Macro-Microdevice-Based Process Intensification of Gas–Liquid Chemical Processes

Due to the microscale effect, the microreactor shows special advantages in the enhancement of the gas–liquid chemical process. However, the balance between the enhancement effect and the high throughput of the gas–liquid chemical process is still a challenge. This study developed a macro-microdevice (feature size 4000 μm) integrated with helical-shaped internal (HSI) to achieve both process intensification and scale-up for the gas–liquid chemical processes. Through a combined approach integrating computational fluid dynamics (CFD) simulations with flow visualization experiments, the gas–liquid process enhancement effect of the HSI was studied. Compared to the average bubble diameter produced by the flow reactor, the macro-microdevice achieves a 41.2% reduction in bubble diameter while maintaining favorable pressure drop characteristics. Effects of pitches, diameter of internal, feature size, and dimensions of the gas inlet on bubble diameter were studied, and the optimal structural parameters were determined. Buckingham’s π theorem-derived model enables precise bubble control via geometric parameters, establishing quantitative guidelines for scalable macro-microdevice intensification. The macro-microdevice would play a key role in gas–liquid chemical processes.