Charge-Transfer-Induced Noncoalescence and Chain Formation of Free Droplets under a Pulsed DC Electric Field

Electrocoalescence technology is an important method for the demulsification of crude oil emulsion, but its development is restricted by the short circuit caused by droplet chain formation. To reveal the formation mechanism of droplet chains, the electrocoalescence behaviors of two droplets and droplet clusters under pulsed direct current (DC) electric fields are experimentally studied. The two droplets usually successively undergo complete coalescence, partial coalescence, and noncoalescence as the electric field strength increases. The critical electric field strengths for complete coalescence under pulsed DC electric fields with different frequencies are obtained. The effects of the electric field waveform and frequency on the noncoalescence characteristics of two droplets and the stability of droplet chains are explored. The droplet chains under a high-frequency electric field are more stable and longer than those under a low-frequency electric field due to the reduction of the movement distance and the generation of daughter droplets from tip streaming. The reversal of the composition of electric forces due to charge transfer is the fundamental mechanism of noncoalescence of two droplets and chain formation in the emulsion under a pulsed DC electric field.

Microfluidic Study of the Electrocoalescence of Aqueous Droplets in Crude Oil

In electrocoalescence, an electric field is applied to a dispersion of conducting water droplets in a poorly conducting oil to force the droplets to merge in the direction of the field. Electrocoalescence is used in petroleum refining to separate water from crude oil and in droplet-based microfluidics to combine droplets of water in oil and to break emulsions. Using a microfluidic design to generate a two-dimensional (2D) emulsion, we demonstrate that electrocoalescence in an opaque crude oil can be visualized with optical microscopy and studied on an individual droplet basis in a chamber whose height is small enough to make the dispersions two dimensional and transparent. From reconstructions of images of the 2D electrocoalescence, the electrostatic forces driving the droplet merging are calculated in a numerically exact manner and used to predict observed coalescence events. Hence, the direct simulation of the electrocoalescence-driven breakdown of 2D emulsions in microfluidic devices can be envisioned.

A three-dimensional electrode for highly efficient electrocoalescence-based droplet merging

Droplet merging is one of the key functions in the ever-widening applications of droplet microfluidics. Enhancing the efficiency of electric field-based droplet merging, namely electrocoalescence, can lead to an increase in platform stability and overcome one of the major bottlenecks in further improving throughputs of droplet microfluidic systems. In this work, a paired three-dimensional (3D) electrode design that can provide a uniform electric field within a droplet merging region, which is also properly aligned with the droplet dipole moments for highly efficient electrocoalescence is presented. A systematic study was conducted to compare the droplet merging performance of the presented 3D electrode design to other commonly used planar electrode, coplanar electrode, dual-coplanar electrode, and liquid metal 3D electrode designs. The presented 3D electrode design reduced the threshold input voltage required to obtain droplet fusion by up to 75%. In addition, a droplet merging efficiency of higher than 95% was consistently observed, compared to less than 85% merging efficiency for the conventionally used electrode designs. We expect that this droplet electrocoalescence design will improve the overall throughput and merging success rate in droplet microfluidic based high-throughput assays.

Hydrodynamic interaction of two deformable drops in confined shear flow

We investigate hydrodynamic interaction between two neutrally buoyant circular drops in a confined shear flow based on a computational fluid dynamics simulation using the volume-of-fluid method. The rheological behaviors of interactive drops and the flow regimes are explored with a focus on elucidation of underlying physical mechanisms. We find that two types of drop behaviors during interaction occur, including passing-over motion and reversing motion, which are governed by the competition between the drag of passing flow and the entrainment of reversing flow in matrix fluid. With the increasing confinement, the drop behavior transits from the passing-over motion to reversing motion, because the entrainment of the reversing-flow matrix fluid turns to play the dominant role. The drag of the ambient passing flow is increased by enlarging the initial lateral separation due to the departure of the drop from the reversing flow in matrix fluid, resulting in the emergence of passing-over motion. In particular, a corresponding phase diagram is plotted to quantitatively illustrate the dependence of drop morphologies during interaction on confinement and initial lateral separation.