Hydrodynamics of Liquid–Liquid Dispersion in an Advanced-Flow Reactor

Hydrodynamics and mass transfer of immiscible liquid–liquid flows are explored in an Advanced-Flow Reactor (AFR). These systems are emerging as one of the major commercial systems for small scale continuous flow chemistry, and characterization of the transport phenomena is critical for reaction implementation. With hexane/water as a model system, we use flow visualization techniques to determine drop size distribution, hexane holdup, and specific interfacial areas for a phase flow rate range of 10–80 mL/min. The complex geometry of the AFR with its continuously changing cross section along the flow path and strategically placed obstacles creates pressure changes that cause drop breakup and enhance mass transfer. Observations show that a wide range of average drop size (0.33–1.3 mm) can be achieved in the AFR depending upon the inlet flow rates and inlet composition. Pressure drop measurements are performed to estimate the power consumption and are used to compare the efficiency of AFR with conventional liquid–liquid contactors. The analysis shows that, similar to microreactors, the AFR can provide specific interfacial areas (1000–10 000 m^–1) and overall mass transfer coefficients (1.9–41 s^–1) a few orders of magnitude larger than conventional stirred tank reactors and also the static mixers.