Multiphase Microchannel Separator

In conventional two-phase separation, mass transport between the two phases can be intensified via increased surface area, usually in the form of smaller droplets or bubbles. The increase in the interfacial surface area typically results in higher energy cost due to agitation or mixing and slower processing time as the smaller droplet phase requires more time to separate. One can increase processing speed in centrifugal extractors but this, in turn, increases energy requirements significantly. Often, microscale process intensification is at odds with macroscale energy efficiency in conventional systems. From a capital cost perspective, current separation methods are economically feasible at large scale due to the inherent cost scaling of hardware manufacturing for traditional unit operations. As a result, they can be prohibitively difficult to translate into smaller modular systems. This project is working on the development of a flexible yet standardized platform for multiphase separation utilizing microchannel processing technology (MPT). Multiphase Microchannel Separation in MPT systems directs flow of each phase by creating a capillary force gradient via size and spacing of micro-scale architectural features, thereby controlling interfacial curvatures and thus capillary forces. With a proper choice of surface properties, the system is designed so that a selected phase cannot overcome capillary forces in one direction of the gradient with inertial and viscous forces, guiding the fluid towards a selected outlet stream. Additionally, a flat plate design can accommodate a larger processing throughput per layer of the device and reduce manufacturing complexity compared to single microchannel devices.