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Slug flow within microchannels exhibits significant potential for process intensification, owing to its distinctive flow mechanism and high controllability. However, the gas-liquid flow pattern in microchannels is regulated by operating conditions, microchannel geometry, and fluid properties, which have a significant impact on the mass transfer process. In this regard, a numerical investigation was conducted employing the Volume of Fluid model within a 0.8 mm contracted T-shaped square cross-section microchannel. Three flow regimes, namely stratified flow, slug flow (further categorized into snapping slug flow, breaking slug flow, and jetting slug flow), and annular flow, were identified. Moreover, the effects of gas slug length due to fluid physical parameters and the flow velocities of gas and liquid were explored. Based on the simulation outcomes, a predictive formula for gas slug length was deduced through dimensional analysis and the π-theorem, demonstrating a favorable agreement with the calculated values. The findings of this study can provide valuable guidance for gas-liquid mass transfer processes in microchannels.

Analysis and prediction of the flow laws of gas-liquid two-phase flow in contracted T-shaped microchannel