Emerging Trends in Chemical Engineering vol 3 issue 3

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STM JOURNALS

1. Experimental Investigations on the Durability of PMMA Microfluidic Devices Fabricated by
Hot Embossing Lithography with Plasma Processing for Bioengineering Applications
Subhadeep Mukhopadhyay 1
2. Binary Distillation Design and Control
K. Nagamalleswara Rao 19
3. Experimental Study on the Surface-Driven Capillary Flow of Aqueous Microparticle
Suspensions in the Straight PMMA Microchannels
Subhadeep Mukhopadhyay 26
4. Reactive Distillation Design and Control
K. Nagamalleswara Rao 31
5. Review on Suitability of Ionic Liquids for Heat Transfer Applications
Divya P. Soman, P. Kalaichelvi, T.K. Radhakrishnan 40
ContentsEmerging Trends in Chemical Engineering

ETCE (2016) 1-18 © STM Journals 2016. All Rights Reserved Page 1
Volume 3, Issue 3
www.stmjournals.com
Experimental Investigations on the Durability of PMMA
Microfluidic Devices Fabricated by Hot Embossing
Lithography with Plasma Processing for Bioengineering
Applications
Subhadeep Mukhopadhyay*
Department of Electronics and Computer Engineering, National Institute of Technology Arunachal
Pradesh, Ministry of Human Resource Development (Government of India), Yupia, Papum Pare,
Arunachal Pradesh, India
Abstract
In this research paper, total 1290 individual static contact angles of different working liquids
have been measured and recorded on the flat polymethylmethacrylate (PMMA) surfaces. Total
474 individual PMMA microfluidic devices have been fabricated by the maskless lithography,
hot embossing lithography and direct bonding technique inside the cleanroom laboratory and
mechanical engineering workshop to determine the durability of these microfluidic devices.
Total nine individual working liquids have been used to record the static contact angles in
materials science laboratory. The durability of PMMA microfluidic devices is determined as
approximately 6 months continuously after the fabrication. The estimated durability is
suitable for any point-of-care purpose with sufficient portability in the bioengineering
applications. This estimation of durability is one novel approach in this research paper. The
measurements on the surface-driven capillary flow of any working liquid in this research
paper are related with the principles of fluid dynamics. The measurements of static contact
angles of all working liquids are related with the principles of fluid statics. Fluid mechanics is
fundamentally divided into fluid dynamics and fluid statics on the basis of the motion of fluid.
Author has performed all the experiments of this research paper during more than 1 year
using his own hands-on completely.
Keywords: PMMA, Static contact angle, Durability, Microfluidic device
INTRODUCTION
Fluid mechanics is fundamentally divided into
fluid dynamics and fluid statics on the basis of
the motion of fluid. Fluid mechanics is an
essential part of mechanical engineering. In
the recent past, Mukhopadhyay et al. have
performed many experiments on fluid
dynamics and fluid statics according to the
published reports [1–9]. The surface-driven
capillary flow is generated by the surface
tension forces at the liquid-solid-gas interfaces
inside any microchannel [1–9]. 100 years ago,
in the year of 1916, Lord Rayleigh studied the
capillary flow inside the capillary tubes in his
own pioneering work and reported in his
article entitled as “On the theory of the
capillary tube” [10]. In the present research-
world, many scientists and researchers have
studied the surface-driven capillary flow inside
the microchannels [11–26]. Polymers are
highly suitable materials to fabricate the
microfluidic devices [27, 28]. Different
lithographic techniques, bonding techniques
and surface modification techniques are used
by many authors to fabricate the microfluidic
devices [27–43]. Surface wettability is an
important surface property related with both of
the solid and liquid to control the surface-
driven capillary flow inside the microchannels
[44–52]. Static contact angle is the
measurement of surface wettability [53–66].
Higher static contact angle of any liquid on
any particular solid surface corresponds to the
lower surface wettability for that particular
liquid on the same solid surface [4].
In this research paper, author has fabricated
total 474 individual PMMA microfluidic

Volume 3, Issue 3
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Binary Distillation Design and Control
K. Nagamalleswara Rao*
Department of Chemical Engineering, School of Civil and Chemical Engineering, VIT University,
Vellore, Tamil Nadu, India
Abstract
This paper discusses design and control strategies of binary distillation process using ASPEN
PLUS V8.8 simulating tool. Steady state design procedure for binary distillation column
design to separate acrolein and propylene is explained. Dynamic simulations were conducted
by designing control structure. The developed control structure contains level controllers,
pressure controllers and temperature controllers. The developed control structure has shown
good performance in withstanding the various process disturbances.
Keywords: ASPEN PLUS V8.8, binary distillation, control structure, dynamic simulations,
steady state design
INTRODUCTION
The distillation design and control literature is
one of the most extensive in the area of process
control [1, 2]. Distillation remains the primary
separation method in the petroleum and
chemical industries, and its practical importance
is unquestionable [3, 4]. Distillation is the most
widely used separation process in the chemical
and petroleum industries. Due to increasing
demands of high product quality, minimum
energy consumption [5–8] and minimum waste
generation process performance should be
improved with tighter control of distillation
columns [9–11].
Distillation control is the main focus of
chemical process control [12–19]. Non-linear
dynamics has been realized for more than
three decades [20, 21] and a few attempts were
made to combat the associated control
difficulties [3, 4, 22–29]. For lack of tight
control, high purity of a distillate product has
been achieved by over-refluxing at the cost of
higher energy consumption [30, 31] and lower
production rate; moreover, such a practice
usually sacrifices the bottom product purity
and, therefore is likely to incur additional
expense for purification or disposal of the
bottom product. There are many different
types of distillation columns and many
different types of control structures. The
selection of the “best” control structure is not
simple as in literature. Factors that influence
the selection include volatilities, product
purities, reflux ratio, column pressure, cost of
energy, and column size [31]. In this study, a
binary system was considered, with the
specific example of acrolein/propylene
separation.
METHODOLOGY
In design and control of binary distillation
columns, phase equilibrium and chemical
equilibrium were studied first because they are
the first principles in designing of any
chemical processes. Steady state design of the
binary distillation was conducted next. For
steady state design 100 kmol/h of acrolein and
100 kmol/h of propylene were sent in to the
column. Numbers of trays are fixed to 10.
Feed streams entering on stage 5. Reactant
feed ratio can be altered until the TAC is
minimized. Steady state design flow sheet is
shown in Figure 1. Dynamic simulations were
conducted by exporting ASPEN steady state
simulation file into ASPEN dynamics as
pressure driven dynamic simulations. Dynamic
simulations were conducted by arranging
different controllers and their performance was
tested to withstand to the process disturbances.
RESULTS AND DISCUSSION
As the phase equilibrium is very important
step for separation operations in process
design, phase equilibrium studies were
conducted first. Knowing both phase

Volume 3, Issue 3
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Experimental Study on the Surface-Driven Capillary Flow
of Aqueous Microparticle Suspensions in the Straight
PMMA Microchannels
Subhadeep Mukhopadhyay*
Department of Electronics and Computer Engineering, National Institute of Technology Arunachal
Pradesh, Ministry of Human Resource Development (Government of India), Yupia, District-Papum
Pare, Arunachal Pradesh, India
Abstract
The straight polymethylmethacrylate (PMMA) microchannels are fabricated by the maskless
lithography, hot embossing lithography and direct bonding technique. Total 120 individual
PMMA microfluidic devices are fabricated by author’s own hands-on completely. Total 120
individual audio video interleave files as ‘FileName.avi’ are recorded and analyzed by
author. The surface-driven capillary flow of different aqueous microparticle suspensions are
recorded in these straight PMMA microchannels. The effects of channel aspect ratio, effective
viscosity and surface wettability on the surface-driven capillary flow of different aqueous
microparticle suspensions are analyzed.
Keywords: PMMA, microchannel, water, suspension
INTRODUCTION
The surface-driven capillary flow of different
liquids has been widely studied by
Mukhopadhyay et al. [1–11]. Effects of
different properties on the surface-driven
capillary flow have been studied [1–11]. These
studies may be useful for commercial
bioengineering applications [3, 7, 9]. Also,
these studies may be useful to study the
nanofluidic flow in future [9].
In this research paper, the pristine PMMA
microfluidic devices are fabricated. Next,
dielectric barrier discharge (DBD) plasma
processed PMMA microfluidic devices are
fabricated. After that, the influence of effective
viscosity on the surface-driven capillary flow
of aqueous microparticle suspensions is
studied in the straight PMMA microchannels.
Finally, the effects of channel aspect ratio and
surface wettability on the surface-driven
capillary flow of aqueous microparticle
suspensions are studied in the straight PMMA
microchannels.
EXPERIMENTAL TECHNIQUES
PMMA is a suitable polymer to fabricate the
microfluidic devices [9]. In this research
paper, PMMA is chosen as material due to its
optical transparency. This optical transparency
facilitates the recording of surface-driven
microfluidic flow. Maskless lithography (non-
contact lithography) and hot embossing
lithography (contact lithography) are the
suitable lithographic techniques to fabricate
the PMMA microfluidic devices. Before
starting the hot embossing lithography, the
silicon based SU-8 stamp should be placed on
the PMMA wafer and one single-side polished
silicon wafer should be placed below the
PMMA wafer. This PMMA wafer is used to
generate PMMA microchannels. After the
creation of PMMA microchannels, the PMMA
wafer is called as PMMA microchannel
substrate.
The experimental arrangement containing
three wafers (stamp, PMMA wafer, and
single-side polished silicon wafer) is placed
inside the embossing chamber to start the hot
embossing lithography. CMOS camera is a
suitable optical instrument to record the
surface-driven capillary flow due to its time-
scale resolution and length-scale resolution.
Direct bonding technique is chosen as the
method to seal the PMMA lid on the PMMA

Volume 3, Issue 3
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Reactive Distillation Design and Control
K. Nagamalleswara Rao*
Department of Chemical Engineering, School of Civil and Chemical Engineering, VIT University,
Vellore, Tamil Nadu, India
Abstract
This study deals with the design and control strategies of reactive distillation process. Steady
state design including phase equilibrium and chemical equilibrium were studied. Dynamic
simulations were conducted by designing control structure. The developed control structure
contains level controller, pressure controller, temperature controller. The developed control
structure has shown good performance in withstanding the various process disturbances.
Keywords: Dynamic simulations, control structure, reactive distillation, steady state design
INTRODUCTION
Reactive distillation is the combination of
reaction and separation processes conducted in
a single unit. This combination increases
conversion and improves selectivity and
facilitates separation tasks [1, 29]. Designing
and operation of this process is more complex
than the individual and conventional chemical
reaction, distillation operation. Advantage of
reactive distillation is, if reactions are
reversible and if the products can be removed
by distillation as the reaction proceeds, high
reactions can be achieved even if the reaction
equilibrium constant is small. Another
advantage is that it avoids the elimination of
complex separation schemes, for example
separation of azeotropes.
Reactive distillation has both, economic and
environmental benefits due to reductions in
capital and energy costs. Examples for the
reactive distillation are: production of MTBE
(Methyl tertiary butyl ether) from isobutene
and methanol, production of ETBE (Ethyl
tertiary butyl ether) from isobutene and
ethanol, production of methyl acetate from
methanol and acetic acid, production of
ethylacetate from ethanol and acetic acid,
hexyl acetate from 1-hexanol and acetic acid,
butyl acetate from butanol and methyl acetate
are well-known. In the case of methyl acetate,
at equilibrium limit, a completely reactive
column can produce high purity methyl acetate
and water as products from pure component
feeds of methanol and acetic acid.
Reactive distillation has several advantages
compared to conventional processes and it is
an important tool for future efficient
processing. RD reduces capital cost and
increases reactant conversion [2, 3]. Energy-
saving procedures are also developed based on
RD and pressure swing distillation results [4,
5]. Design of RD columns becomes
complicated by interaction between phase and
chemical reaction equilibrium [6]. In
conventional distillation, an increase in
fractionation is always associated with an
improvement in process performance
(separation of key components); the same does
not necessarily apply to reactive distillation.
Using different examples, several reactive
distillation columns were designed for various
feed compositions and design philosophies. It
was found that the best designs incorporated
high reflux ratios with a restricted number of
theoretical stages, and that increasing the
number of theoretical stages could actually be
detrimental to process performance [6].
In general, however, it may be said that the
design of reactive distillation columns is not
only a compromise between performance and
energy consumption (as is the case with
conventional distillation) but an optimization
of a wide range of interacting parameters. It is
found that the reactive distillation process has
distinct advantages over the conventional
batch reactor process [7]. Study of the
potential of entrainer in reactive distillation
involving high boiling reactants is done to

Volume 3, Issue 3
www.stmjournals.com
Review on Suitability of Ionic Liquids for Heat
Transfer Applications
Divya P. Soman, P. Kalaichelvi*, T.K. Radhakrishnan
Department of Chemical Engineering, National Institute of Technology Tiruchirappalli,
Tamil Nadu, India
Abstract
The thermophysical properties of thermal fluids play a key role in the design of heat transfer
equipment. Better their properties, greater is the efficiency of the heat transfer equipment. The
field of ionic liquids (ILs) is growing, at a very fast pace, as many beneficial properties of
these are identified and utilized. The suitability of the ionic liquids as thermal fluid can be
assured by examining their thermophysical properties. In this paper, a review of the studies of
thermophysical properties of ILs such as thermal conductivity, heat capacity, density and
viscosity and their applications in heat transfer are highlighted. Basically, ILs are used as
solvents and due to their favorable properties, they can be efficiently used in heat transfer
applications also. Since there are more reviews on benefits of ILs available, in this review,
applications of them in heat transfer are focused.
Keywords: Ionic liquids, thermal conductivity, specific heat, density, viscosity, heat transfer
*Author for Correspondence E-mail: kalai@nitt.edu
INTRODUCTION
Physical properties of thermal fluids greatly
influence the efficiency of heat transfer
systems and hence there is a strong incentive
to develop fluids with improved properties.
Recently, the demand for heat transfer fluids
that can be reused and/or regenerated is
increasing to a great extent due to pollution
and economical reasons.
Ionic liquids are fluids with specific properties
such as high thermal stability, low volatility,
and low flammability, which are favorable for
heat transfer applications [1, 2]. The ILs are
mostly used as solvents [3–11], besides being
used as heat transfer fluids in solar collectors
[12–14], as catalysts [9, 15–19], electrolytes
[9, 20–26], as reaction media [9, 27–31] and in
biosensors [32]. However, very few
researchers have reported about their
applications in the heat transfer aspects.
This review provides a brief introduction on
ILs followed by an overview of their
thermophysical properties viz., density,
thermal conductivity, heat capacity, viscosity
and surface tension. In addition, the
applications of ILs in heat transfer are also
emphasized.
IONIC LIQUIDS
ILs are a class of organic salts with melting
point temperatures below 100°C [1, 3, 33, 34].
The ILs are classified into four types based on
the type of their cations, as: (1)
alkylammonium-, (2) dialkylimidazolium-, (3)
phosphonium- and (4) N-alkylpyridinium-
based ILs (Figure 1) [33].

Emerging Trends in Chemical Engineering vol 3 issue 3

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Emerging Trends in Chemical Engineering vol 3 issue 3