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In this paper, we present the results of a systematic numerical study of the flow and mixing modes of fluids in micromixers of various configurations, in particular, an analysis of passive micromixers, the most widely used in practice, as well as the main methods to intensify mixing. The advantages of microstructure reactors can significantly reduce reaction times and increase productivity compared to traditional bulk reactors. Four different geometries of micromixers, including the straight T-shaped microchannel, were considered. The effect of the geometrical patterns of micromixers, as well as of the Reynolds number on flow regimes and mixing efficiency were analyzed. The Reynolds number varied from 1 to 300. Unlike other studies, the efficiency of the considered mixers was for the first time compared with the cost of pressure loss during pumping. As a result, the efficiency of the most optimal micromixer in terms of hydraulic mixing and the optimal operation ranges were determined. It was shown that the maximum normalized mixing efficiency in the entire range of Re numbers was noted for mixer, in which a vortex-based intensification of mixing occurs due to the flow swirling in cylindrical chambers. This mixer allows mixing the fluids 600 times more efficiently than a straight T-mixer, while all other conditions being equal.

Analysis of Hydraulic Mixing Efficiency in Widespread Models of Micromixers