Simulation of droplet generation by mixing nozzles

In various chemical processes thorough homogeneous mixing is of great importance. Due to their small characteristic dimensions, micromixers have a great potential to achieve fast and uniform mixing. However, in the field of powder synthesis from precipitation processes the use of standard micromixers is severely limited because of rapid clogging of the microchannels. As an alternative, mixing nozzles which are less susceptible to fouling can provide a sufficient mixing quality. The flow field and fluid distribution inside multi-fluid droplets during droplet formation is simulated. Depending on the geometry and flow rates, complex velocity fields and flow distributions are found and the impact on the mixing efficiency is qualitatively deduced. Furthermore, we point out how the tendency of fouling can be further reduced with the help of improved nozzle geometries.