaction and thus emulsification process. Based on the measured droplet size and size distribution, two geometries are compared, aimed at evaluating the advantages and disadvantages of swirl flow in the collision region for producing high quality emulsion. One configuration, "600-600", corresponds to inlet channels of identical size (600 ?m × 600 ?m), while the other one, "600-300", has a smaller channel for dispersed phase which is off-axis with the water channel. The results show that flow characteristics during dispersing process are significantly different for viscous and turbulent conditions. Dominated by Reynolds number, the flow patterns are classified into three regimes. The more turbulent the flow is, the finer and more monodispersed droplets will be in the o/w emulsion. In the medium Reynolds number regime, characteristics of flow are closer to laminar flow using higher oil volume fraction, compared to small oil volume content. It is particularly evident with 600-300 system because of lowering velocity gradient between two phase streams. Based on results of drop mean diameter and polydispersity index, 600-300 system which generates swirl flow structure only exhibits a superior performance, compared to the conventional equal-size geometry, at relatively higher Reynolds number.