Microchannel emulsification: from computational fluid dynamics to predictive analytical model.

Emulsion droplet formation was investigated in terrace-based microchannel systems that generate droplets through spontaneous Laplace pressure driven snap-off. The droplet formation mechanism was investigated through high-speed imaging and computational fluid dynamics (CFD) simulation, and we found good agreement in the overall shape of the phases during droplet formation. An analytical model was derived from the insights that were gained from the CFD simulations, which describes the droplet diameter as a function of applied pressure. The analytical model covers the influence of both process parameters and geometry of the terrace well and can be used for fast optimization and evaluation studies.