Scaled-out multilayer gas-liquid microreactor with integrated velocimetry sensors

We describe the design and flow distribution of a scaled-out gas-liquid silicon-based microreactor that consists of three vertically stacked reaction layers each containing 20 reaction channels. The reaction channels are operated in parallel from single feeds of gas and liquid with a liquid throughput of 80 mL/h. Gas and liquid are introduced to the device through single inlet ports, flow vertically to the reaction layers, and are controllably distributed to the horizontal reaction channels through gas and liquid auxiliary channels that present pressure drops significantly larger than that across the reaction channels. The product mixture flows out of the device through a single outlet port. Flow visualization by pulsed-laser fluorescence imaging reveals that the flow regime is uniform across the top layer. By integrating waveguided optical multiphase flow sensors, slug-flow properties are measured across the reaction channels on the top and middle layers; comparable slug frequencies and slug velocities are obtained.