A conservative level-set method (LSM) embedded in a computational fluid dynamics (CFD) simulation provides a useful approach for the studying the physics and underlying mechanism in two-phase flow. Detailed two-dimensional (2D) computational microfluidics flow simulations have been carried out to examine systematically the influence of different controlling parameters such as flow rates, viscosities, surface wettability, and interfacial tensions between two immiscible fluids

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A two-phase flow predictive model with the integration of conservative level-set method (LSM) and Carreau-Yasuda constitutive equation was developed herein. The LSM was chosen as a potential interface capturing scheme for elucidating the interfacial phenomena including insight into the mechanism of shear-thinning droplets. In present paper, the dynamics of shear-dependent droplet emergence, growth, detachment and translocation in a Newtonian microsystem were examined via computational fluid dynamics (CFD) analysis. Dilute sodium carboxymethylcellulose (Na-CMC) solution was treated as dispersed phase (70 mPa.s < <10.2644 Pa.s) whereas the olive oil (68 mPa.s) was designated as continuous phase. Visualisation experiments were carried out and these laboratory data were used to validate the simulation results. Detailed 2D simulations were presented to examine systematically the impact of fluid properties on the droplet breakup rate at predefined flow rate ratio, Q of 0.05. The results yielded an inflection point in the dependence of droplet breakup rate on Na-CMC concentration was found in between the dilute and semi-dilute concentration regimes. This inflection point displays a non-monotonic profile which is mainly caused by the considerable viscosity effect of Na-CMC polymer when its concentration increases above a critical value (C > C*~0.40 wt%). This striking