# CFD Simulation and Structural Optimization Analysis of Micromixing Processes in T-Shaped Microreactors

## TL;DR

This study uses simulations to analyze how different T-shaped microreactor designs affect mixing and pressure drop, finding that a venturi structure with a 45° angle offers the best balance.

## Contribution

The novel contribution is the structural optimization analysis of T-shaped microreactors using CFD to balance micromixing efficiency and pressure drop.

## Key findings

- The venturi structure with a 45° contraction angle balances micromixing efficiency and pressure drop effectively.
- Baffle structures provide the best micromixing but cause the highest pressure drop.
- Micromixing times range from 0.025 to 0.234 ms across different reactor designs.

## Abstract

Microreactors offer remarkable advantages in intensifying mixing/mass transfer and hold promising prospects for industrial applications. In this study, T-shaped microreactors (TMRs) integrated with baffle, orifice-plate, and venturi structures (featuring different contraction angles) were designed. Based on the Villermaux–Dushman reaction system, three-dimensional computational fluid dynamics (CFD) models were established to simulate the fluid flow and mixing-reaction processes in these microreactors. The results demonstrate that peaks in velocity, turbulent kinetic energy, and turbulent dissipation rate consistently emerge in the confluence region of the two fluid streams. In the operating range of this study, the baffle configuration exhibits the highest micromixing performance but also induces the largest pressure drop, followed by the orifice-plate structure. Notably, the venturi structure not only enhances micromixing efficiency but also results in a minimal increase in pressure drop and eliminates flow dead zones. Specifically, the venturi structure with a 45° contraction angle achieves a balance between energy consumption and micromixing efficiency. Using the agglomeration model, the micromixing times of the microreactors with various structures were determined to range from 0.025 to 0.234 ms.