Microfluidic Study of Fast Gas–Liquid Reactions

Visualization-enhanced under-oil open microfluidic system for in situ characterization of multi-phase chemical reactions

Under-oil open microfluidic system, utilizing liquid-liquid boundaries for confinements, offers inherent advantages including clogging-free flow channels, flexible access to samples, and adjustable gas permeation, making it well-suited for studying multi-phase chemical reactions that are challenging for closed microfluidics. However, reports on the novel system have primarily focused on device fabrication and functionality demonstrations within biology, leaving their application in broader chemical analysis underexplored. Here, we present a visualization-enhanced under-oil open microfluidic system for in situ characterization of multi-phase chemical reactions with Raman spectroscopy. The enhanced system utilizes a semi-transparent silicon (Si) nanolayer over the substrate to enhance visualization in both inverted and upright microscope setups while reducing Raman noise from the substrate. We validated the system's chemical stability and capability to monitor gas evolution and gas-liquid reactions in situ. The enhanced under-oil open microfluidic system, integrating Raman spectroscopy, offers a robust open-microfluidic platform for label-free molecular sensing and real-time chemical/biochemical process monitoring in multi-phase systems.

Continuous-Flow Microreactor Accelerates Molecular Collisions for Lignin Depolymerization to Phenolic Monomers and Oligomers

Effective depolymerization of lignin is the most important step for its comprehensive utilization. So far, most of the studies on depolymerization of lignin focused on batch processing, whereas only a few studies relied on the microreactor. In this study, we developed a continuous-flow microreactor for depolymerization of lignin into monomeric and oligomeric compounds. The yields of monomers and oligomers can be adjusted by varying the temperature, pressure, residence time, NaOH dosage, and solvent. Under optimized conditions, the lignin conversion rate was 77.73 wt %, and the monomer yield was 13.26 wt %, with 77.81% being phenolic compounds. In addition, comparative characterizations on the raw lignin and products demonstrated that the oil products were mainly composed of phenolic tetramers and trimers, and the effective cleavage of the β-O-4 linkage of S-type lignin was responsible for the high yield of 2,6-dimethoxyphenol. It indicated that raw lignin could be effectively depolymerized continuously using the continuous-flow microreactor, and it will be a new strategy for comprehensive utilization of lignin to produce fine-chemical intermediates.

A spectIR-fluidic reactor for monitoring fast chemical reaction kinetics with on-chip attenuated total reflection Fourier transform infrared spectroscopy

Microfluidics has emerged as a powerful technology with diverse applications in microbiology, medicine, chemistry, and physics. While its potential for controlling and studying chemical reactions is well recognized, the extraction and analysis of useful chemical information generated within microfluidic devices remain challenging. This is mainly due to the limited tools available for in situ measurements of chemical reactions. In this study, we present a proof-of-concept spectIR-fluidic reactor design that combines microfluidics with Fourier transform infrared (FTIR) spectroscopy for in situ kinetic studies of fast reactions. By integrating a multi-ridge silicon attenuated total reflection (ATR) wafer into the microfluidic device, we enable multi-point measurements for precise reaction time monitoring. As such, this work establishes a validated foundation for studying fast chemical reactions using on-chip ATR-FTIR spectroscopy in a microfluidic reactor environment, which enables simultaneous monitoring of reagents, intermediates, and products using a phosphate proton transfer reaction. The spectIR-fluidic reactor platform offers customizable designs, allowing for the investigation of reactions with various time scales, and has the potential to significantly advance studies exploring reaction mechanisms and optimization.

In Situ TEM Observation of Stagnant Liquid Layer Activation in Nanochannel

The kinetics of mass transfer in a stagnant fluid layer next to an interface govern numerous dynamic reactions in diffusional micro/nanopores, such as catalysis, fuel cells, and chemical separation. However, the effect of the interplay between stagnant liquid and flowing fluid on the micro/nanoscopic mass transfer dynamics remains poorly understood. Here, by using liquid cell transmission electron microscopy (TEM), we directly tracked microfluid unit migration at the nanoscale. By tracking the trajectories, an unexpected mass transfer phenomenon in which fluid units in the stagnant liquid layer migrated two orders faster during gas-liquid interface updating was identified. Molecular dynamics (MD) simulations indicated that the chemical potential difference between nanoscale liquid layers led to convective flow, which greatly enhanced mass transfer on the surface. Our study opens up a pathway toward research on mass transfer in the surface liquid layers at high spatial and temporal resolutions.

Determination of fast gas–liquid reaction kinetics in flow

A flow concept is developed to measure fast gas–liquid reaction kinetics based on a tube-in-tube reactor.

Mass transfer dynamics in the dissolution of Taylor bubbles

The knowledge of thermodynamic and mass transfer parameters in gas-liquid systems is critical for the design of macroscale units for separation and reaction processes. The phenomenon of shrinkage of Taylor bubbles upon dissolution has the capability of supplying these design parameters, provided a reliable mathematical model is available for data deconvolution. Unfortunately, the existing models in the literature suffer from at least one of the following three major limitations. First, mass transfer between the bulk liquid segment and the surrounding liquid film has been incorrectly estimated. Second, the liquid segment is assumed to be well mixed, even though there is clear evidence of the contrary in the literature [Yang et al., Chem. Eng. Sci., 2017, 169, 106]. Third, an average mass transfer coefficient is assumed to be valid throughout the dissolution process, despite the fact that bubble velocities can change significantly during dissolution. In this work, we have rectified these limitations and developed a detailed model that takes into account the local concentration gradients and the flow profiles, without resorting to the computationally expensive, full numerical simulations of the fluid flow and concentration distribution equations. To validate the model, experiments were carried out in circular, silica capillaries of different radii by generating segmented flow of CO₂ in physical solvents, and the diffusivity and the solubility were subsequently extracted with an error of less than 5%. This work can be extended to the study of gas-liquid-solid reactions in the Taylor flow configuration, and applied to the design of catalyst-coated monolithic reactors.

In situ visualization of hydrophilic spatial heterogeneity inside microfluidic chips by fluorescence microscopy

Fluorescence visualization for hydrophilic spatial heterogeneity inside microfluidic chips is a long-standing challenge owing to the lack of fluorescent dyes with high contrast between the target and the background noise. Herein, we used boronic acid in aggregation-induced emission (AIE) molecules as an anchor group towards modified hydroxyl groups, and an in situ visualization approach for hydrophilic spatial heterogeneity inside microfluidic chips was demonstrated. This success is based on the high-contrast of fluorescent behaviors for AIE molecules in aqueous solution and their immobilization by hydroxyl groups inside the microfluidic channels. In comparison to conventional laboratory-based ex situ techniques, the proposed strategy provides a direct representation for hydrophilic spatial heterogeneity, including the quantity and distribution of hydroxyl groups. This discovery not only identifies a previously unknown variability in hydrophilic spatial heterogeneity inside microfluidic channels, but also guides an optimal hydrophilic modification method in the channels.

Visualization of two-phase reacting flow behavior in a gas–liquid–solid microreactor

The hydrodynamic characteristics of gas–liquid two-phase flow can significantly affect the performance of gas–liquid–solid microreactors.

Preparative microdroplet synthesis of carboxylic acids from aerobic oxidation of aldehydes

Single liquid-phase and liquid-liquid phase reactions in microdroplets have shown much faster kinetics than that in the bulk phase. This work extends the scope of microdroplet reactions to gas-liquid reactions and achieves preparative synthesis. We report highly efficient aerobic oxidation of aldehydes to carboxylic acids in microdroplets. Molecular oxygen plays two roles: (1) as the sheath gas to shear the aldehyde solution into microdroplets, and (2) as the sole oxidant. The dramatic increase of the surface-area-to-volume ratio of microdroplets compared to bulk solution, and the efficient mixing of gas and liquid phases using spray nozzles allow effective mass transfer between aldehydes and molecular oxygen. The addition of catalytic nickel(ii) acetate is shown to accelerate further microdroplet reactions of this kind. We show that aliphatic, aromatic, and heterocyclic aldehydes can be oxidized to the corresponding carboxylic acids in a mixture of water and ethanol using the nickel(ii) acetate catalyst, in moderate to excellent yields (62-91%). The microdroplet synthesis is scaled up to make it preparative. For example, aerobic oxidation of 4-tert-butylbenzaldehyde to 4-tert-butylbenzoic acid was achieved at a rate of 10.5 mg min-1 with an isolated product yield of 66%.

Indirect fabrication of versatile 3D microfluidic device by a rotating plate combined 3D printing system

Rapid on-demand sacrificial printing techniques using suitable combinations of resin and sacrificial materials would be desirable to fabricate versatile and functional microfluidic devices with complex designs and chemical resistance.

Janus Reactors with Highly Efficient Enzymatic CO2 Nanocascade at Air-Liquid Interface

Though enzymatic cascade reactors have been the subject of intense research over the past few years, their application is still limited by the complicated fabrication protocols, unsatisfactory stability and lack of effective reactor designs. In addition, the spatial positioning of the cascade reactor has so far not been investigated, which is of significant importance for biphase catalytic reaction systems. Inspired by the Janus properties of the lipid cellular membrane, here we show a highly efficient Janus gas-liquid reactor for CO₂ hydration and conversion. Within the Janus reactor, nanocascades containing the nanoscale compartmentalized carbonic anhydrase and formic dehydrogenase were positioned at a well-defined gas-liquid interface, with a high substrate concentration gradient. The Janus reactor exhibited 2.5 times higher CO₂ hydration efficiency compared with the conventional gas-liquid contactor with pristine membranes, and the formic acid conversion rate can reach approximately 90%. Through this work, we provide evidence that the spatial arrangement of the nanocascade is also crucial to efficient reactions, and the Janus reactor can be a promising candidate for the biphase catalytic reactions in environmental, biological and energy aspects.

Automated in Situ Measurement of Gas Solubility in Liquids with a Simple Tube-in-Tube Reactor

Data on the solubilities of gases in liquids are foundational for assessing a variety of multiphase separations and gas-liquid reactions. Taking advantage of the tube-in-tube reactor design built with semipermeable Teflon AF-2400 tubes, liquids can be rapidly saturated without direct contacting of gas and liquid. The gas solubility can be determined by performing steady-state flux balances of both the gas and liquid flowing into the reactor system. Using this type of reactor, a fully automated strategy has been developed for the rapid in situ measurement of gas solubilities in liquids. The developed strategy enables precise gas solubility measurements within 2-5 min compared with 4-5 h using conventional methods. This technique can be extended to the discrete multipoint steady-state and continuous ramped-multipoint data acquisition methods. The accuracy of this method has been validated against several gas-liquid systems, showing less than 2% deviation from known values. Finally, this strategy has been extended to measure the temperature dependence of gas solubilities in situ and to estimate the local enthalpy of dissolution across a defined temperature range.

A droplet-chip/mass spectrometry approach to study organic synthesis at nanoliter scale

A droplet-based microfluidic device with seamless hyphenation to electrospray mass spectrometry was developed to rapidly investigate organic reactions in segmented flow providing a versatile tool for drug development. A chip-MS interface with an integrated counterelectrode allowed for a flexible positioning of the chip-emitter in front of the MS orifice as well as an independent adjustment of the electrospray potentials. This was necessary to avoid contamination of the mass spectrometer as well as sample overloading due to the high analyte concentrations. The device was exemplarily applied to study the scope of an amino-catalyzed domino reaction with low picomole amount of catalyst in individual nanoliter sized droplets.

The hydrodynamics of segmented two-phase flow in a circular tube with rapidly dissolving drops

This article discusses boundary integral simulations of dissolving drops flowing through a cylindrical tube for large aspect ratio drops. The dynamics of drop dissolution is determined by three dimensionless parameters: λ, the viscosity of the drop fluid relative to the suspending fluid; Ca, the capillary number defining the ratio of the hydrodynamic force to the interfacial tension force; and k, a dissolution constant based on the velocity of dissolution. For a single dissolving drop, the velocity in the upstream region is greater than the downstream region, and for sufficiently large k, the downstream velocity can be completely reversed, particularly at low Ca. The upstream end of the drop travels faster and experiences greater deformation than the downstream end. The film thickness, δ, between the drop and the tube wall is governed by a delicate balance between dissolution and changes in the outer fluid velocity resulting from a fixed pressure drop across the tube and mass continuity. Therefore, δ, and consequently, the drop average velocity, can increase, decrease or be relatively invariant in time. For two drops flowing in succession, while low Ca drops maintain a nearly constant separation distance during dissolution, at sufficiently large Ca, for all values of k, dissolution increases the separation distance between drops. Under these conditions, the liquid segments between two adjacent drops can no longer be considered as constant volume stirred tanks. These results will guide the choices of geometry and operating parameters that will facilitate the characterization of fast gas-liquid reactions via two-phase segmented flows.

Quantifying the efficiency of CO2 capture by Lewis pairs

A microfluidic strategy is used to assess the relative efficiency and thermodynamic parameters of CO₂ binding by three Lewis acid/base combinations.

A microfluidic strategy has been used for the time- and labour-efficient evaluation of the relative efficiency and thermodynamic parameters of CO₂ binding by three Lewis acid/base combinations, where efficiency is based on the amount of CO₂ taken up per binding unit in solution. Neither tBu₃P nor B(C₆F₅)₃ were independently effective at CO₂ capture, and the combination of the imidazolin-2-ylidenamino-substituted phosphine (NIiPr)₃P and B(C₆F₅)₃ was equally ineffective. Nonetheless, an archetypal frustrated Lewis pair (FLP) comprised of tBu₃P and B(C₆F₅)₃ was shown to bind CO₂ more efficiently than either the FLP derived from tetramethylpiperidine (TMP) and B(C₆F₅)₃ or the highly basic phosphine (NIiPr)₃P. Moreover, the proposed microfluidic platform was used to elucidate the thermodynamic parameters for these reactions.

Dynamics of bubble breakup at a T junction

The gas-liquid interfacial dynamics of bubble breakup in a T junction was investigated. Four regimes were observed for a bubble passing through the T junction. It was identified by the stop flow that a critical width of the bubble neck existed: if the minimum width of the bubble neck was less than the critical value, the breakup was irreversible and fast; while if the minimum width of the bubble neck was larger than the critical value, the breakup was reversible and slow. The fast breakup was driven by the surface tension and liquid inertia and is independent of the operating conditions. The minimum width of the bubble neck could be scaled with the remaining time as a power law with an exponent of 0.22 in the beginning and of 0.5 approaching the final fast pinch-off. The slow breakup was driven by the continuous phase and the gas-liquid interface was in the equilibrium stage. Before the appearance of the tunnel, the width of the depression region could be scaled with the time as a power law with an exponent of 0.75; while after that, the width of the depression was a logarithmic function with the time.

Superamphiphobic Silicon-Nanowire-Embedded Microsystem and In-Contact Flow Performance of Gas and Liquid Streams

Gas and liquid streams are invariably separated either by a solid wall or by a membrane for heat or mass transfer between the gas and liquid streams. Without the separating wall, the gas phase is present as bubbles in liquid or, in a microsystem, as gas plugs between slugs of liquid. Continuous and direct contact between the two moving streams of gas and liquid is quite an efficient way of achieving heat or mass transfer between the two phases. Here, we report a silicon nanowire built-in microsystem in which a liquid stream flows in contact with an underlying gas stream. The upper liquid stream does not penetrate into the lower gas stream due to the superamphiphobic nature of the silicon nanowires built into the bottom wall, thereby preserving the integrity of continuous gas and liquid streams, although they are flowing in contact. Due to the superamphiphobic nature of silicon nanowires, the microsystem provides the best possible interfacial mass transfer known to date between flowing gas and liquid phases, which can achieve excellent chemical performance in two-phase organic syntheses.

A model-based technique for the determination of interfacial fluxes in gas–liquid flows in capillaries

A non-invasive method to quantify interfacial mass transfer in gas–liquid flow is presented.

Fast diffusion-limited lyotropic phase transitions studied in situ using continuous flow microfluidics/microfocus-SAXS

Fast concentration-induced diffusion-limited lyotropic phase transitions can be studied in situ with millisecond time resolution using continuous flow microfluidics in combination with microfocus small-angle X-ray scattering. The method was applied to follow a classical self-assembly sequence where amphiphiles assemble into micelles, which subsequently assemble into an ordered lattice via a disorder/order transition. As a model system we selected the self-assembly of an amphiphilic block copolymer induced by the addition of a nonsolvent. Using microchannel hydrodynamic flow-focusing, large concentration gradients can be generated, leading to a deep quench from the miscible to the microphase-separated state. Within milliseconds the block copolymers assembly via a spinodal microphase separation into micelles, followed by a disorder/order transition into an FCC liquid-crystalline phase with late-stage domain growth and shear-induced domain orientation into a mesocrystal. A comparison with a slow macroscopic near-equilibrium kinetic experiment shows that the fast structural transitions follow a direct pathway to the equilibrium structure without the trapping of metastable states.

Shaken, and stirred: oscillatory segmented flow for controlled size-evolution of colloidal nanomaterials

We introduce oscillatory segmented flow as a compact microfluidic format that accommodates slow chemical reactions for the solution-phase processing of colloidal nanomaterials. The strategy allows the reaction progress to be monitored at a dynamic range of up to 80 decibels (i.e., residence times of up to one day, equivalent to 720-14,400 times the mixing time) from only one sensing location. A train of alternating gas bubbles and liquid reaction compartments (segmented flow) was initially formed, stopped and then subjected to a consistent back-and-forth motion. The oscillatory segmented flow was obtained by periodically manipulating the pressures at the device inlet and outlet via square wave signals generated by non-wetted solenoid valves. The readily implementable format significantly reduced the device footprint as compared with continuous segmented flow. We investigated mixing enhancement for varying liquid segment lengths, oscillation amplitudes and oscillation frequencies. The etching of gold nanorods served as a case study to illustrate the utility of the approach for dynamic characterization and precise control of colloidal nanomaterial size and shape for 5 h. Oscillatory segmented flows will be beneficial for a broad range of lab-on-a-chip applications that require long processing times.

Microfluidic studies of carbon dioxide

Carbon dioxide (CO2) sequestration, storage and recycling will greatly benefit from comprehensive studies of physical and chemical gas-liquid processes involving CO2. Over the past five years, microfluidics emerged as a valuable tool in CO2-related research, due to superior mass and heat transfer, reduced axial dispersion, well-defined gas-liquid interfacial areas and the ability to vary reagent concentrations in a high-throughput manner. This Minireview highlights recent progress in microfluidic studies of CO2-related processes, including dissolution of CO2 in physical solvents, CO2 reactions, the utilization of CO2 in materials science, and the use of supercritical CO2 as a "green" solvent.