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Process Analysis, Design, and Intensification in Microfluidics and

Chemical Engineering

Book · January 2019

DOI: 10.4018/978-1-5225-7138-4

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Harrson S. Santana Joao Lameu Silva Junior

University of Campinas University of Campinas
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Osvaldir Pereira Taranto

University of Campinas
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Preface

Defined as the science and technology applied in structures of dimensions ranging

from tens to hundreds of micrometers, the Microfluidics represents a great potential
for chemical processes design, development and optimization. On the other hand, the
Chemical Engineering comprehends skills of project design of industrial processes,
usually resulting in large chemical plants as we already know. Therefore, what is
common between these two distinct process scales?
The microfluidic devices provide advantages regarding the traditional macroscopic
process. The main advantages of microfluidic devices are: low amount of reactants
and samples, short reaction times, low fabrication costs, high surface area-to-volume
ratio (about 20000 m2 m-3 against 1000 m2 m-3 of conventional reactors) and high
rates of heat and mass transfer.
In addition, the microscale processes can achieve higher production rates
applying the numbering-up concept. This concept consists in a modular scale-up
design, using multiple units of the optimized microdevice operating continuously
in parallel, resulting in a higher volumetric rate capacity and flexible operation
and maintenance. The numbering-up concept provides a smart, effective and faster
time-to-market result, allowing the development of new products and processes.
This is fundamental to increase the product variety, an essential key for the modern
industries to overcome the challenges outcome from the volatile globalized markets.
In this context, the present book will approach the relationship of these two
technology areas and how they influence the industrial process and society. The
purpose of this book is to be used as a source of information and references for beginners
to expert readers in Microfluidics and its application in Chemical Engineering.
Each chapter, written by specialists in their occupation fields, provides concepts
and specific information, updating the literature and providing advice and insights
about the topics. The main idea of the book is to provide an approach beyond the
Microfluidic or Chemical Engineering fields, building new pathways and means
to develop processes and products in industrial and academic areas, contributing to
the Microfluidics progress, and even, looking forward that the Microfluidics could
be integrate regular subject matter in Chemical Engineering courses.
Preface

The target audience of this book is consisted by professionals and researchers

working in engineering markets, Microfluidics and Chemical Engineering companies,
and Universities and Institutes of Technology.

WHAT IS MICROFLUIDICS?

Microfluidics is commonly defined as the science and the technology of systems

handling low amount of fluids using structures with dimensions ranging from tens
to hundreds of micrometers - the microdevices (Whitesides, 2006).
Another definition was made by Nguyen and Wereley (2006): Microfluidics is
the science and the engineering of systems which the fluid behavior is distinct from
the conventional flow mostly due to the reduced length scale of the system. This
definition is more comprehensive than the previous, once it provides an important
insight about the fluid flow in the microdevices. In the conventional macroscale, the
fluid flow behavior is described by the classical continuum mechanics developed
since the age of Isaac Newton (1643-1747). In contrast, the definition of Microfluidics
by Nguyen and Wereley (2006) could lead to the erroneous idea that the classical
fluid mechanics could not predict correctly the flow behavior in microdevices. This
assumption must be treated carefully, since depending on the case, the classical
fluid mechanics is capable to predict the microscale fluid flow properly (Santana,
Silva Jr., & Taranto, 2015).
The aforementioned definitions clarified the main aspects of Microfluidics. From
the interpretation by Whitesides (2006), the Microfluidics handles low amount
of fluids in microscale. Nguyen and Wereley (2006) augmented the definition
introducing the fluid flow theory. Now, we will expand the Microfluidics concept.
Lo (2013) defined Microfluidics as the science and the technology about the fluid
flow behavior, controlled manipulation of fluids and design of devices and systems
capable to execute reliably tasks in microchannels with typical dimensions ranging
from tens to hundreds of micrometers. We particularly appreciate this definition,
once it combines the previous interpretation with the microdevice design, an essential
feature in microscale, mostly for chemical processes, in which a scale down (i.e.,
the reduction of the scale) is not an easy task, since each scale possesses their own
transport phenomena characteristics. Accordingly, at the beginning of chemical
process development in microscale, the microdevices are designed considering the
Microfluidics characteristics.
The tools developed in Microfluidics allowed the obtaining of advantages
regarding macroscale methods. The achievement of high conversion and selectivity

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associated with short residence times enables the advancement of chemical processes,
resulting in the creation of new products and production methods in a faster way for
the industry and has been increasing the interest of professionals in the most diverse
knowledge fields, including the Chemical and Processing Engineering.

WHAT IS THE CHEMICAL ENGINEERING?

According to the European Federation of Chemical Engineering (EFCE), the

Chemical Engineering covers conception, development, design, improvement and
application of processes and products, including also, economic analysis, design,
manufacturing, operation, control and management of industrial processing plants
jointly with research and educational fields about these subjects (Gillet, 2001).
This definition highlights the broad field of Chemical Engineering, involving not
only the professionals employed in daily functions inside the industries (the Process
Engineers), but also, professionals involved with the conception and implementation
of industrial plant projects and professional engineers engaged in Universities and
researches and technology institutes. From this viewpoint, we can state that the
Chemical Engineer manages the laboratory scale chemistry to industrial scale process,
allowing an effective large scale production of the products used daily by all of us.
Another interesting description about the Chemical Engineer is provided by the
American Institute of Chemical Engineers (AIChE): “The Chemical Engineering is
the career that the knowledge of mathematics, chemistry and other natural sciences,
acquired by study, experience and practice is applied in order to develop economic
means for the use of materials and energy resources in the benefit of mankind”
(AIChE, 2016).
Based on the aforementioned knowledge, the Chemical Engineer can act and
collaborate in diversified areas from the large scale production of commodities to
research institutes and industries including pharmaceutical, electronics and robotics.

PROCESS INTENSIFICATION: THE LINK BETWEEN

CHEMICAL ENGINEERING AND MICROFLUIDICS

There is no general and shared definition about Process Intensification (PI). Along
the years, some authors proposed distinct interpretations, aiding the conceptualization
of PI.

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The first definition was stated by Ramshaw (1995) at the 1st International
Conference on Process Intensification in the Chemical Industry. Ramshaw (1995)
defined PI as the strategy for size reduction of a chemical plant in order to achieve
a determined production goal. The size reduction could be performed by the size
reduction of individual process parts or by the decrease in the number of involved
unities. By the time, Ramshaw (1995) addressed volume reductions about orders
of 100 or more. These orders of magnitude appeared very challenging, once the
miniaturization concepts were still not widespread in Chemical Engineering, causing
the Chemical Engineers to think over the size reduction to achieve the process
intensification.
Stankiewicz and Moulijn (2000) stated that a volume decrease by the order of
two already can be classified as PI. They expanded the PI definition exclusively
over the reduction of plant size or equipment size. According to Stankiewicz and
Moulijn (2000), the PI consists in the development of new equipment and techniques
in order to promote significant enhancement in manufacturing and processing,
considerably decreasing the ratio between equipment size/production capacity,
the energy consumption and the waste generation, and consequently resulting in
sustainable and economic technologies.
In brief, any development in the Chemical Engineering leading to a technology
substantially small, clear and energetically efficient is a Process Intensification,
according to the previous definitions.
Lutze et al. (2010) extended the PI definitions. They declared that the PI can be
achieved by addition or reinforcement of the process phenomena by the integration
of operations and functions, or alternatively, by the oriented reinforcement of the
phenomena in a specific operation, enhancing some attributes as the increment of
capacity, productivity, flexibility and safety and the decrease of energy consumption
and waste generation.
In this context, Microfluidics appears as an interesting tool aiming for the Process
Intensification in the most diverse Chemical Engineering process fields.

BOOK ORGANIZATION

The main idea of the book is to provide an approach beyond the Microfluidics or
Chemical Engineering fields, building new pathways and means to develop processes
and products in industrial and academic areas. The book contemplates 10 chapters.
The description of each one of these chapters is provided following.
Chapter 1 evaluates the hydrodynamics and mass transfer of Taylor flows
in microchannels of both Gas-Liquid and Liquid-Liquid systems. The classical
theoretical approach with some simplifying assumptions was performed and the

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results were confirmed by comparison with experimental data. It was shown that
the main parameters of two-phase Taylor flows could be quite precisely described
theoretically: mean bubble/droplet velocity, liquid film thickness, real gas holdup,
pressure drop. Moreover, it was discussed the peculiarities of Liquid-Liquid flows
compared to Gas-Liquid Taylor flows in capillaries, as well, the wettability effect on
hydrodynamics and mass transfer intensification of Gas-Liquid and Liquid-Liquid
Taylor flow in micro channels.
Chapter 2 presents an overview about the development and applications of
Computational Fluid Dynamics (CFD) on Chemical Engineering and Microfluidics.
The fundamental points of the CFD, listing the advantages and precautions of this
numerical technique were provided. The fundamental transport equations – total
mass (continuity), momentum, energy and species mass balances – and the usual
boundary conditions used in CFD were explained. The main approaches used
in multicomponent single-phase flows, single-phase flow in porous media and
multiphase flows in microscale were detailed, as well, the numerical mesh types
and its quality parameters. A brief introduction of Finite Volume Method (FVM),
used by most of the available CFD codes was also performed, describing the main
numerical solution features.
Chapter 3 investigates the mixing efficiency of a novel micromixing unit, a
passive micromixer based on blowing and vortex shedding mechanisms, which are
used to promote an irregular flow downstream. The main goal of the chapter is the
determination of the governing parameters that provide the highest mixing efficiency
at the exit of the channel and the required input power to make both fluids to flow and
mix. The system under study consisted in a two-dimensional straight microchannel
with a square pillar centered across the channel. The main fluid flows through the
microchannel from the main inlet to the outlet, while the second fluid is injected
through the pillar forming two small jets at the upstream corners.
Chapter 4 presents a method for deriving an analytical solution to the momentum
balance of a liquid in a capillary tube. The authors introduced an extended solution
of the well-established Lucas-Washburn equation. The extended solution included
the entrapped gas pressure term and excluded the gravity term. Furthermore, the
governing equation is non-dimensionalized and a non-dimensional viscous term
was found. Numerical approach was also included in this study where commercial
CFD software was used for solving the problem numerically. Comparison between
analytical and numerical solutions is also shown.
In Chapter 5, the control of immiscible liquid-liquid two-phase flow has been
discussed and tested thoroughly. Oleic acid-water flow in microchannels of 240 μm
in width and 8 μm in height was studied as a microfluidic demo system for building
blocks of future multifunctional integrated System-on-Chip (SoC) or System-in-
a-Package (SiP).

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Preface

The main goal of Chapter 6 was to demonstrate experimentally and numerically

the capability of the micro-heat exchanger use in the continuous process of ethanol
excess recovery from the biodiesel. The influence of flow rate, ethanol/biodiesel
molar ratio and temperature on the ethanol evaporation performance was evaluated
in experimental and numerical runs.
Chapter 7 provides a guide for microfluidic devices development and optimization
focused on chemical analysis applications, which includes medicine, biology,
chemistry and environmental monitoring, showing high-level performance associated
with a specific functionality, exploiting Low Temperature Co-fired Ceramic (LTCC)
technology as prototype material used for microfluidic devices fabrication.
In Chapter 8 the topic of smart sensors with emphasis on temperature sensing,
one of the most important variable in Microfluidics and in Chemical Engineering,
is introduced. This chapter first surveys traditional analog temperature sensors to
provide a strong motivation for the need to adopt better and smarter techniques that
mainly rely on digital technology, e.g. Complementary-Metal-Oxide-Semiconductor
(CMOS) designs. Different interfacing techniques that do not need Analog-to-
Digital-Conversion (ADCs) are introduced. Different applications were explored
including automotive accessories, weather forecast, health care, industrial processing,
firefighting, and consumer electronics. Both wired and wireless technologies,
including the Internet-of-Things (IoT), were investigated as means for transmitting
the sensed data for further processing and data logging.
Chapter 9 presents a numerical investigation of heat and mass transfer
characteristics during the evaporation of liquid films in vertical tube. A two-
phase model was developed to simulate laminar film evaporation into laminar gas
flow. The liquid film evaporation was evaluated under adiabatic and heated wall
conditions for both pure and binary liquid film. The obtained results concerns two
industrial processes. The first part of the chapter was devoted to the analysis of the
thermal protection of vertical channel wall, while the second part was devoted to
the desalination process by falling liquid film.
Chapter 10 presents a validation of the selection criteria for the construction
of granulation and drying equipment. Based on the simulation results, various
constructions of the apparatus components are offered. The computer simulation
allowed offering an algorithm of the optimization calculations of the granulation
and drying equipment. New constructive solutions to perform the granulation and
the drying processes in the devices with a directional fluidized bed are offered.
The editors are grateful for the support and the patience of our families during
this project. We could never have completed this journey without you. The editors
thank God for having you as family.

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 Preface

Moreover, the editors would like to immensely thank all the authors that
contributed with theirs researches and make possible the accomplishment of this
project. The editors also are grateful to the reviewers that contributed to the quality
of this book. Finally, the authors acknowledge the book development editor and
the IGI Global team.

Harrson Silva Santana

University of Campinas, Brazil

João Lameu da Silva Júnior

Federal Institute of Education, Science, and Technology of South of Minas
Gerais, Brazil

Osvaldir Pereira Taranto

University of Campinas, Brazil

REFERENCES

American Institute of Chemical Engineers (AIChE) Constitution. (2016). Available

in: https://www.aiche.org/about/governance/constitution
Gillet, J. E. (2001). Chemical Engineering Education in the Next Century.
Chemical Engineering & Technology, 24(6), 561–570. doi:10.1002/1521-
4125(200106)24:6<561::AID-CEAT561>3.0.CO;2-X
Lo, R. C. (2013). Application of Microfluidics in Chemical Engineering. Chemical
Engineering & Process Techniques, 1, 1002.
Lutze, P., Gani, R., & Woodley, J. M. (2010). Process intensification: A perspective
on process synthesis. Chemical Engineering and Processing: Process Intensification.,
49(6), 547–558. doi:10.1016/j.cep.2010.05.002
Nguyen, N.-T., & Wereley, S. T. (2006). Fundamentals and applications of
microfluidics. Boston: Publishing House Artech House.
Ramshaw, C. (1995). The Incentive for Process Intensification. International
Conference on Process Intensification for the Chemical Industry, London, UK.

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Santana, H. S., Silva, J. L. Jr, & Taranto, O. P. (2015). Numerical simulations of

biodiesel synthesis in microchannels with circular obstructions. Chemical Engineering
and Processing: Process Intensification, 98, 137–146. doi:10.1016/j.cep.2015.10.011
Stankiewicz, A. I., & Moulijn, J. A. (2000). Process Intensification: Transforming
Chemical Engineering. Chemical Engineering Progress, 96(1), 22–33.
Whitesides, G. M. (2006). The origins and the future of microfluidics. Nature,
442(7101), 368–373. doi:10.1038/nature05058 PMID:16871203

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