Microflow systems are increasingly used for chemical and biochemical reactions as well as continuous processes. They enable more efficient reaction control, leading to process intensification. They are particularly suitable for exothermic and potentially explosive reactions, as well as for processes involving toxic or unstable intermediates. They contribute to improved safety and better environmental sustainability of production, while also enabling faster synthesis of active pharmaceutical ingredients, lower consumption of energy and solvents, and more precise control of reaction parameters.In microsystems, due to the small dimensions, laminar flow prevails, so mixing is mainly limited to diffusion, which represents a key challenge. We designed a microfluidic system and found that the geometry of microchannels has a significant impact on mixing efficiency. Serpentine channels generate Dean vortices, SAR structures enable splitting and recombination of flows, while a Tesla diode improves homogenization through asymmetric flow. More complex geometries generally enhance mixing but increase pressure drop and fabrication complexity.
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