A wide range of existing passive micromixers are reviewed, and quantitative analyses of ten typical passive micromixers were performed to compare their mixing indices, pressure drops, and mixing costs under the same axial length and flow conditions across a wide Reynolds number range of 0.01–120. The tested micromixers were selected from five types of micromixer designs. The analyses of flow and mixing were performed using continuity, Navier-Stokes and convection-diffusion equations. The results of the comparative analysis were presented for three different Reynolds number ranges: low-Re (Re ≤ 1), intermediate-Re (1 < Re ≤ 40), and high-Re (Re > 40) ranges, where the mixing mechanisms are different. The results show a two-dimensional micromixer of Tesla structure is recommended in the intermediate- and high-Re ranges, while two three-dimensional micromixers with two layers are recommended in the low-Re range due to their excellent mixing performance.

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The present work proposes a micromixer consisting of circular mixing modules and three-dimensional subchannels, which uses a split and recombination process and unbalanced collisions as the main mixing mechanisms. Three micromixer configurations with different locations of the forward-and backwardfacing steps were tested at several Reynolds numbers between 0.1 and 120. The steady incompressible momentum and continuity equations in conjunction with the advection-diffusion equation were solved for the analysis of mixing and fluid flow. The micromixer configuration with three-dimensional step structures in both subchannels showed the most excellent mixing capability. In comparison with a previous micromixer of the same type, the suggested micromixer demonstrates far better efficiency at medium Reynolds numbers. The number of mixing modules and geometric parameters were also varied to estimate its impact on the mixing capability. The suggested micromixer exhibited a mixing index higher than 0.86 for Re ≥ 20 and 0.95 for Re ≥ 50.

The present work proposes a planar micromixer design comprising hybrid mixing modules of split-and-recombine units and curved channels with radial baffles. The mixing performance was evaluated numerically by solving the continuity and momentum equations along with the advection-diffusion equation in a Reynolds number range of 0.1–80. The variance of the concentration of the mixed species was considered to quantify the mixing index. The micromixer showed far better mixing performance over whole Reynolds number range than an earlier split-and-recombine micromixer. The mixer achieved mixing indices greater than 90% at Re ≥ 20 and a mixing index of 99.8% at Re = 80. The response of the mixing quality to the change of three geometrical parameters was also studied. A mixing index over 80% was achieved within 63% of the full length at Re = 20.

In order to maximize the mixing performance of a micromixer with an integrated three-dimensional serpentine and split-and-recombination configuration, multi-objective optimizations were performed at two different Reynolds numbers, 1 and 120, based on numerical simulation. Numerical analyses of fluid flow and mixing in the micromixer were performed using three-dimensional Navier-Stokes equations and convection-diffusion equation. Three dimensionless design variables that were related to the geometry of the micromixer were selected as design variables for optimization. Mixing index at the exit and pressure drop through the micromixer were employed as two objective functions. A parametric study was carried out to explore the effects of the design variables on the objective functions. Latin hypercube sampling method as a design-of-experiment technique has been used to select design points in the design space. Surrogate modeling of the objective functions was performed by using radial basis neural network. Concave Pareto-optimal curves comprising of Pareto-optimal solutions that represents the trade-off between the objective functions were obtained using a multi-objective genetic algorithm at Re = 1 and 120. Through the optimizations, maximum enhancements of 18.8% and 6.0% in mixing index were achieved at Re = 1 and 120, respectively.

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