<p>Electroemulsification offers an energy-efficient, surfactant sparing alternative to mechanical dispersion. While uniform fields deform droplets symmetrically, non-uniform fields impose steep field gradients that localize Maxwell stresses, enabling precise, low power control of droplet formation, migration and breakup. This review synthesizes diverse studies on electroemulsification to elucidate how key mechanisms such as the Taylor-Melcher Framework, dielectrophoresis, space-charge and ionic wind govern droplet behavior across single and multiphase regimes. We map the roles of conductivity, permittivity, viscosity ratios, and field frequency in dictating droplet deformation and breakup in electroemulsification. Comparative analysis shows that non-uniform configurations routinely achieve narrower size distributions and lower specific energy than uniform systems, while mitigating electrode fouling through contactless or insulated designs. Emerging nozzleless corona and microelectrode platforms further extend operation to high viscosity or biocompatible systems, though throughput remains constrained by the submillimeter active zone. Critical challenges include scaling high gradient emitters, predicting droplet trajectories in leaky dielectric regimes, and balancing polydispersity against production rate. We conclude by outlining research priorities into areas such as designing parallel emitter arrays that keep strong field gradients while expanding the active area; and secondly, developing a unified electrokinetic model that links charge convection, interfacial rheology and fluid flow. Addressing these will accelerate translation of non-uniform field electroemulsification from laboratory demonstrations to continuous, industry scale processes.</p>

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Electroemulsification mechanisms under non-uniform electric field

  • Priscilla Adiweh Aprepary,
  • Ehsan Khoshbakhtnejad,
  • Bibiyan Krishna Shrestha,
  • Simon-Peter Bortey,
  • Niloufar Sadoughipour,
  • Hossein Sojoudi

摘要

Electroemulsification offers an energy-efficient, surfactant sparing alternative to mechanical dispersion. While uniform fields deform droplets symmetrically, non-uniform fields impose steep field gradients that localize Maxwell stresses, enabling precise, low power control of droplet formation, migration and breakup. This review synthesizes diverse studies on electroemulsification to elucidate how key mechanisms such as the Taylor-Melcher Framework, dielectrophoresis, space-charge and ionic wind govern droplet behavior across single and multiphase regimes. We map the roles of conductivity, permittivity, viscosity ratios, and field frequency in dictating droplet deformation and breakup in electroemulsification. Comparative analysis shows that non-uniform configurations routinely achieve narrower size distributions and lower specific energy than uniform systems, while mitigating electrode fouling through contactless or insulated designs. Emerging nozzleless corona and microelectrode platforms further extend operation to high viscosity or biocompatible systems, though throughput remains constrained by the submillimeter active zone. Critical challenges include scaling high gradient emitters, predicting droplet trajectories in leaky dielectric regimes, and balancing polydispersity against production rate. We conclude by outlining research priorities into areas such as designing parallel emitter arrays that keep strong field gradients while expanding the active area; and secondly, developing a unified electrokinetic model that links charge convection, interfacial rheology and fluid flow. Addressing these will accelerate translation of non-uniform field electroemulsification from laboratory demonstrations to continuous, industry scale processes.