Achieving ultra‐rapid liquid–liquid extraction: Introducing a novel “pre‐dispersion” stage within a chaotic microreactor

Abstract Achieving ultra‐rapid and high‐efficiency liquid–liquid extraction with minimal energy consumption remains a significant challenge in the chemical separation process, especially for separating substances in demanding environments. This challenge is addressed by the development of a novel oscillating feedback microreactor (OFM) equipped with a multi‐orifice pre‐dispersion stage (i.e., MOFM). The MOFM's distinctive structural design ingeniously combines pre‐dispersion (through microporous inlets) and chaotic droplet fragmentation (through OFM structure). Computational fluid dynamics simulations reveal that three chaotic secondary flows (feedback, vortex, and oscillation) are effectively generated to enhance liquid–liquid dispersion and mass transfer within MOFM. Meanwhile, experimental results demonstrate extraction efficiencies approaching 100% within millisecond residence times, representing a 54% improvement in efficiency and a 111% increase in mass transfer coefficient compared to conventional designs. Predictive models for pressure drop and mass transfer coefficient, validated against experimental data, provide a robust theoretical foundation for the design and optimization of next‐generation chaotic microreactors.