Transition-state theory predicts clogging at the microscale

Clogging transition and anomalous transport in driven suspensions in a disordered medium

We study computationally the dynamics of forced, Brownian particles through a disordered system. As the concentration of mobile particles and/or fixed obstacles increase, we characterize the different regimes of flow and address how clogging develops. We show that clogging is preceded by a wide region of anomalous transport, characterized by a power law decay of intermittent bursts. We analyze the velocity distribution of the moving particles and show that this abnormal flow region is characterized by a coexistence between mobile and arrested particles, and their relative populations change smoothly as clogging is approached. The comparison of the regimes of anomalous transport and clogging with the corresponding scenarios of particles pushed through a single bottleneck show qualitatively the same trends highlighting the generality of the transport regimes leading to clogging.

High-Throughput Fabrication of Size-Controlled Pickering Emulsions, Colloidosomes, and Air-Coated Particles via Clog-Free Jetting of Suspensions

Microcapsules with a liquid core and a solid shell composed of hydrophobic nanoparticles are broadly applied in food, pharmaceutics, and biotechnologies. For example, Pickering emulsions, colloidosomes, or antibubbles (droplets surrounded by air layers in water) enable controlled release of active agents, biocompatibility, and contact-less liquid transportation. However, producing controlled nanoparticle- or polymer-laden hydrophobic shells at scale is highly challenging, since bulk methods are polydisperse and microfluidic chips are prone to clogging and slow. Here, clog-free coating of an aqueous jet with silica nanoparticle suspensions with concentrations up to 10% (w/v), as well as high concentrations of polymers (30% (w/v) poly(lactic acid) (PLA)), is demonstrated, enabling continuous generation of microcapsules at flow rates up to 4 mL min^-1 . Pickering emulsions are converted into capsules, providing hydrophobic shells consisting of nanoparticles for controlled release. As a highlight, the scalable fabrication of air-coated capsules (antibubbles) in the sub-millimeter range is demonstrated. The shell contains an air film that protects the liquid core for days yet enables ultrasound-induced release within 3 min. By enabling rapid fabrication of controlled Pickering emulsions, colloidosomes, antibubbles, and biodegradable capsules, jetting through a liquid layer (JetALL) provides a versatile platform for advanced applications in food, pharmacy, and life science.

Flow dynamics through discontinuous clogs of rigid particles in tapered microchannels

Suspended particles flowing through complex porous spaces exhibit clogging mechanisms determined by factors including their size, deformability, and the geometry of the confinement. This study describes the clogging of rigid particles in a microfluidic device made up of parallel microchannels that taper from the inlet to the outlet, where the constriction width is approximately equal to the particle size. This converging geometry summarizes the dynamics of clogging in flow channels with constrictions that narrow over multiple length scales. Our novel approach allows the investigation of suspension flow dynamics in confined systems where clogs are formed both by sieving and bridging mechanisms simultaneously. Here, flow tests are conducted at constant driving pressures for different particle volume fractions, and a power-law decay which appears to be peculiar to the channels' tapered geometry is observed in all cases. Compared to non-tapered channels, the power-law behavior shows flowrate decay is significantly weaker in tapered channels. This weaker flowrate decay is explained by the formation of discontinuous clogs within each channel. Micrographs of the clogged channels reveal clogs do not grow continuously from their initial positions around the channels' outlet. Rather, new clogs spanning the width of the channel at their points of inception are successively formed as the cake grows toward the inlet area in each microchannel. The results show changes in particle volume fraction at constant driving pressure affect the clogging rate without impacting the underlying dynamics. Unexpectedly, analyses of the particles packing behavior in the microchannels, and post-clogging permeability of the microfluidic devices, reveal the presence of two distinct regimes of driving pressure, though only a small portion of the total device volume and channels surface area are occupied by clogs, regardless of the particle volume fraction. This novel investigation of discontinuous clogging over multiple particle diameters provides unique insights into additional mechanisms to control flow losses in filtration and other confined systems.

Particle movements provoke avalanche-like compaction in soft colloid filter cakes

During soft matter filtration, colloids accumulate in a compressible porous cake layer on top of the membrane surface. The void size between the colloids predominantly defines the cake-specific permeation resistance and the corresponding filtration efficiency. While higher fluxes are beneficial for the process efficiency, they compress the cake and increase permeation resistance. However, it is not fully understood how soft particles behave during cake formation and how their compression influences the overall cake properties. This study visualizes the formation and compression process of soft filter cakes in microfluidic model systems. During cake formation, we analyze single-particle movements inside the filter cake voids and how they interact with the whole filter cake morphology. During cake compression, we visualize reversible and irreversible compression and distinguish the two phenomena. Finally, we confirm the compression phenomena by modeling the soft particle filter cake using a CFD-DEM approach. The results underline the importance of considering the compression history when describing the filter cake morphology and its related properties. Thus, this study links single colloid movements and filter cake compression to the overall cake behavior and narrows the gap between single colloid events and the filtration process.

Dynamics of progressive pore clogging by colloidal aggregates

The flow of a suspension through a bottleneck often leads to its obstruction. Such a continuous flow to clogging transition has been well characterized when the constriction width to particle size ratio, W/D, is smaller than 3-4. In such cases, the constriction is either blocked by a single particle that is larger than the constriction width (W/D < 1), or there is an arch formed by several particles that try to enter it together (2 < W/D < 4). For larger W/D ratios, 4 < W/D < 10, the blockage of the constriction is presumed to be due to the successive accumulations of particles. Such a clogging mechanism may also apply to wider pores. The dynamics of this progressive obstruction remains largely unexplored since it is difficult to see through the forming clog and we still do not know how particles accumulate inside the constriction. In this paper, we use particle tracking and image analysis to study the clogging of a constriction/pore by stable colloidal particles. These techniques allow us to determine the shape and the size of all the objects, be they single particles or aggregates, captured inside the pore. We show that even with the rather monodisperse colloidal suspension we used individual particles cannot clog a pore alone. These individual particles can only partially cover the pore surface whilst it is the very small fraction of aggregates present in the suspension that can pile up and clog the pore. We analyzed the dynamics of aggregate motion up to the point of capture within the pore, which helps us to elucidate why the probability of aggregate capture inside the pore is high.

Microstructure of the near-wall layer of filtration-induced colloidal assembly

This paper describes an experimental study of filtration of a colloidal suspension using microfluidic devices. A suspension of micrometer-scale colloids flows through parallel slit-shaped pores at fixed pressure drop. Clogs and cakes are systematically observed at pore entrance, for variable applied pressure drop and ionic strength. Based on image analysis of the layer of colloids close to the device wall, global and local studies are performed to analyse in detail the near-wall layer microstructure. Whereas global porosity of this layer does not seem to be affected by ionic strength and applied pressure drop, a local study shows some heterogeneity: clogs are more porous at the vicinity of the pore than far away. An analysis of medium-range order using radial distribution function shows a slightly more organized state at high ionic strength. This is confirmed by a local analysis using two-dimension continuous wavelet decomposition: the typical size of crystals of colloids is larger for low ionic strength, and it increases with distance from the pores. We bring these results together in a phase diagram involving colloid-colloid repulsive interactions and fluid velocity.

Microfluidics Used as a Tool to Understand and Optimize Membrane Filtration Processes

Membrane filtration processes are best known for their application in the water, oil, and gas sectors, but also in food production they play an eminent role. Filtration processes are known to suffer from a decrease in efficiency in time due to e.g., particle deposition, also known as fouling and pore blocking. Although these processes are not very well understood at a small scale, smart engineering approaches have been used to keep membrane processes running. Microfluidic devices have been increasingly applied to study membrane filtration processes and accommodate observation and understanding of the filtration process at different scales, from nanometer to millimeter and more. In combination with microscopes and high-speed imaging, microfluidic devices allow real time observation of filtration processes. In this review we will give a general introduction on microfluidic devices used to study membrane filtration behavior, followed by a discussion of how microfluidic devices can be used to understand current challenges. We will then discuss how increased knowledge on fundamental aspects of membrane filtration can help optimize existing processes, before wrapping up with an outlook on future prospects on the use of microfluidics within the field of membrane separation.

Clogging-jamming connection in narrow vertical pipes

We report experimental evidence of clogging due to the spontaneous development of hanging arches when a granular sample composed of spherical particles flows down a narrow vertical pipe. These arches, akin to the ones responsible for silo clogging, can only be possible due to the role of frictional forces; otherwise they will be unstable. We find that, contrary to the silo case, the probability of clogging in vertical narrow tubes does not decrease monotonically with the ratio of the pipe-to-particle diameters. This behavior is related to the clogging prevention caused by the spontaneous ordering of particles apparent in certain aspect ratios. More importantly, by means of numerical simulations, we discover that the interparticle normal force distributions broaden in systems with higher probability of clogging. This feature, which has been proposed before as a distinctive feature of jamming in sheared granular samples, suggests that clogging and jamming are connected in pipe flow.

Microtechnological Tools to Achieve Sustainable Food Processes, Products, and Ingredients

One of the major challenges we face as humankind is supplying a growing world population with sufficient and healthy foods. Although from a worldwide perspective sufficient food is produced, locally, the situation can be dire. Furthermore, the production needs to be increased in a sustainable manner for future generations, which also implies prevention of food waste, and making better use of the available resources. How to contribute to this as food technologists is an ultimate question, especially since the tools that can investigate processes at relevant time scales, and dimensions, are lacking. Here we propose the use of microtechnology and show examples of how this has led to new insights in the fields of ingredient isolation (filtration), and emulsion/foam formation, which will ultimately lead to better-defined products. Furthermore, microfluidic tools have been applied for testing ingredient functionality, and for this, various examples are discussed that will expectedly contribute to making better use of more sustainably sourced starting materials (e.g., novel protein sources). This review will wrap up with a section in which we discuss future developments. We expect that it will be possible to link food properties to the effects that foods create in vivo. We thus expand the scope of this review that is technical in nature, toward physiological functionality, and ultimately to rational food design that is targeted to improve human health.

Conformational changes influence clogging behavior of micrometer-sized microgels in idealized multiple constrictions

Clogging of porous media by soft particles has become a subject of extensive research in the last years and the understanding of the clogging mechanisms is of great importance for process optimization. The rise in the utilization of microfluidic devices brought the possibility to simulate membrane filtration and perform in situ observations of the pore clogging mechanisms with the aid of high speed cameras. In this work, we use microfluidic devices composed by an array of parallel channels to observe the clogging behavior of micrometer sized microgels. It is important to note that the microgels are larger than the pores/constrictions. We quantify the clog propensity in relation to the clogging position and particle size and find that the majority of the microgels clog at the first constriction independently of particle size and constriction entrance angle. We also quantify the variations in shape and volume (2D projection) of the microgels in relation to particle size and constriction entrance angle. We find that the degree of deformation increases with particle size and is dependent of constriction entrance angle, whereas, changes in volume do not depend on entrance angle.

Microfluidic model systems used to emulate processes occurring during soft particle filtration

Cake layer formation in membrane processes is an inevitable phenomenon. For hard particles, especially cake porosity and thickness determine the membrane flux, but when the particles forming the cake are soft, the variables one has to take into account in the prediction of cake behavior increase considerably. In this work we investigate the behavior of soft polyacrylamide microgels in microfluidic model membranes through optical microscopy for in situ observation both under regular flow and under enhanced gravity conditions. Particles larger than the pore are able to pass through deformation and deswelling. We find that membrane clogging time and cake formation is not dependent on the applied pressure but rather on particle and membrane pore properties. Furthermore, we found that particle deposits subjected to low pressures and low g forces deform in a totally reversible fashion. Particle deposits subjected to higher pressures only deform reversibly if they can re-swell due to capillary forces, otherwise irreversible compression is observed. For membrane processes this implies that when using deformable particles, the pore size is not a good indicator for membrane performance, and cake formation can have much more severe consequences compared to hard particles due to the sometimes-irreversible nature of soft particle compression.

Decoupling Geometrical and Kinematic Contributions to the Silo Clogging Process

Based on the implementation of a novel silo discharge procedure, we are able to control the grains velocities regardless of the outlet size. This allows isolating the geometrical and kinematic contributions to the clogging process. We find that, for a given outlet size, reducing the grains velocities to extremely low values leads to a clogging probability increment of almost two orders of magnitude, hence revealing the importance of particle kinematics in the silo clogging process. Then, we explore the contribution of both variables, outlet size and grains velocity, and we find that our results agree with an already known exponential expression that relates clogging probability with outlet size. We propose a modification of such expression revealing that only two parameters are necessary to fit all the data: one is related with the geometry of the problem, and the other with the grains kinematics.

Pore cross-talk in colloidal filtration

Blockage of pores by particles is found in many processes, including filtration and oil extraction. We present filtration experiments through a linear array of ten channels with one dimension which is sub-micron, through which a dilute dispersion of Brownian polystyrene spheres flows under the action of a fixed pressure drop. The growth rate of a clog formed by particles at a pore entrance systematically increases with the number of already saturated (entirely clogged) pores, indicating that there is an interaction or “cross-talk” between the pores. This observation is interpreted based on a phenomenological model, stating that a diffusive redistribution of particles occurs along the membrane, from clogged to free pores. This one-dimensional model could be extended to two-dimensional membranes.

From cooperative to uncorrelated clogging in cross-flow microfluidic membranes

The operational lifetime of filtration membranes is reduced by the clogging of pores and subsequent build-up of a fouling or cake layer. Designing membrane operations in which clogging is delayed or even mitigated completely, requires in-depth insight into its origins. Due to the complexity of the clogging process, simplified model membranes fabricated in microfluidic chips have emerged as a powerful tool to study how clogs emerge and deteriorate membrane efficiency. However, to date, these have focussed solely on dead-end filtration, while cross-flow filtration is of greater practical relevance at the industrial scale. As such, the microscopic mechanisms of clogging in crossflow geometries have remained relatively ill-explored. Here we use a microfluidic filtration model to probe the kinetics and mechanisms of clogging in crossflow. Our study exposes two findings: (i) the primary clogging rate of individual pores depends only on the trans-membrane flux, whose strong effects are explained quantitatively by extending existing models with a term for flux-controlled flow-enhanced barrier crossing, (ii) cross-membrane flow affects the pore-pore communication, leading to a transition from correlated to uncorrelated clogging of the membrane, which we explain qualitatively by deriving a dimensionless number which captures two essential regimes of clogging at the microscale.

Flow of colloidal suspensions through small orifices

In this work, we numerically study a dense colloidal suspension flowing through a small outlet driven by a pressure drop using lattice-Boltzmann methods. This system shows intermittent flow regimes that precede clogging events. Several pieces of evidence suggest that the temperature controls the dynamic state of the system when the driving force and the aperture size are fixed. When the temperature is low, the suspension's flow can be interrupted during long time periods, which can be even two orders of magnitude larger than the system's characteristic time (Stokes). We also find that strong thermal noise does not allow the formation of stable aggregate structures avoiding extreme clogging events, but, at the same time, it randomizes the particle trajectories and disturbs the advective particle flow through the aperture. Moreover, examining the particle velocity statistics, we obtain that in the plane normal to the pressure drop the colloids always move as free particles regardless of the temperature value. In the pressure drop direction, at high temperature the colloids experience a simple balance between advective and diffusive transport, but at low temperature the nature of the flow is much more complex, correlating with the occurrence of very long clogging events.

Clogging of microfluidic systems

The transport of suspensions of microparticles in confined environments is associated with complex phenomena at the interface of fluid mechanics and soft matter. Indeed, the deposition and assembly of particles under flow involve hydrodynamic, steric and colloidal forces, and can lead to the clogging of microchannels. The formation of clogs dramatically alters the performance of both natural and engineered systems, effectively limiting the use of microfluidic technology. While the fouling of porous filters has been studied at the macroscopic level, it is only recently that the formation of clogs has been considered at the pore-scale, using microfluidic devices. In this review, we present the clogging mechanisms recently reported for suspension flows of colloidal particles and for biofluids in microfluidic channels, including sieving, bridging and aggregation of particles. We discuss the technological implications of the clogging of microchannels and the schemes that leverage the formation of clogs. We finally consider some of the outstanding challenges involving clogging in human health, which could be tackled with microfluidic methods.