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A new passive micromixer based on the concept of unbalanced splits and cross-collisions of fluid streams is designed and fabricated. Experimental and numerical studies have been carried out on the micromixer at Reynolds numbers ranging from 10 to 80. The three-dimensional Navier-Stokes equations have been used to analyze the mixing and flow behavior of the micromixer, which is composed of two sub-channels of unequal widths which repeatedly undergo splitting and recombination. The difference between the mass flow rates in the two sub-channels creates an unbalanced collision of the two fluid streams. Mixing is mainly due to the combined effect of unbalanced collisions of the fluid streams and Dean vortices. The micromixer shows interesting mixing behavior for different ratios of the widths of the two split sub-channels. The sub-channels wherein the major sub-channel is twice as wide as the minor sub-channel exhibit the highest mixing performance at Reynolds numbers larger than 40. The results show the lowest mixing performance for the case of uniform width, where balanced collisions occur.

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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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