Turbulencja w mikrokanale i jej wpływ na proces emulsyfikacji
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1 Polish Academy of Sciences Institute of Fundamental Technological Research Turbulencja w mikrokanale i jej wpływ na proces emulsyfikacji S. Błoński, P.Korczyk, T.A. Kowalewski
2 PRESENTATION OUTLINE 0 Introduction I II Flow structure investigation in the vicinity of the processing element by Particle Image Velocimetry Visualization of droplets break-up process and emulsion flow in the vicinity of the processing element III IV Numerical simulation of the flow through the planar emulsifier Summary and conclusions
3 Structuring nano-particles at the interface Oil Oil Water Oil Water The emulsion with thin layers of third substance at the surface between oil and water The structure of nanomaterial after removing water and oil
4 MAIN IDEA 1. Well defined turbulent flow in emulsificator with micro-channel 2. Emulsification of oil in water to obtain uniform in size micro-emulsion in turbulent flow 3. Drop nano-particle interaction 4. Composite layer formation at the interface 5. Removal of both fluids to achieve new material
5 Production of droplets emulsion in turbulent flow Experimental cell with optical access for flow investigation inside emulsifier High speed imaging and velocity measurements gap: 0.4mm x 15mm, flow rate: up to dm 3 /s
6 Primary aim of the experiment Instantaneous velocity and vorticity by micro-piv technique Flow structure Turbulence structure Shear stress field Drops break-up Validation of the CFD models Optimisation of the drops size and shape Optimisation of the emulsifier geometry
7 EXPERIMENTAL METHODS Full Field Measurements of velocity and drops shape: Epifluorescent microscope Nikon ECLIPSE E-50i PIV Camera PCO SensiCam (resolution 1280x1024) Double Pulse Laser Nd-YAG - SoloPIV NewWave (30mJ per pulse) High Speed CMOS Camera PCO 1200.hs (up to fps; 636fps in full resolution 1280x1024) Laser CW Ar 5W Fluorescent micro- and nanoparticles (30nm 7 µm) Other equipment: Optical system for forming and redirection of laser light (lenses, mirrors, etc.) Pressure system (gas cylinder with argon, pressure regulator and conduits, pressure sensor) Two precision syringe pumps
8 EXPERIMENTAL SETUP Fluorescent particles under microscope Schematic set-up for micropiv
9 EXPERIMENTAL SETUP focus plane micro-channel
10 EXPERIMENTAL SETUP
11 EXPERIMENTAL SETUP
12 GEOMETRY OF THE MODELS Geometry G1 non-transparent processing element size of the gap: 1 x 0.4 x 15 mm Geometry G2 transparent processing element size of the gap: 2 x 0.4 x 15 mm Geometry G3 for jet breakup observation channel size: 30 x 8 x 10 mm needle diameter: 0.5 mm
13 OUR QUESTIONS TO ANSWER Production of droplets emulsion in turbulent flow Is flow turbulent, what is the critical Re number?
14 EXPERIMENTAL INVESTIGATION zone 1 zone 2 zone 3 zone 1: 2.5 x 15 mm zone 2: 0.4 x 15 mm zone 3: 7.5 x 15 mm Processing element
15 EXPERIMENTAL RESULTS Laminar turbulent transition flow direction processing element Laminar flow v = ~ 0.1 m/s Re = ~ 250 Transition flow v = ~ 0.4 m/s Re = ~ 1000
16 Part I Micro-PIV RESULTS
17 Micro-PIV RESULTS Processing element Fluorescent particles 1.4 mm
18 Micro-PIV RESULTS Micro-PIV measurements was done for flow rate Q 2 =0.204dm 3 /s using geometry G1 (non-transparent proc.el.) Schematic view of the emulsifier with coordinates system and positions of selected profiles Profile P1 X [mm] Y [mm] -0.2 Z [mm] 0 Used tracers: fluorescent particles, 2µm in diameter P2 P3 P4 P Microscope lens: 10x/NA0.3/WD17.30mm Images width corresponds to 0.7mm
19 Micro-PIV RESULTS Velocity field Position P1 flow rate = dm 3 /s
20 Micro-PIV RESULTS Velocity field Position P2 flow rate = dm 3 /s
21 Micro-PIV RESULTS Instantaneous velocity field and fluctuations field velocity field fluctuations field Position: 1mm behind processing element, 0.3mm below glass wall flow rate = dm 3 /s
22 Micro-PIV RESULTS Instantaneous velocity field and fluctuations field velocity field fluctuations field Position: 3mm behind processing element, 0.3mm below glass wall flow rate = dm 3 /s
23 Micro-PIV RESULTS Instantaneous velocity field and fluctuations field velocity field fluctuations field Position: 8mm behind processing element, 0.3mm below glass wall flow rate = dm 3 /s
24 Micro-PIV RESULTS P3, P4 and P5 profiles of the X-Velocity and mean turbulent kinetic energy (xz) V x =<V x >+V x V z =<V z >+V z tke xz =<V x2 >+<V z2 >
25 Part II Drops break-up visualization RESULTS
26 Used geometry: G2 (emulsifier with transparent element) Used materials: Drops break-up visualization 1. de-ionized water + 10mM NaCl + S50 silicone oil (0.01) 2. de-ionized water + 10mM NaCl + S50 silicone oil (0.01) + 1%wt SDS 3. de-ionized water + 10mM NaCl + S500 silicone oil (0.01) + 1%wt SDS Flow rate: Q 2 = dm 3 /s Used microscope lens: 10x/NA0.3/WD17.30mm images width corresponds to 432µm Interval time between images: 1µs or 5 µs
27 Position Velocity V d [m/s] Comments water + 10mM NaCl + S50 oil Gap 12.1 lack of oil-drops deformations x = 0; y = lack of oil-drops deformations x = 2; y = oil-drops deformations occurs x = 5; y = lack of oil-drops deformations water + 10mM NaCl + S50 oil + 1%wt SDS Gap 12.3 lack of oil-drops deformations x = 2; y = lack of oil-drops deformations x = 2; y = lack of oil-drops deformations x = 2; y = oil-drops deformations occurs x = 2; y = oil-drops deformations occurs water + 10mM NaCl + S500 oil + 1%wt SDS Gap 12.6 lack of oil-drops deformations x = 0; y = lack of oil-drops deformations x = 2; y = oil-drops deformations occurs
28 Drops break-up visualization results drops in the gap v d =12.1m/s drops just behind processing element v d =10.8m/s drops 5mm behind processing element v d =6.7m/s Non-deformed drops of S50 silicone oil Mixture without surfactant Image width corresponds to 432 µm
29 Drops break-up visualization results Deformed drops of S50 silicone oil 2mm behind processing element Mixture without surfactant Drops velocity: v d =4.5m/s Image width corresponds to 432 µm
30 Drops break-up visualization results drops in the gap v d =12.3 m/s drops 2mm behind processing element just below wall v d =10.3 m/s drops 2mm behind processing element 0.1mm below wall v d =10.9 m/s Non-deformed drops of S50 silicone oil Mixture with 1%wt SDS surfactant Image width corresponds to 432 µm
31 Drops break-up visualization results Deformed drops of S50 silicone oil Mixture with 1%wt SDS surfactant Image width corresponds to 432 µm drops 2mm behind processing element and 0.2mm below wall v d =9.7 m/s drops 2mm behind processing element and 0.4mm below wall v d =4.7 m/s
32 Drops break-up visualization results drops in the gap v d =12.6 m/s drops just behind processing element 0.2mm below wall v d =11.3 m/s Non-deformed drops of S500 silicone oil Mixture with 1%wt SDS surfactant Image width corresponds to 432 µm
33 Drops break-up visualization results drops 2mm behind processing element And 0.2mm below wall v d =10.5 m/s Deformed drops of S500 silicone oil Mixture with 1%wt SDS surfactant Image width corresponds to 432 µm
34 Drops break-up visualization results S50 silicone oil + 1%wt SDS S500 silicone oil + 1%wt SDS mean drops size: 10.1 µm mean drops size: 20.7 µm Motionless emulsion observer under microscope Image width corresponds to 432 µm
35 Part III Numerical simulation RESULTS
36 NUMERICAL SIMULATION Numerical simulation was done using two geometries: G1 one quarter of the model with non-transparent processing element G1v full 3D geometry of the model with non-transparent processing element G2 one quarter of the model with transparent processing element G1 G2
37 NUMERICAL SIMULATION CFD Modelling Using Fluent 6.2 Numerical simulation was done in following steps: 1. 3D unsteady laminar flow 2. 3D steady flow, turbulence model: k-ε with Standard Wall Function 3. 3D steady flow, turbulence model: k-ε with Enhanced Wall Treatment 4. + grid adaptation based on the gradient of velocity magnitude 5. + grid adaptation based on the Y plus value
38 NUMERICAL SIMULATION CFD Modelling Using Fluent 6.2 Mesh in the vicinity of the processing element for Geometry G1 Geometry G2 Generated mesh Mesh size: cells, faces, nodes
39 NUMERICAL SIMULATION Laminar unsteady simulations was done using: Used package and version Flow type Flowed medium Mass flow-rate Inlet Outlet Discretization Scheme Time Step Size Geometry and grid Fluent , double precision, segregated three-dimensional, laminar, unsteady, incompressible water, constant density ρ= kg/m 3 and viscosity µ= kg/ms kg/s or kg/s mass-flow inlet pressure outlet Pressure: standard Momentum: Second Order Upwind 1e -7 s - one quarter of the model geometry (G1); cells - whole model geometry (G1v); cells
40 NUMERICAL SIMULATION Contours of velocity magnitude Geometry G1 non-transparent processing element Laminar unsteady flow, Q 2 = dm 3 /s time step t = s
41 NUMERICAL SIMULATION Contours of velocity magnitude Geometry G2 transparent processing element Laminar unsteady flow, Q 2 = dm 3 /s time step t = s
42 NUMERICAL SIMULATION Contours of averaged velocity magnitude Geometry G1v non-transparent processing element Laminar unsteady flow, Q 2 = dm 3 /s time step t = s
43 NUMERICAL SIMULATION Contours of averaged velocity magnitude Geometry G1v non-transparent processing element Laminar unsteady flow, Q 2 = dm 3 /s time step t = s
44 NUMERICAL SIMULATION Contours of mean square value of the velocity fluctuations Geometry G1v non-transparent processing element xz 2 x 2 z tke = V + V Laminar unsteady flow, Q 2 = dm 3 /s time step t = s
45 Final simulations was done for geometry G1 and G2 using: Used package and version Flow type Viscous Mass flow-rate Inlet Outlet Grid Adaptation Fluent , double precision, segregated three-dimensional, steady, incompressible standard k ε turbulence model with Enhanced Wall Treatment kg/s (one quarter of Q=0.204 kg/s) mass-flow inlet turbulence intensity 12.1% hydraulic diameter pressure outlet turbulence intensity 12.1% hydraulic diameter dynamic adaptation based on velocity magnitude gradient: refine threshold , interval: 20 iterations Y plus : allowed value 1 2
46 NUMERICAL SIMULATION Velocity vectors in the vicinity of the processing element k-ε model + Enhanced Wall Treatment, Q 2 = dm 3 /s Geometry G1 Geometry G2 [m/s]
47 NUMERICAL SIMULATION Contours of velocity magnitude k-ε model + Enhanced Wall Treatment, Q 2 = dm 3 /s Geometry G1 Geometry G2 [m/s]
48 NUMERICAL SIMULATION Contours of velocity magnitude selected cross-sections k-ε model + Enhanced Wall Treatment, Q 2 = dm 3 /s Geometry G1 Geometry G2 [m/s]
49 NUMERICAL SIMULATION Contours of velocity x-component k-ε model + Enhanced Wall Treatment, Q 2 = dm 3 /s Geometry G1 Geometry G2 [m/s]
50 NUMERICAL SIMULATION Contours of turbulent kinetic energy k-ε model + Enhanced Wall Treatment, Q 2 = dm 3 /s Geometry G1 Geometry G2 [m 2 /s 2 ]
51 NUMERICAL SIMULATION Horizontal profile (P01) of the averaged Turbulent Dissipation Rate Epsilon through the gap k-ε model + Enhanced Wall Treatment, Q 2 = dm 3 /s k-ε model + Enhanced Wall Treatment, geometryg1; Q 2 = dm 3 /s g1ke non-transparent g2ke transparent processing element Epsilon averaged over whole gap: ε ε avg 5 2 g1 ke = m / 3 s avg 5 2 g 2 ke = m / 2 s 3 3
52 NUMERICAL SIMULATION Vertical profiles of Turbulent Dissipation Rate k-ε model + Enhanced Wall Treatment, Q 2 = dm 3 /s 1mm (P3) 3mm (P4) 8mm (P5) behind processing element g1ke non-transparent processing element g2ke transparent processing element
53 NUMERICAL SIMULATION Vertical profiles of Turbulent Kinetic Energy k-ε model + Enhanced Wall Treatment, Q 2 = dm 3 /s 1mm (P3) 3mm (P4) 8mm (P5) behind processing element g1ke non-transparent processing element g2ke transparent processing element
54 NUMERICAL vs. EXPERIMENTAL RESULTS Comparison of the numerical and experimental x-velocity profiles: 1mm (P3) 3mm (P4) 8mm (P5) behind processing element Fluent: k-ε model + Enhanced Wall Treatment, Q 2 = dm 3 /s, geometry G1
55 THEORETICAL ESTIMATION OF DROPS SIZE Kolmogorov-Hinze theory for turbulent flows and small differences of the fluids viscosity d = ρ c σ ε 2 5 Davis theory for turbulent flows and significant differences of the fluids viscosity d = ρ K σ + µ 2 d c ε ( ε d ) max Where: d drops diameter, σ interfacial tension ρ c medium density, µ d drops viscosity, ε - turbulent dissipation rate, K constant (K=0.748)
56 DROPS SIZE ESTIMATION Estimated dependence between Turbulent Dissipation Rate Epsilon and oil-drops diameter Estimation for two silicone oils: S50 oil: S500 oil: S µ 50 d = 50mPas S µ d 500mPas 500 = Dispersing medium properties: ρ c = 998 kg/m 3 σ=5.5 mn/m which corresponds to properties of de-ionized water with 1%wt SDS
57 DROPS SIZE ESTIMATION Results of the oil drops diameter estimation Hinze model both oils [µm] Davis model oil S50 [µm] Davis model oil S500 [µm] max. epsilon value in gap ε max = m 2 /s avg. epsilon value in gap ε avg = m 2 /s Experiment: mean oil-drops size: 10.1 µm for S50 oil 20.7 µm for S500 oil
58 CONCLUSIONS Almost uniform velocity flow field in the gap region - turbulence is still not fully developed Transition from laminar to turbulent flow regime occurs probably behind the processing element (strong recirculation zone, fluctuations of the velocity, asymmetry of the flow) Numerical modelling can be applied for predicting conditions for oil-droplets break-up in a shear flow Turbulent-flow drop break-up model (Hinze) appears to work well Validation of the numerical models of turbulent flow in micro-channel using µpiv is possible but difficult due to: - low particle concentration - short measurement time at high flow rates
59 ACKNOWLEDGMENTS This investigation was conducted in the framework of EMMA project, supported by Austrian Ministry of Science and Education contract no.: GZ /1-VI/6a/2003 CONEX
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