Three-dimensional numerical investigations of a novel passive micromixer were carried out to analyze the hydrodynamic and thermal behaviors of Nano-Non-Newtonian fluids. Mass and heat transfer characteristics of two heated fluids have been investigated to understand the quantitative and qualitative fluid faction distributions with temperature homogenization. The effect of fluid behavior and different Al₂O₃ nanoparticles concentrations on the pressure drop and thermal mixing performances were studied for different Reynolds number (from 0.1 to 25). The performance improvement simulation was conducted in intervals of various Nanoparticles concentrations (φ = 0 to 5%) with Power-law index (n) using CFD. The proposed micromixer displayed a mixing energy cost of 50–60 comparable to that achieved for a recent micromixer (2021y) in terms of fluid homogenization. The analysis exhibited that for high nanofluid concentrations, having a strong chaotic flow enhances significantly the hydrodynamic and thermal performances for all Reynolds numbers. The visualization of vortex core region of mass fraction and path lines presents that the proposed design exhibits a rapid thermal mixing rate that tends to 0.99%, and a mass fraction mixing rate of more than 0.93% with very low pressure losses, thus the proposed micromixer can be utilized to enhance homogenization in different Nano-Non-Newtonian mechanism with minimum energy.

In this study, a numerical investigation based on the CFD method is carried out to study the unsteady laminar flow of Newtonian fluid with a high viscosity in a three-dimensional simulation of a twisted double planetary mixer, which is composed of two agitating rods inside a moving tank. The considered stirring protocol is a “Continuous sine squared motion” by using the dynamic mesh model and user-defined functions (UDFs)to define the velocity profiles. The chaotic advection is obtained in our active mixers by the temporal modulation of rotational velocities of the moving walls in order to enhance the mixing of the fluid for a low Reynolds number and a high Peclet number. For this goal, we applied the Poincaré section and Lyapunov exponent as reliable mathematic tools for checking mixing quality by tracking a number of massless particles inside the fluid domain. Additionally, we investigated the development of fluid kinematics proprieties, such as vorticity, helicity, strain rate and elongation rate, at various time periods in order to view the impact of temporal modulation on the flow properties. The results of the mentioned simulation showed that it is possible to obtain a chaotic advection after a relatively short time, which can deeply enhance mixing fluid efficiency.

The present paper investigates the steady laminar flow and thermal mixing performance of non-Newtonian Al₂O₃ nanofluids within a two-layer cross-channel micromixer, employing three-dimensional numerical simulations to solve the governing equations across a low Reynolds number range (0.1 to 50). It also addresses secondary flows and thermal mixing performance with two distinct inlet temperatures for thin nanofluids. Additionally, it explores how fluid properties and varying concentrations of Al₂O₃ nanoparticles impact thermal mixing efficiency and entropy generation. Simulations were conducted to optimize performance by adjusting the power law index (n) across different nanoparticle concentrations (1–5%). The findings show that magnetohydrodynamics can enhance mixing efficiency by generating vortices and altering flow behavior, providing important guidance for improving microfluidic system designs in practical applications.