Bubble formation and breakup dynamics in microfluidic devices: A review

High-Speed Generation of Microbubbles with Constant Cumulative Production in a Glass Capillary Microfluidic Bubble Generator

This work reports a simple bubble generator for the high-speed generation of microbubbles with constant cumulative production. To achieve this, a gas-liquid co-flowing microfluidic device with a tiny capillary orifice as small as 5 μm is fabricated to produce monodisperse microbubbles. The diameter of the microbubbles can be adjusted precisely by tuning the input gas pressure and flow rate of the continuous liquid phase. The co-flowing structure ensures the uniformity of the generated microbubbles, and the surfactant in the liquid phase prevents coalescence of the collected microbubbles. The diameter coefficient of variation (CV) of the generated microbubbles can reach a minimum of 1.3%. Additionally, the relationship between microbubble diameter and the gas channel orifice is studied using the low Capillary number (Ca) and Weber number (We) of the liquid phase. Moreover, by maintaining a consistent gas input pressure, the CV of the cumulative microbubble volume can reach 3.6% regardless of the flow rate of the liquid phase. This method not only facilitates the generation of microbubbles with morphologic stability under variable flow conditions, but also ensures that the cumulative microbubble production over a certain period of time remains constant, which is important for the volume-dominated application of chromatographic analysis and the component analysis of natural gas.

Behind the Non-Uniform Breakup of Bubble Slug in Y-Shaped Microchannel: Dynamics and Mechanisms

Bubble flow in confined geometries is a problem of fundamental and technological significance. Among all the forms, bubble breakup in bifurcated microchannels is one of the most commonly encountered scenarios, where an in-depth understanding is necessary for better leveraging the process. This study numerically investigates the non-uniform breakup of a bubble slug in Y-shaped microchannels under different flow ratios, Reynolds numbers, and initial bubble volumes. Overall, the bubble can either breakup or non-breakup when passing through the bifurcation and shows different forms depending on flow regimes. The flow ratio-Reynolds number phase diagrams indicate a power-law transition line of breakup and non-breakup. The bubble takes longer to break up with rising flow ratios yet breaks earlier with higher Reynolds numbers and volumes. Non-breakup takes less time than the breakup patterns. Flow ratio is the origin of non-uniform breakup. Both the Reynolds number and initial volume influence the bubble states when reaching the bifurcation and thus affect subsequent processes. Bubble neck dynamics are analyzed to describe the breakup further. The volume distribution after breaking up is found to have a quadratic relation with the flow ratio. Our study is hoped to provide insights for practical applications related to non-uniform bubble breakups.

Air trap and removal on a pressure driven PDMS-based microfluidic device

With the development of microfluidic technology, microfluidic chips have played a positive role in applications such as cell culture, microfluidic PCR, and nanopore gene sequencing. However, the presence of bubbles interferes with fluid flow and has a significant impact on experimental results. There are many reasons for the generation of bubbles in microfluidic chips, such as pressure changes inside the chip, air vibration inside the chip, and the open chip guiding air into the chip when driving fluid. This study designed and prepared a microfluidic device based on polydimethylsiloxane. First, air was actively introduced into the microfluidic chip, and bubbles were captured through the microfluidic device to simulate the presence of bubbles inside the chip in biological experiments. To remove bubbles trapped in the microfluidic chip, distilled water, distilled water containing surfactants, and mineral oil were pumped into the microfluidic chip. We compared and discussed the bubble removal efficiency under different driving fluids, driving pressures, and open/closed channel configurations. This study helps to understand the mechanism of bubble formation and removal in microfluidic devices, optimize chip structure design and experimental reagent selection, prevent or eliminate bubbles, and reduce the impact of bubbles on experiments.

3D Motion Manipulation for Micro- and Nanomachines: Progress and Future Directions

In the past decade, micro- and nanomachines (MNMs) have made outstanding achievements in the fields of targeted drug delivery, tumor therapy, microsurgery, biological detection, and environmental monitoring and remediation. Researchers have made significant efforts to accelerate the rapid development of MNMs capable of moving through fluids by means of different energy sources (chemical reactions, ultrasound, light, electricity, magnetism, heat, or their combinations). However, the motion of MNMs is primarily investigated in confined two-dimensional (2D) horizontal setups. Furthermore, three-dimensional (3D) motion control remains challenging, especially for vertical movement and control, significantly limiting its potential applications in cargo transportation, environmental remediation, and biotherapy. Hence, an urgent need is to develop MNMs that can overcome self-gravity and controllably move in 3D spaces. This review delves into the latest progress made in MNMs with 3D motion capabilities under different manipulation approaches, discusses the underlying motion mechanisms, explores potential design concepts inspired by nature for controllable 3D motion in MNMs, and presents the available 3D observation and tracking systems.

Industrial application of microbubble generation methods for recovering fine particles through froth flotation: A review of the state-of-the-art and perspectives

The depletion of high-grade and coarse-grain ores has led to an increasing demand for the development of efficient separation technologies for low-grade and fine-grain ores. However, conventional froth flotation techniques are not adequate to efficiently recover fine and ultrafine particles (typically <10-15 μm) due to the low collision probability between these particles and the relatively large bubbles used in the process. The introduction of microbubbles has shown promise in enhancing particle recovery, making it a subject of significant interest. Thus, this review focuses on microbubble generation methods that have the potential to be scaled up for industrial applications, with a specific emphasis on their suitability for froth flotation. The methods are categorized based on their scalability: high-hydrodynamic cavitation, porous media/medium-dissolved air, electrolysis/low-microfluidics, and acoustic methods. The bubble generation mechanisms, characteristics, advantages and limitations of each method and its applications in froth flotation are discussed to provide suggestions for improvement. There is still no appropriate technology that can optimize bubble size distribution, production rate and cost together for industrial froth flotation application. Therefore, novel approaches of combining multiple methods are also explored to achieve the potential synergic effects. By addressing the limitations of current microbubble generation methods and proposing potential enhancements, this review aims to contribute to the development of efficient and cost-effective microbubble generation technologies for fine and ultrafine particles in the froth flotation industry.

A general neural network model co-driven by mechanism and data for the reliable design of gas-liquid T-junction microdevices

In recent years, many models have been developed to describe the gas-liquid microdispersion process, which mainly rely on mechanistic analysis and may not be universally applicable. In order to provide a more comprehensive model and, most significantly, to provide a model for design, we have established a general database of microbubble generation in T-junction microdevices, including 854 data points from 12 pieces of literature. A neural network model that combines mechanistic and data modeling is developed. By transfer learning, more accurate results can be obtained. Additionally, we have proposed a design method that enables a relative deviation of less than 5% from the expected bubble size. A new device was designed and prepared to confirm the reliability of the method, which can prepare smaller bubbles than other common T-junction devices. In this way, a general and universal database and model are established and a design method for a gas-liquid T-junction microreactor is developed.

Biocatalytic Foams from Microdroplet-Formulated Self-Assembling Enzymes

Industrial biocatalysis plays an important role in the development of a sustainable economy, as enzymes can be used to synthesize an enormous range of complex molecules under environmentally friendly conditions. To further develop the field, intensive research is being conducted on process technologies for continuous flow biocatalysis in order to immobilize large quantities of enzyme biocatalysts in microstructured flow reactors under conditions that are as gentle as possible in order to realize efficient material conversions. Here, monodisperse foams consisting almost entirely of enzymes covalently linked via SpyCatcher/SpyTag conjugation are reported. The biocatalytic foams are readily available from recombinant enzymes via microfluidic air-in-water droplet formation, can be directly integrated into microreactors, and can be used for biocatalytic conversions after drying. Reactors prepared by this method show surprisingly high stability and biocatalytic activity. The physicochemical characterization of the new materials is described and exemplary applications in biocatalysis are shown using two-enzyme cascades for the stereoselective synthesis of chiral alcohols and the rare sugar tagatose.

Research Progress on Displacement Mechanism of Supercritical CO2 in Low-Permeability Heavy Oil Reservoir and Improvement Mechanism of Displacement Agents

With the continuous growth of global energy demand and the late stage of conventional oilfield exploitation, the demand for developing and utilizing low-permeability heavy oil reservoirs is becoming increasingly urgent. However, the exploitation of low-permeability heavy oil reservoirs faces many challenges due to their high viscosity, low permeability, and complex geological conditions. To overcome these challenges, researchers have gradually introduced SC-CO2 as an oil displacement agent in the exploitation of heavy oil reservoirs. However, the oil displacement mechanism of SC-CO2 in low-permeability heavy oil reservoirs and its improvement mechanism are still not completely understood. The article provides a detailed study and understanding of the oil displacement mechanism of SC-CO2, which involves the expansion of heavy oil volume through SC-CO2 dissolution. This mechanism reduces the capillary resistance and flow resistance during the oil flow process. The permeation of CO2 disrupts the internal structure and arrangement of heavy oil, reducing its viscosity. CO2 extracts both light and heavy components from the heavy oil, reducing the residual oil saturation. In addition, the mechanism of improving the effect of oil displacement agents such as nanoparticles, polymers, and surfactants on SC-CO2 displacement was also explored. By further exploring the mechanisms and improvement mechanisms of SC-CO2 displacement for heavy oil, it can guide the selection and optimization of oil displacement agents. Furthermore, understanding the mechanism can also provide a theoretical basis for engineering practice and technical innovation. While the research on CO2 flooding is analyzed and evaluated, the obstacles and challenges that still exist at this stage are indicated, and future research work on CO2 in low-permeability heavy oil reservoirs is proposed.

Strategy for Fast Decision on Material System Suitability for Continuous Crystallization Inside a Slug Flow Crystallizer

There is an increasing focus on two-phase flow in micro- or mini-structured apparatuses for various manufacturing and measurement instrumentation applications, including the field of crystallization as a separation technique. The slug flow pattern offers salient features for producing high-quality products, since narrow residence time distribution of liquid and solid phases, intensified mixing and heat exchange, and an enhanced particle suspension are achieved despite laminar flow conditions. Due to its unique features, the slug flow crystallizer (SFC) represents a promising concept for small-scale continuous crystallization achieving high-quality active pharmaceutical ingredients (API). Therefore, a time-efficient strategy is presented in this study to enable crystallization of a desired solid product in the SFC as quickly as possible and without much experimental effort. This strategy includes pre-selection of the solvent/solvent mixture using heuristics, verifying the slug flow stability in the apparatus by considering the static contact angle and dynamic flow behavior, and modeling the temperature-dependent solubility in the supposed material system using perturbed-chain statistical associating fluid theory (PC-SAFT). This strategy was successfully verified for the amino acids l-alanine and l-arginine and the API paracetamol for binary and ternary systems and, thus, represents a general approach for using different material systems in the SFC.

Accelerating Effects of Flow Behavior Index n on Breakup Dynamics for Droplet Evolution in Non-Newtonian Fluids

This paper studied the evolution of NaAlg solution micro-droplet in a coaxial microchannel. The Bird–Carreau model was used to characterize the flow properties of NaAlg solution. As the mass fraction decreased, the flow behavior index n also decreased, indicating that the NaAlg solution was increasingly shear-thinning. There were three stages during the micro-droplet evolution, which were the growth stage, the squeezing stage, and the pinch-off stage. This paper led the flow behavior index n to estimate the effects of rheological property on the breakup dynamics of micro-droplet. We proposed two new prediction models of the minimum neck width w_m which were affected by |n| in the squeezing and pinch-off stages for the non-Newtonian fluids. In addition, this paper indicated the rate ratio Q_d/Q_c was another factor on the w_m model in the squeezing stage and the H(λ) of Stokes mechanism was a function governed by |n|² in the pinch-off stage.

Towards High Throughput Structuring of Liquid Foams in Microchannels: Effect of Geometry, Flowrate and Formulation

This work is part of a study aiming to design a high-throughput foaming microsystem. The main focused field of application is the food industry. With the objective of improving the design of the microdevice, the effects of the geometry and the nature of the liquid base are presently investigated through visualizations of the flow typology of bubbles trains, aiming to expand the knowledge on key parameters that lead to an improved gas breakup. The tested set of conditions is not encountered in traditional microfluidics systems: i.e., throughputs up to 19 L·h⁻¹ for the liquid phase, process velocities around 20 m·s⁻¹ and flow of complex fluids. The behavior of solutions based on xanthan gum (XG) and whey proteins (WPI) is compared to that of solutions containing one of these ingredients or other ones (caseinates, glycerol). The structural and end-used properties of the final foams, namely the bubble diameter and rheological behavior, are evaluated. The incorporation of XG induces bubble shape stabilization even at the highest shear rates (~10⁵ s⁻¹) encountered in the mixing channel. “Controlled” interfacial breakup by tip-streaming or binary breakup are only observed with the WPI/XG biopolymers. This study indubitably highlights the essential role of the process/formulation interaction in the development of structural and functional properties of food foams when using microfluidics at high throughput.

Continuous biphasic chemical processes in a four-phase segmented flow reactor

A four-phase segmented flow regime for continuous biphasic reaction processes is introduced, characterized over 1500 automatically conducted experiments, and used for biphasic ligand exchange of CdSe quantum dots.

Trapping and control of bubbles in various microfluidic applications

As a simple, clean and effective tool, micro bubbles have enabled advances in various lab on a chip (LOC) applications recently. In bubble-based microfluidic applications, techniques for capturing and controlling the bubbles play an important role. Here we review active and passive techniques for bubble trapping and control in microfluidic applications. The active techniques are categorized based on various types of external forces from optical, electric, acoustic, mechanical and thermal fields. The passive approaches depend on surface tension, focusing on optimization of microgeometry and modification of surface properties. We discuss control techniques of size, location and stability of microbubbles and show how these bubbles are employed in various applications. To finalize, by highlighting the advantages of these approaches along with the current challenges, we discuss the future prospects of bubble trapping and control in microfluidic applications.

Investigation of Hydrodynamic and Heat Transfer Characteristics of Gas-liquid Taylor flow in Square Microchannel

Heat transfer and flow characteristics under air-water Taylor flow in a square microchannel with T-junction were investigated in this work. Different hydraulic diameters of models were discussed numerically by VOF method. Flow patterns such as bubbly flow, slug flow, annular flow and churn flow were identified by both numerical simulation and experimental methods. Simulation results including bubble formation process, bubble length, bubble velocity, void fraction and heat transfer fit well with literature data. The pressure differential of two sides in gas phase played an important role in bubble development. The gas and liquid superficial velocities were found to have a significant impact on bubble behavior. And the higher liquid viscosity would promote higher bubble velocity, also enhance heat transfer, but weaken the void fraction. The results showed a tiny but not ignorable effect of geometric dimensioning on bubble and liquid slug lengths. An appropriate correlation was proposed to estimate bubble length, and the deviation was −10 ~ + 15 %. By using moving frame of reference technique, the internal circulations inside the moving slugs were displayed more clearly.

Application of Microfluidics in the Production and Analysis of Food Foams

Emulsifiers play a key role in the stabilization of foam bubbles. In food foams, biopolymers such as proteins are contributing to long-term stability through several effects such as increasing bulk viscosity and the formation of viscoelastic interfaces. Recent studies have identified promising new stabilizers for (food) foams and emulsions, for instance biological particles derived from water-soluble or water-insoluble proteins, (modified) starch as well as chitin. Microfluidic platforms could provide a valuable tool to study foam formation on the single-bubble level, yielding mechanistic insights into the formation and stabilization (as well as destabilization) of foams stabilized by these new stabilizers. Yet, the recent developments in microfluidic technology have mainly focused on emulsions rather than foams. Microfluidic devices have been up-scaled (to some extent) for large-scale emulsion production, and also designed as investigative tools to monitor interfaces at the (sub)millisecond time scale. In this review, we summarize the current state of the art in droplet microfluidics (and, where available, bubble microfluidics), and provide a perspective on the applications for (food) foams. Microfluidic investigations into foam formation and stability are expected to aid in optimization of stabilizer selection and production conditions for food foams, as well as provide a platform for (large-scale) production of monodisperse foams.

Modeling the Excess Velocity of Low-Viscous Taylor Droplets in Square Microchannels

Microscopic multiphase flows have gained broad interest due to their capability to transfer processes into new operational windows and achieving significant process intensification. However, the hydrodynamic behavior of Taylor droplets is not yet entirely understood. In this work, we introduce a model to determine the excess velocity of Taylor droplets in square microchannels. This velocity difference between the droplet and the total superficial velocity of the flow has a direct influence on the droplet residence time and is linked to the pressure drop. Since the droplet does not occupy the entire channel cross-section, it enables the continuous phase to bypass the droplet through the corners. A consideration of the continuity equation generally relates the excess velocity to the mean flow velocity. We base the quantification of the bypass flow on a correlation for the droplet cap deformation from its static shape. The cap deformation reveals the forces of the flowing liquids exerted onto the interface and allows estimating the local driving pressure gradient for the bypass flow. The characterizing parameters are identified as the bypass length, the wall film thickness, the viscosity ratio between both phases and the C a number. The proposed model is adapted with a stochastic, metaheuristic optimization approach based on genetic algorithms. In addition, our model was successfully verified with high-speed camera measurements and published empirical data.