A novel generation of 3D SAR-based passive micromixer: efficient mixing and low pressure drop at low Reynolds number

Abstract This study introduces a novel generation of 3D splitting and recombination (SAR) passive micromixer with microstructures placed on the top and bottom floors of microchannels called a ‘chain mixer’. Both experimental verification and numerical analysis of the flow structure of this type of passive micromixer have been performed to evaluate the mixing performance and pressure drop of the microchannel, respectively. We propose here two types of chain mixer—chain 1 and chain 2—and compare their mixing performance and pressure drop with other micromixers, T-, O- and tear-drop micromixers. Experimental tests carried out in the laminar flow regime with a low Reynolds number range, 0.083 Re 4.166, and image-based techniques are used to evaluate the mixing efficiency. Also, the computational fluid dynamics code, ANSYS FLUENT-13.0 has been used to analyze the flow and pressure drop in the microchannel. Experimental results show that the chain and tear-drop mixer’s efficiency is very high because of the SAR process: specifically, an efficiency of up to 98% can be achieved at the tested Reynolds number. The results also show that chain mixers have a lower required pressure drop in comparison with a tear-drop micromixer.