Scale-out of small channel two-phase flow contactors

In process engineering, flows in small channels are characterized by increased specific interfacial area and improved mass transfer rates. The two-phase flow patterns significantly influence the performance of fluidic devices. While many studies have studied flow pattern in single channels, there is still a lack of general guidelines on how to replicate the performance of a single unit to multiple ones for scale-up while avoiding fluid maldistribution and flow fluctuations among channels. We report a double manifold system for the scale up of two-phase liquid processes in small channels, based on a resistance network model. The manifold consists of 5 parallel single channels with total flow rates of both phases ranging from 0.2 to 50 mL/min. The flow patterns and distribution in the manifold channels were investigated for a hexane water-system. Under the conditions used, plug flow is expected in the single channels. In the double manifold system, it was found that in each of the parallel single channels plug flow also established, while the flow distribution was uniform for different flow rates. An infrared LED sensor was developed to monitor the flow distribution and measure plug length in the manifold channels.