Tandem emulsification for high-throughput production of double emulsions

Core-shell double emulsions produced using microfluidic methods with controlled structural parameters exhibit great potential in a wide range of applications, but the low production rate of microfluidic methods hinders the exploitation of the capabilities of microfluidics to produce double emulsions with well-defined features. A major obstacle towards the scaled-up production of core-shell double emulsions is the difficulty of achieving robust spatially controlled wettability in integrated microfluidic devices. Here, we use tandem emulsification, a two-step process with microfluidic devices, to scale up the production. With this method, single emulsions are generated in a first device and are re-injected directly into a second device to form uniform double emulsions. We demonstrate the application of tandem emulsification for scalable core-shell emulsion production with both integrated flow focusing and millipede devices and obtain emulsions of which over 90% are single-core monodisperse double emulsion drops. With both mechanisms, the shell thickness can be controlled, so that shells as thin as 3 μm are obtained for emulsions 50 μm in radius.

Coagulation of Agglomerates Consisting of Polydisperse Primary Particles

The ballistic agglomeration of polydisperse particles is investigated by an event-driven (ED) method and compared to the coagulation of spherical particles and agglomerates consisting of monodisperse primary particles (PPs). It is shown for the first time to our knowledge that increasing the width or polydispersity of the PP size distribution initially accelerates the coagulation rate of their agglomerates but delays the attainment of their asymptotic fractal-like structure and self-preserving size distribution (SPSD) without altering them, provided that sufficiently large numbers of PPs are employed. For example, the standard asymptotic mass fractal dimension, Df, of 1.91 is attained when clusters are formed containing, on average, about 15 monodisperse PPs, consistent with fractal theory and the literature. In contrast, when polydisperse PPs with a geometric standard deviation of 3 are employed, about 500 PPs are needed to attain that Df. Even though the same asymptotic Df and mass-mobility exponent, Dfm, are attained regardless of PP polydispersity, the asymptotic prefactors or lacunarities of Df and Dfm increase with PP polydispersity. For monodisperse PPs, the average agglomerate radius of gyration, rg, becomes larger than the mobility radius, rm, when agglomerates consist of more than 15 PPs. Increasing PP polydispersity increases that number of PPs similarly to the above for the attainment of the asymptotic Df or Dfm. The agglomeration kinetics are quantified by the overall collision frequency function. When the SPSD is attained, the collision frequency is independent of PP polydispersity. Accounting for the SPSD polydispersity in the overall agglomerate collision frequency is in good agreement with that frequency from detailed ED simulations once the SPSD is reached. Most importantly, the coagulation of agglomerates is described well by a monodisperse model for agglomerate and PP sizes, whereas the detailed agglomerate size distribution can be obtained by scaling the average agglomerate size to the SPSD.

Mass-mobility characterization of flame-made ZrO2 aerosols: primary particle diameter and extent of aggregation

Gas-borne nanoparticles undergoing coagulation and sintering form irregular or fractal-like structures affecting their transport, light scattering, effective surface area, and density. Here, zirconia (ZrO(2)) nanoparticles are generated by scalable spray combustion, and their mobility diameter and mass are obtained nearly in situ by differential mobility analyzer (DMA) and aerosol particle mass (APM) measurements. Using these data, the density of ZrO(2) and a power law between mobility and primary particle diameters, the structure of fractal-like particles is determined (mass-mobility exponent, prefactor and average number, and surface area mean diameter of primary particles, d(va)). The d(va) determined by DMA-APM measurements and this power law is in good agreement with the d(va) obtained by ex situ nitrogen adsorption and microscopic analysis. Using this combination of measurements and above power law, the effect of flame spray process parameters (e.g., precursor solution and oxygen flow rate as well as zirconium concentration) on fractal-like particle structure characteristics is investigated in detail. This reveals that predominantly agglomerates (physically-bonded particles) and aggregates (chemically- or sinter-bonded particles) of nanoparticles are formed at low and high particle concentrations, respectively.

Fragmentation and restructuring of soft-agglomerates under shear

Soft-agglomerate restructuring, break-up (or fragmentation) and relaxation are studied in a simple shear flow by a discrete element method (DEM). The agglomerates, held together by van der Waals forces, rotate in the shear flow and are stretched into nearly linear structures (fractal dimension approaches unity) until they fracture at their weakest point resulting in lognormally-shaped fragment size distributions asymptotically. Individual fragments relax in the flow towards more compact agglomerates than the parent ones. The evolution of the average number of particles per fragment is described by generalized scaling laws between shear rate, onset (time-lag) of fragmentation, asymptotic fragment mass and size consistent with experimental and theoretical studies in the literature. The initial effective fractal dimension of the agglomerates influences the final one of the fragments.