Performance Evaluation and Scale-Up Behavior of an Engineered In-Line Mixer for 3D Printing

We present a design strategy of in-line mixers for 3D printing and an evaluation protocol that comprehensively characterizes the performance of hydrodynamics, reagent mixing, heat exchange, and reaction behavior. For demonstration, we engineer a split-and-recombination (SAR)-type mixer with stationary oblique baffles which effectively blends two streams in the laminar flow regime, particularly at low and intermediate Reynolds number. The 3D printing technique that opens up new design freedom and enables rapid model evaluation and optimization is low-cost and easy to implement in the laboratory. Simulations of hydrodynamics, heat transfer, and mass transfer including reactions form a solid foundation of mixer evaluation. Experimental results of the Villermaux-Dushman reaction and pressure measurement validate the numerical model and illustrate the difference between the designed SAR mixer and a conventional T-mixer. In addition, superior mixing performance of the SAR mixer is confirmed by the mixing intensity simulations, as compared with T-/helical mixers. The presented model yields new insights into the scalability and applicability of the 3D-printed integrated reactor.

Automated summary

This study presents a design strategy for in-line mixers for 3D printing and an evaluation protocol to comprehensively characterize their performance. A split-and-recombination type mixer with stationary oblique baffles is engineered for demonstration, showing effective blending at low to intermediate Reynolds numbers. The low-cost and easy implementation of 3D printing allows for rapid model evaluation and optimization in the laboratory setting.