Investigation on global and local <scp>RTD</scp> , mixing, and heat transfer of a high‐throughput passive chaotic microreactor

Abstract Understanding residence time distribution (RTD) and mass/heat performance is crucial for microreactor design and optimization. This study investigates global and local RTD in a chaotic microreactor using computational fluid dynamics (CFD) simulations and experiments, and a new RTD model is established. Global RTD analysis indicates that higher flow rates reduce channeling and stagnant flows, decreasing RTD variance by 80.7% within the range of 5–20 mL/min. Local RTD analysis reveals continuous stirred tank reactor (CSTR)‐like mixing characteristics within individual stages, enabling rapid homogenization. Enhanced chaotic mixing reduces micromixing time by four orders of magnitude at high flow rates, and significantly improves heat transfer, with an increase in Nusselt number of 220.7%. Optimized RTD and intensified chaotic mixing collectively establish a spatiotemporally uniform reaction environment, enabling high‐throughput synthesis of Mn 0.75 Ni 0.25 CO 3 microparticles with a uniform size distribution ( σ = 0.36 μm), demonstrating scalable synthesis potential.