Rapid microfluidic screening of CO2 solubility and diffusion in pure and mixed solvents

Deep learning-augmented T-junction droplet generation

Droplet generation technology has become increasingly important in a wide range of applications, including biotechnology and chemical synthesis. T-junction channels are commonly used for droplet generation due to their integration capability of a larger number of droplet generators in a compact space. In this study, a finite element analysis (FEA) approach is employed to simulate droplet production and its dynamic regimes in a T-junction configuration and collect data for post-processing analysis. Next, image analysis was performed to calculate the droplet length and determine the droplet generation regime. Furthermore, machine learning (ML) and deep learning (DL) algorithms were applied to estimate outputs through examination of input parameters within the simulation range. At the end, a graphical user interface (GUI) was developed for estimation of the droplet characteristics based on inputs, enabling the users to preselect their designs with comparable microfluidic configurations within the studied range.

Capillary Microreactor for Initial Screening of Three Amine-Based Solvents for CO2 Absorption, Desorption, and Foaming

Microreactor is a very attractive laboratory device for screening conditions and solvents in an efficient, safe and fast manner. Most reported work on microreactors for CO2 capturing deals with absorption and mass transfer performance with a limited number of studies on solvent regeneration. For the first time, foaming, which is a major operational challenge of CO2 capturing is being studied in combination with absorption and desorption in a capillary microreactor setup. To demonstrate the setup capabilities, three known amine-based solvents (MEA, MDEA, and AMP) were selected for the screening and evaluation studies. MEA had the highest CO2 absorption efficiency while MDEA had the lowest one. CO2 absorption efficiency increased with temperature, liquid flow rate, and amine concentration as per the literature. During the absorption work, the Taylor flow regime was maintained at the reactor inlet. CO2 desorption of loaded amine solutions was investigated at different concentrations and temperatures up to 85°C. MDEA solution had the highest desorption efficiency, followed by AMP and the least desorption efficiency was that of MEA. Foaming experimental results showed that MEA had a larger foaming region compared to AMP. However, more foaming happened with AMP at higher gas and liquid flow rates. A plug flow mathematical reactor model was developed to simulate the MEA-CO2 system. The model captured well the performance and trends of the studied system, however the absolute prediction deviated due to uncertainties in the used physical properties and mass transfer correlation. Selecting a solvent for chemical absorption depends on many more factors than these three studied parameters. Still, microreactor proves a valuable tool to generate experimental results under different conditions, with the least amount of consumables (less than 1 L solvents were used), in a fast manner, combined with a knowledge insight because of the uniqueness of the Taylor flow regime.

Microfluidic mass transfer of CO2 at elevated pressures: implications for carbon storage in deep saline aquifers

Carbon capture and sequestration (CCS) in a deep saline aquifer is one of the most promising technologies to mitigate anthropologically emitted carbon dioxide. Accurately quantifying the mass transport of CO₂ at pore-scales is crucial but challenging for successful CCS deployment. Here, we conduct high-pressure microfluidic experiments, mimicking reservoir conditions up to 9.5 MPa and 35 °C, to elucidate the microfluidic mass transfer process of CO₂ at three different states (i.e., gas, liquid, and supercritical phase) into water. We measure the size change of CO₂ micro-bubbles/droplets generated using a microfluidic T-junction to estimate the volumetric mass transfer coefficient (k_La), quantifying the rate change of CO₂ concentration under the driving force of concentration gradient. The results show that bubbles/droplets under high-pressure conditions reach a steady state faster than low pressure. The measured volumetric mass transfer coefficient increases with the Reynolds number (based on the liquid slug) and is nearly independent of the injection pressure for both the gas and liquid phases. In addition, k_La significantly enlarges with increasing high pressure at the supercritical state. Compared with various chemical engineering applications using millimeter-sized capillaries (with typical k_La measured ranging from ≈0.005 to 0.8 s^-1), the microfluidic results show a significant increase in the volumetric mass transfer of CO₂ into water by two to three orders of magnitude, O (10²-10³), with decreasing hydrodynamic diameter (of ≈50 μm).

Experimental Studies of Droplet Formation Process and Length for Liquid–Liquid Two-Phase Flows in a Microchannel

In this study, changes in the droplet formation mechanism and the law of droplet length in a two-phase liquid–liquid system in 400 × 400 μm standard T-junction microchannels were experimentally studied using a high-speed camera. The study investigated the effects of various dispersed phase viscosities, various continuous phase viscosities, and two-phase flow parameters on droplet length. Two basic flow patterns were observed: slug flow dominated by the squeezing mechanism, and droplet flow dominated by the shear mechanism. The dispersed phase viscosity had almost no effect on droplet length. However, the droplet length decreased with increasing continuous phase viscosity, increasing volume flow rate in the continuous phase, and the continuous-phase capillary number Cac. Droplet length also increased with increasing volume flow rate in the dispersed phase and with the volume flow rate ratio. Based on the droplet formation mechanism, a scaling law governing slug and droplet length was proposed and achieved a good fit with experimental data.

Accelerating gas-liquid chemical reactions in flow

Over the past decade, continuous flow reactors have emerged as a powerful tool for accelerated fundamental and applied studies of gas-liquid reactions, offering facile gas delivery and process intensification. In particular, unique features of highly gas-permeable tubular membranes in flow reactors (i.e., tube-in-tube flow reactor configuration) have been exploited as (i) an efficient analytic tool for gas-liquid solubility and diffusivity measurements and (ii) reliable gas delivery/generation strategy, providing versatile adaptability for a wide range of gas-liquid processes. The tube-in-tube flow reactors have been successfully adopted for rapid exploration of a wide range of gas-liquid reactions (e.g., amination, carboxylation, carbonylation, hydrogenation, ethylenation, oxygenation) using gaseous species both as the reactant and the product, safely handling toxic and flammable gases or unstable intermediate compounds. In this highlight, we present an overview of recent developments in the utilization of such intensified flow reactors within modular flow chemistry platforms for different gas-liquid processes involving carbon dioxide, oxygen, and other gases. We provide a detailed step-by-step guideline for robust assembly and safe operation of tube-in-tube flow reactors. We also discuss the current challenges and potential future directions for further development and utilization of tubular membrane-based flow reactors for gas-liquid processes.

Studying key processes related to CO2 underground storage at the pore scale using high pressure micromodels

Micromodels experimentation for studying and understanding CO₂ geological storage mechanisms at the pore scale.

Fabrication and verification of a glass-silicon-glass micro-/nanofluidic model for investigating multi-phase flow in shale-like unconventional dual-porosity tight porous media

Unconventional shale or tight oil/gas reservoirs that have micro-/nano-sized dual-scale matrix pore throats with micro-fractures may result in different fluid flow mechanisms compared with conventional oil/gas reservoirs. Microfluidic models, as a potential powerful tool, have been used for decades for investigating fluid flow at the pore-scale in the energy field. However, almost all microfluidic models were fabricated by using etching methods and very few had dual-scale micro-/nanofluidic channels. Herein, we developed a lab-based, quick-processing and cost-effective fabrication method using a lift-off process combined with the anodic bonding method, which avoids the use of any etching methods. A dual-porosity matrix/micro-fracture pattern, which can mimic the topology of shale with random irregular grain shapes, was designed with the Voronoi algorithm. The pore channel width range is 3 μm to 10 μm for matrices and 100-200 μm for micro-fractures. Silicon is used as the material evaporated and deposited onto a glass wafer and then bonded with another glass wafer. The channel depth is the same (250 nm) as the deposited silicon thickness. By using an advanced confocal laser scanning microscopy (CLSM) system, we directly visualized the pore level flow within micro/nano dual-scale channels with fluorescent-dyed water and oil phases. We found a serious fingering phenomenon when water displaced oil in the conduits even if water has higher viscosity and the residual oil was distributed as different forms in the matrices, micro-fractures and conduits. We demonstrated that different matrix/micro-fracture/macro-fracture geometries would cause different flow patterns that affect the oil recovery consequently. Taking advantage of such a micro/nano dual-scale 'shale-like' microfluidic model fabricated by a much simpler and lower-cost method, studies on complex fluid flow behavior within shale or other tight heterogeneous porous media would be significantly beneficial.

Mass transfer dynamics in the dissolution of Taylor bubbles

The knowledge of thermodynamic and mass transfer parameters in gas-liquid systems is critical for the design of macroscale units for separation and reaction processes. The phenomenon of shrinkage of Taylor bubbles upon dissolution has the capability of supplying these design parameters, provided a reliable mathematical model is available for data deconvolution. Unfortunately, the existing models in the literature suffer from at least one of the following three major limitations. First, mass transfer between the bulk liquid segment and the surrounding liquid film has been incorrectly estimated. Second, the liquid segment is assumed to be well mixed, even though there is clear evidence of the contrary in the literature [Yang et al., Chem. Eng. Sci., 2017, 169, 106]. Third, an average mass transfer coefficient is assumed to be valid throughout the dissolution process, despite the fact that bubble velocities can change significantly during dissolution. In this work, we have rectified these limitations and developed a detailed model that takes into account the local concentration gradients and the flow profiles, without resorting to the computationally expensive, full numerical simulations of the fluid flow and concentration distribution equations. To validate the model, experiments were carried out in circular, silica capillaries of different radii by generating segmented flow of CO₂ in physical solvents, and the diffusivity and the solubility were subsequently extracted with an error of less than 5%. This work can be extended to the study of gas-liquid-solid reactions in the Taylor flow configuration, and applied to the design of catalyst-coated monolithic reactors.

Flow Toolkit for Measuring Gas Diffusivity in Liquids

Precise knowledge of gas diffusivity in liquids is critical for describing complex multiphase reaction systems. Here we present a high-throughput flow concept to measure gas diffusivity in liquids. This strategy takes advantage of the tube-in-tube reactor design whereby semipermeable Teflon AF-2400 tubes facilitate fast mass transfer between gas and liquid without directly contacting the two fluids. Coupled pseudosteady-state flux balances over the gas and liquid describe the gas dissolution rate and corresponding diffusivity with the aid of a single gas flow meter and a continuously ramped liquid flow rate. This in situ method demonstrates excellent accuracy in diffusion coefficient measurements, with less than 5% deviation from established techniques.

Microfluidic approaches for accessing thermophysical properties of fluid systems

Thermophysical properties of fluid systems under high pressure and high temperature conditions are highly desirable as they are used in many industrial processes both from a chemical engineering point of view and to push forward the development of modeling approaches.

Catalytic activity of nickel nanoparticles stabilized by adsorbing polymers for enhanced carbon sequestration

This work shows the potential of nickel (Ni) nanoparticles (NPs) stabilized by polymers for accelerating carbon dioxide (CO₂) dissolution into saline aquifers. The catalytic characteristics of Ni NPs were investigated by monitoring changes in diameter of CO₂ microbubbles. An increase in ionic strength considerably reduces an electrostatic repulsive force in pristine Ni NPs, thereby decreasing their catalytic potential. This study shows how cationic dextran (DEX), nonionic poly(vinyl pyrrolidone) (PVP), and anionic carboxy methylcellulose (CMC) polymers, the dispersive behaviors of Ni NPs can be used to overcome the negative impact of salinity on CO₂ dissolution. The cationic polymer, DEX was less adsorbed onto NPs surfaces, thereby limiting the Ni NPs’ catalytic activity. This behavior is due to a competition for Ni NPs’ surface sites between the cation and DEX under high salinity. On the other hand, the non/anionic polymers, PVP and CMC could be relatively easily adsorbed onto anchoring sites of Ni NPs by the monovalent cation, Na⁺. Considerable dispersion of Ni NPs by an optimal concentration of the anionic polymers improved their catalytic capabilities even under unfavorable conditions for CO₂ dissolution. This study has implications for enhancing geologic sequestration into deep saline aquifers for the purposes of mitigating atmospheric CO₂ levels.

Hydrodynamic shrinkage of liquid CO2 Taylor drops in a straight microchannel

Hydrodynamic shrinkage of liquid CO2 drops in water under a Taylor flow regime is studied using a straight microchannel (length/width ~100). A general form of a mathematical model of the solvent-side mass transfer coefficient (k s) is developed first. Based on formulations of the surface area (A) and the volume (V) of a general Taylor drop in a rectangular microchannel, a specific form of k s is derived. Drop length and speed are experimentally measured at three specified positions of the straight channel, namely, immediately after drop generation (position 1), the midpoint of the channel (position 2) and the end of the channel (position 3). The reductions of drop length (L x , x  =  1, 2, 3) from position 1 to 2 and down to 3 are used to quantify the drop shrinkage. Using the specific model, k s is calculated mainly based on L x and drop flowing time (t). Results show that smaller CO2 drops produced by lower flow rate ratios ([Formula: see text]) are generally characterized by higher (nearly three times) k s and Sherwood numbers than those produced by higher [Formula: see text], which is essentially attributed to the larger effective portion of the smaller drop contributing in the mass transfer under same levels of the flowing time and the surface-to-volume ratio (~104 m-1) of all drops. Based on calculated pressure drops of the segmented flow in microchannel, the Peng-Robinson equation of state and initial pressures of drops at the T-junction in experiments, overall pressure drop (ΔP t) in the straight channel as well as the resulted drop volume change are quantified. ΔP t from position 1-3 is by average 3.175 kPa with a ~1.6% standard error, which only leads to relative drop volume changes of 0.3‰ to 0.52‰.

Multicomponent diffusion coefficients from microfluidics using Raman microspectroscopy

Diffusion is slow. Thus, diffusion experiments are intrinsically time-consuming and laborious. Additionally, the experimental effort is multiplied for multicomponent systems as the determination of multicomponent diffusion coefficients typically requires several experiments. To reduce the experimental effort, we present the first microfluidic diffusion measurement method for multicomponent liquid systems. The measurement setup combines a microfluidic chip with Raman microspectroscopy. Excellent agreement between experimental results and literature data is achieved for the binary system cyclohexane + toluene and the ternary system 1-propanol + 1-chlorobutane + heptane. The Fick diffusion coefficients are obtained from fitting a multicomponent convection-diffusion model to the mole fractions measured in experiments. Ternary diffusion coefficients can be obtained from a single experiment; high accuracy is already obtained from two experiments. Advantages of the presented measurement method are thus short measurement times, reduced sample consumption, and less experiments for the determination of a multicomponent diffusion coefficient.

Microfluidic and nanofluidic phase behaviour characterization for industrial CO2, oil and gas

Microfluidic systems that leverage unique micro-scale phenomena have been developed to provide rapid, accurate and robust analysis, predominantly for biomedical applications. These attributes, in addition to the ability to access high temperatures and pressures, have motivated recent expanded applications in phase measurements relevant to industrial CO₂, oil and gas applications. We here present a comprehensive review of this exciting new field, separating microfluidic and nanofluidic approaches. Microfluidics is practical, and provides similar phase properties analysis to established bulk methods with advantages in speed, control and sample size. Nanofluidic phase behaviour can deviate from bulk measurements, which is of particular relevance to emerging unconventional oil and gas production from nanoporous shale. In short, microfluidics offers a practical, compelling replacement of current bulk phase measurement systems, whereas nanofluidics is not practical, but uniquely provides insight into phase change phenomena at nanoscales. Challenges, trends and opportunities for phase measurements at both scales are highlighted.

Automated in Situ Measurement of Gas Solubility in Liquids with a Simple Tube-in-Tube Reactor

Data on the solubilities of gases in liquids are foundational for assessing a variety of multiphase separations and gas-liquid reactions. Taking advantage of the tube-in-tube reactor design built with semipermeable Teflon AF-2400 tubes, liquids can be rapidly saturated without direct contacting of gas and liquid. The gas solubility can be determined by performing steady-state flux balances of both the gas and liquid flowing into the reactor system. Using this type of reactor, a fully automated strategy has been developed for the rapid in situ measurement of gas solubilities in liquids. The developed strategy enables precise gas solubility measurements within 2-5 min compared with 4-5 h using conventional methods. This technique can be extended to the discrete multipoint steady-state and continuous ramped-multipoint data acquisition methods. The accuracy of this method has been validated against several gas-liquid systems, showing less than 2% deviation from known values. Finally, this strategy has been extended to measure the temperature dependence of gas solubilities in situ and to estimate the local enthalpy of dissolution across a defined temperature range.

The hydrodynamics of segmented two-phase flow in a circular tube with rapidly dissolving drops

This article discusses boundary integral simulations of dissolving drops flowing through a cylindrical tube for large aspect ratio drops. The dynamics of drop dissolution is determined by three dimensionless parameters: λ, the viscosity of the drop fluid relative to the suspending fluid; Ca, the capillary number defining the ratio of the hydrodynamic force to the interfacial tension force; and k, a dissolution constant based on the velocity of dissolution. For a single dissolving drop, the velocity in the upstream region is greater than the downstream region, and for sufficiently large k, the downstream velocity can be completely reversed, particularly at low Ca. The upstream end of the drop travels faster and experiences greater deformation than the downstream end. The film thickness, δ, between the drop and the tube wall is governed by a delicate balance between dissolution and changes in the outer fluid velocity resulting from a fixed pressure drop across the tube and mass continuity. Therefore, δ, and consequently, the drop average velocity, can increase, decrease or be relatively invariant in time. For two drops flowing in succession, while low Ca drops maintain a nearly constant separation distance during dissolution, at sufficiently large Ca, for all values of k, dissolution increases the separation distance between drops. Under these conditions, the liquid segments between two adjacent drops can no longer be considered as constant volume stirred tanks. These results will guide the choices of geometry and operating parameters that will facilitate the characterization of fast gas-liquid reactions via two-phase segmented flows.

Microfluidic technique for measuring wax appearance temperature of reservoir fluids

A microfluidic technique for measuring wax appearance temperature (WAT) of reservoir fluids is presented. The technique is based on continuous monitoring of pressure across a microchannel as wax particles are deposited and gradually clog the channel. A rapid pressure increase was observed as the temperature was systematically decreased to wax appearance temperature. The relationship between pressure change rate and sample temperature is explored as the working principle in the proposed WAT measurement technique. This technique yields results which are comparable to measurements obtained from a cross-polar microscopy technique (CPM); the current industry-standard for WAT measurement. The method is validated by systematically investigating phase transition of pure hydrocarbons, binary mixtures, and real crude oils. The new technique has two distinct advantages over the existing industry standard methods in that its experimental setup is much simpler and it can be adapted to field applications. The microchannel can be easily cleaned and reused to test different samples.

Oscillatory multiphase flow strategy for chemistry and biology

Continuous multiphase flow strategies are commonly employed for high-throughput parameter screening of physical, chemical, and biological processes as well as continuous preparation of a wide range of fine chemicals and micro/nano particles with processing times up to 10 min. The inter-dependency of mixing and residence times, and their direct correlation with reactor length have limited the adaptation of multiphase flow strategies for studies of processes with relatively long processing times (0.5-24 h). In this frontier article, we describe an oscillatory multiphase flow strategy to decouple mixing and residence times and enable investigation of longer timescale experiments than typically feasible with conventional continuous multiphase flow approaches. We review current oscillatory multiphase flow technologies, provide an overview of the advancements of this relatively new strategy in chemistry and biology, and close with a perspective on future opportunities.

Stabilization of carbon dioxide (CO2) bubbles in micrometer-diameter aqueous droplets and the formation of hollow microparticles

We report an approach to stabilize carbon dioxide (CO2) gas bubbles encapsulated in micrometer-diameter aqueous drops when water in the aqueous drops is evaporated. CO2-in-water-in-oil double emulsion drops are generated using microfluidic approaches and evaporation is conducted in the presence of sodium dodecyl sulfate (SDS), poly(vinyl alcohol) (PVA) and/or graphene oxide (GO) particles dispersed in the aqueous phase of the double emulsion drops. We examine the roles of the bubble-to-drop size ratio, PVA and GO concentration in the stabilization of CO2 bubbles upon water evaporation and show that thin-shell particles with encapsulated CO2 bubbles can be obtained under optimized conditions. The developed approach offers a new strategy to study CO2 dissolution and stability on the microscale and the synthesis of novel gas-core microparticles.

A model-based technique for the determination of interfacial fluxes in gas–liquid flows in capillaries

A non-invasive method to quantify interfacial mass transfer in gas–liquid flow is presented.

Calculating the volume of elongated bubbles and droplets in microchannels from a top view image

We present a theoretical model to calculate the volume of bubbles and droplets in segmented microflows from given dimensions of the microchannel and measured lengths of bubbles and droplets.

Dissolution without disappearing: multicomponent gas exchange for CO2 bubbles in a microfluidic channel

We studied the dissolution dynamics of CO2 gas bubbles in a microfluidic channel, both experimentally and theoretically. In the experiments, spherical CO2 bubbles in a flow of a solution of sodium dodecyl sulfate (SDS) first shrink rapidly before attaining an equilibrium size. In the rapid dissolution regime, the time to obtain a new equilibrium is 30 ms regardless of SDS concentration, and the equilibrium radius achieved varies with the SDS concentration. To explain the lack of complete dissolution, we interpret the results by considering the effects of other gases (O2, N2) that are already dissolved in the aqueous phase, and we develop a multicomponent dissolution model that includes the effect of surface tension and the liquid pressure drop along the channel. Solutions of the model for a stationary gas bubble show good agreement with the experimental results, which lead to our conclusion that the equilibrium regime is obtained by gas exchange between the bubbles and liquid phase. Also, our observations from experiments and model calculations suggest that SDS molecules on the gas-liquid interface form a diffusion barrier, which controls the dissolution behaviour and the eventual equilibrium radius of the bubble.

Shaken, and stirred: oscillatory segmented flow for controlled size-evolution of colloidal nanomaterials

We introduce oscillatory segmented flow as a compact microfluidic format that accommodates slow chemical reactions for the solution-phase processing of colloidal nanomaterials. The strategy allows the reaction progress to be monitored at a dynamic range of up to 80 decibels (i.e., residence times of up to one day, equivalent to 720-14,400 times the mixing time) from only one sensing location. A train of alternating gas bubbles and liquid reaction compartments (segmented flow) was initially formed, stopped and then subjected to a consistent back-and-forth motion. The oscillatory segmented flow was obtained by periodically manipulating the pressures at the device inlet and outlet via square wave signals generated by non-wetted solenoid valves. The readily implementable format significantly reduced the device footprint as compared with continuous segmented flow. We investigated mixing enhancement for varying liquid segment lengths, oscillation amplitudes and oscillation frequencies. The etching of gold nanorods served as a case study to illustrate the utility of the approach for dynamic characterization and precise control of colloidal nanomaterial size and shape for 5 h. Oscillatory segmented flows will be beneficial for a broad range of lab-on-a-chip applications that require long processing times.

Microfluidic studies of carbon dioxide

Carbon dioxide (CO2) sequestration, storage and recycling will greatly benefit from comprehensive studies of physical and chemical gas-liquid processes involving CO2. Over the past five years, microfluidics emerged as a valuable tool in CO2-related research, due to superior mass and heat transfer, reduced axial dispersion, well-defined gas-liquid interfacial areas and the ability to vary reagent concentrations in a high-throughput manner. This Minireview highlights recent progress in microfluidic studies of CO2-related processes, including dissolution of CO2 in physical solvents, CO2 reactions, the utilization of CO2 in materials science, and the use of supercritical CO2 as a "green" solvent.

Initial microfluidic dissolution regime of CO2 bubbles in viscous oils

We examine the initial dynamical behavior of dissolving microbubbles composed of carbon dioxide gas in highly viscous silicone oils over a range of flow rates and pressure conditions. Microfluidic periodic trains of CO(2) bubbles are used to probe the interrelation between bubble dissolution and high-viscosity multiphase flows in microgeometries. We investigate bubble morphology from low to large capillary numbers and calculate the effective mass diffusion flux across the interface by tracking and monitoring individual bubbles during shrinkage. The initial flux is characterized using a dissolution coefficient that reveals the influence of the oil molecular weight on the dissolution process. Our findings show the possibility to control and exploit the interplay between capillary and mass transfer phenomena with highly viscous fluids in small-scale systems.

Laminated thin-film Teflon chips for petrochemical applications

We present Teflon-based microfluidic chips fabricated by laminating multiple layers of laser-cut Teflon film. In addition to being solvent-resistant, these chips enable simple multilayer fabrication, have uniform rectangular cross-section and are sufficiently thin to (1) reduce cost, (2) enable rapid temperature control, and (3) provide optical transparency. The chips can be fabricated without a cleanroom from start to finish in less than 2 h. We demonstrate the potential of this approach by measuring the displacement of an oil solution by carbon dioxide in a nine-layer thin-film Teflon chip modelling porous media. Optical transparency through the 9-layers enables the determination of an oil recovery rate. We also demonstrate a thin-film chip measurement of the viscosity of heavy oil/toluene mixtures.