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Continuous Counter-Current Microfluidic Liquid-Liquid Extraction Achieved Using a Pair of Wettable Screen Meshes.

Quinn McCulloch1,2,3, Xeph Ivankovich1, George S Goff1

  • 1Materials Synthesis and Integrated Devices (MPA-11), Los Alamos National Laboratory, Los Alamos, New Mexico, USA.

Journal of Separation Science
|January 19, 2026
PubMed
Summary
This summary is machine-generated.

This study introduces a novel microfluidic device for stable, continuous counter-current liquid-liquid extraction, overcoming previous flow challenges. The device achieved approximately 37 equilibrium stages, demonstrating efficient separation performance over 36 hours.

Keywords:
Raman spectroscopysolvent extractionsurface functionalizationsurface patterningwettability

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Area of Science:

  • Chemical Engineering
  • Separation Science
  • Microfluidics

Background:

  • Continuous counter-current microfluidic liquid-liquid extraction offers efficient separations in a small footprint.
  • Stable flow in such devices is challenging due to the need for capillary forces to exceed hydrodynamic forces.

Purpose of the Study:

  • To present a novel microfluidic device and flow strategies for stable, long-duration continuous counter-current liquid-liquid extraction.
  • To develop and apply methodologies for quantifying the separation performance and theoretical equilibrium stages achieved.

Main Methods:

  • Fabrication of a woven mesh screen-based microfluidic device architecture.
  • Surface functionalization for conjugate wettability and flow optimization to prevent bubbles and carryover.
  • Automated Raman spectroscopy for in-line solute quantitation in a ternary system (tert-butanol in toluene/water).

Main Results:

  • Achieved stable, continuous counter-current flow for over 36 hours with good performance.
  • Quantified separation performance, observing approximately 37 equilibrium stages (37 ± 13) using Kremser Group Method analysis.
  • Demonstrated device efficacy with a ternary system featuring a low solute partition ratio.

Conclusions:

  • The novel microfluidic device and flow approaches successfully overcome force-balance challenges for stable counter-current extraction.
  • The device architecture is easily fabricated and enables high-performance separations with a significant number of theoretical equilibrium stages.
  • This work paves the way for practical applications of continuous counter-current microfluidic extraction.