The aim of this study is the development of an emulsification device for two immiscible liquids with a total volume of approximately 3 mL. The heart of the device is a piston, with an aluminum plate fixed at its tip, which moves periodically up and down inside a rectangular cell. The plate geometry (uniform or non-uniform height) affects significantly both the emulsions stability and the size of the droplets of the prepared emulsions. Five parameters are examined during testing (surfactant type, surfactant concentration, proportion of immiscible liquids, piston stroke frequency, duration of emulsification) and all of them appear to have an important role in the resulting droplet size distribution. A macroscopic theoretical model is developed for the determination of the main hydrodynamic parameters of the innovative device. It is shown that the non-uniform height plate achieves higher shear rates when compared to the uniform height plate because of the smaller gap between the plate and the cell walls. However, the benefits of the higher shear rate are overturned by the larger effective breakage time encountered in the uniform height plate resulting from the larger surface area of its sides. The results of the emulsification experiments are analyzed using the parameter values derived by the developed model.
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