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CHAPTER 1 Introduction CHAPTER OUTLINE 1.1 MicromixersandMixinginMicroscale...............................................................................................1 1.2 MicromixersasMicroreactors...........................................................................................................5 1.3 OrganizationoftheBook....................................................................................................................7 References..............................................................................................................................................8 1.1 MICROMIXERS AND MIXING IN MICROSCALE Thisbookdiscussesthedesign,fabrication,andcharacterizationofmicromixers,whicharedefinedas miniaturizedmixingdevicesforatleasttwodifferentphases,whichcouldbeliquids,solids,orgases. The structures of a micromixer are fabricated partially or in whole, using microtechnology or precisionengineering.Thecharacteristicchannelsizeofmicromixersisinthesub-millimeterrange. Common channel widths are on the order of 100–500mm, while channel length could be a few millimetersormore.Thechannelheightisontheorderofthechannelwidthorissmaller.Theoverall volumedefinedbyamicromixerisfrommicroliterstomilliliters.Comparedtomolecularsizescale, the length scale and volume scale of micromixers are very large. This fact leads to two key char- acteristics of micromixers. First, designing the micromixers relies on manipulating the flow using channel geometry or external disturbances. Second, while micromixers bring advantages and new featuresintochemicalengineering,molecular-levelprocessessuchasreactionkineticsremainalmost unchanged. Mixing is a transport process for species, temperature, and phases to reduce inhomogeneity. Mixing leads to secondary effects such as reaction and change in properties. In conventional macroscale mixing techniques, there are three established terminologies for mixing: macromixing, mesomixing, and micromixing [1]. Macromixing refers to mixing governed by the largest scale of fluid motion. For instance, the scale of macromixing corresponds to the diameter of the mixing tank. Micromixing is mixing at the smallest scale of fluid motion and molecular motion. In conventional macroscale mixing, the smallest scale of fluid motion is the size of turbulent eddies, also called the Kolmogorov scale. Mesomixing is in the scale between macromixing and micro- scale. Although micromixers may have dimensions on the order of micrometers, transport process in micromixers may still be classified as mesomixing. Since structures in micromixers may have a size approaching the Kolmogorov scale, this book avoids the use of micromixing for describing mixing processes. Therearemanydifferentwaystoprovidemixinginmacroscalesuchasmoleculardiffusion,eddy diffusion,advection,andTaylordispersion.Eddydiffusionisthetransportoflargegroupsofspecies 1 Nam-TrungNguyen:Micromixers,Secondedition.DOI:10.1016/B978-1-4377-3520-8.00001-2 Copyright(cid:1)2012ElsevierInc.Allrightsreserved. 2 CHAPTER 1 Introduction andrequiresaturbulentflow.Becauseofthedominantviscouseffectinmicroscale,turbulenceisnot possible in micromixers. Mixing based on eddy diffusion is therefore not relevant for micromixers. Thus, the main transport phenomena in micromixers include molecular diffusion, advection, and Taylor dispersion. Molecular diffusion is caused by the random motion of molecules. This transport mechanism is characterized by the molecular diffusion coefficient. Advection is the transport phenomenacausedbyfluidmotion.AsimpleEulerianvelocitycanleadtoachaoticdistributionofthe mixedspecies.Astableandlaminarflowcanalsoleadtochaoticadvection.Thus,chaoticadvection wouldbeidealforthelaminarflowconditioninmicromixers.Taylordispersionisadvectioncausedby a velocity gradient. Axial dispersion occurs due to advection and inter-diffusion of fluid layers with different velocities.Due tothiseffect, mixingbased onTaylordispersion can betwoorthree orders faster than that based on pure molecular diffusion. Designingmicromixersisacompletelynewengineeringdiscipline,becauseexistingdesignsin macroscale cannot simply scale down for microscale applications. One of the main challenges related to miniaturization is the dominance of surface effects over volume effects. Actuation conceptsbasedonvolumeforcesworkingwellin macroscalemayhaveproblemsinmicroscale.A magnetic stirrer is a typical example of the ratio between surface forces and volume forces. It consists of a magnet bar and a rotating magnet or stationary electromagnets creating a rotating magnetic field. The driving magnetic force is proportional to the volume of the magnet bar, while thefrictionforceisproportionaltoitssurface.Scalingdownthestirrerfollowstheso-calledcube- squarelaw.Thismeansshrinkingdownthestirbar10timeswouldroughlydecreaseitsvolumeby 1000timesanditssurfaceonlyby100times.Withitsoriginalsize,theexternalmagneticfieldcan generateaforceofthesameorderofthefrictionforceandcausethestirbartomove.Scalingdown thesize10timesinthesamemagneticfieldwouldcreateasmalldrivingforce,whichisonly1/10th of the friction force. As a consequence, the stir bar cannot move. A surface force-based actuation conceptwouldallowscalingdownbecausetheratiobetweendrivingforceandfrictionforcewould remain unchanged. The dominant surface phenomena in microscale also affect mixing processes with immiscible interfaces. For a solid–liquid system, mixing starts with suspension of the solid particles. The dis- solving process follows suspension. The largesurface-to-volumeratio inmicroscale isan advantage for the dissolving process, making it easily achievable. Thus, the main challenge is the suspension process.Becauseoftheirrelativelylargesizesandthecorrespondinglysmalldiffusioncoefficient,the particlecanonlybesuspendedinmicroscalewiththehelpofchaoticadvection.Therefore,thequality ofsolid–liquidmixing inmicroscale isdetermined by the suspension process. Inasystemofimmiscibleliquids,additionalenergyisneededtoovercomeinterfacialtension.On theonehand,dispersing theimmisciblephasesisadifficulttask.Ontheotherhand,surfacetension breaksthestretchedfluidintosegmentsandformsmicrodroplets.Theadvantageofmicroscaleisthat theformationprocesscanbecontrolleddowntoeachindividualdroplet.Therefore,anemulsionwith homogenous droplet size can beachievedin micromixers. Gas–liquid systems are other systems affected by the dominant surface phenomena. Some appli- cationssuchashydrogenation,oxidation,carbonation,andchlorinationrequiregas–liquiddispersion. Unlike liquid–liquid emulsion, gas molecules can be absorbed into the liquid phase. The gas–liquid mixing process consists of two processes: dispersion of the gas bubble and absorption of gas mole- cules.Whileabsorptionispromotedduetothelargeravailableinterfacialarea,dispersionoftinygas bubblesisthe main challenge indesigning micromixersfor a gas–liquidsystem. 1.1 Micromixers and mixing in microscale 3 Besides surface phenomena, the laminar flow condition is another challenge for designing micromixers.Theproblemsinmicromixersaresimilartothoseinmacroscalelaminarmixers.Laminar mixersexistinmanyprocessesoffood,biotechnological,andpharmaceuticalindustriesbecauseofthe high viscosity and slow flow velocity involved. For many applications, the flow velocity in micro- mixerscannotbetoohigh.Thesmallsizeofmicromixersleadstoanextremelylargeshearstressin mixingdevices,evenatrelativelyslowflowvelocities.Thisshearstressmaydamagecellsandother sensitive bioparticles. In complex fluids with large molecules and cells, the fluid properties become non-Newtonianathighshearstress.Ontheonehand,thehighshearcompromisesboththemetabolic andphysicalintegrityofcells.Ontheotherhand,viscoelasticeffectsunderthisconditionmayleadto flowinstability, which can bewell utilized for improvingmixing. In this book, micromixers are categorized as passive micromixers and active micromixers [2] (Fig. 1.1). Except the kinetic energy of the flow itself, passive micromixers do not require external energyfor disturbance. Themixingprocessrelies entirely on diffusion orchaotic advection.Passive mixersarefurthercategorizedaccordingtothewayinwhichtheinterfacebetweenthemixedphasesis arranged:parallellamination,seriallamination,segmentation,chaoticadvection,andmultiphaseflow. In active micromixers, disturbances are induced by an external field. Thus, active mixers can be categorized according to the physical phenomenon of the disturbance as a pressure-driven flow, electrohydrodynamics, dielectrophoretics, electrokinetics, magnetohydrodynamics, acoustics, and heat.Thedesignsofactivemicromixersareoftencomplexbecauseofadditionalcomponents.External power sources are needed for the operation of active micromixers. Thus, the integration of active mixersinamicrofluidicsystemisbothchallengingandexpensive.Incontrast,passivemicromixersdo notrequireexternalactuatorsexceptthoseforfluiddelivery.Passivemicromixersarerobust,stablein operation, and easily integrated in a more complex system. Figure 1.1 depicts an overview on the different typesof micromixers discussedin thisbook. The time scale of mixing processes changes with miniaturization. Most micromixers are used as areactionplatformforanalysisorsynthesis.Mixingandchemicalreactionsareinterrelated[3].While reaction kinetics and reaction time do not change with miniaturization, mixing time can be signifi- cantlyaffectedbythemixerdesignaswellasbythemixertype.Thisfactleadstotwoimportantissues relatedtochemicalreaction:measurementofrealreactionkineticsandcontroloverreactionproducts. Inmacroscale,mixingtimeisusuallymuchlargerthanreactiontime.Thereactionrateistherefore mostlydeterminedbythemixingtime.Inmicroscale,mixingtimecanbereducedtothesameorderor evenlessthanthereactiontime.Measurementofrealreactionkineticsisthereforepossibleinmicroscale. Mixingtimeand,consequently,thereactionproductscanbepossiblycontrolledinmicroscale.If thereactionresultsinonlyoneproduct,mixingtimecanonlyaffectthereactionrate.Iftherearemore than one product, mixing time determines the product composition and distribution. The following example shows the impact of mixing type on reaction results. Assuming a reaction between the substrate S and reagent R: SþR/P (1.1) 1 whereP isthedesiredreactionproduct.However,P canreactwithRtoformanundesiredproductP : 1 1 2 P þR/P (1.2) 1 2 If mixing relies on the relatively slow process of molecular diffusion, as in the case of a parallel laminationmicromixer,P hasenoughtimetoreactwithR.Therefore,themainproductofthereaction 1 4 CHAPTER 1 Introduction FIGURE1.1 Passiveandactivemicromixers. 1.2 Micromixers as microreactors 5 FIGURE1.2 Effectofmicromixertypeonachemicalreactionwithmorethanoneproduct:(a)fastmixingwithchaotic advectionand(b)slowmixingwithmoleculardiffusion.(S:substrate,R:reagent,P1:product1,P2:product2). processisP .Ifmixingoccursquickly,forinstance,throughchaoticadvection,allmoleculesofRare 2 utilizedinthefirstreactiontoformP ,notmanyRmoleculesareleftforthesecondaryreaction.Thus, 1 the main productofthe reaction isP . Figure 1.2 illustrates this problem. 1 1.2 MICROMIXERS AS MICROREACTORS Since2000,wehavewitnessedincreasingactivitiesintheuseofmicrofluidictechnologyinanalytical chemistry and chemical production. Mixing is the central process of most microfluidic devices for medicaldiagnostics,geneticsequencing,chemistryproduction,drugdiscovery,andproteomics.The impactofmicromixersonmicrofluidicsystemsforchemicalanalysisandsynthesisissimilartothatof transistorsinintegratedcircuits.Althoughmicromixersforanalysisandsynthesisaredifferent,some applications require both classes. For instance, in combinatorial chemistry and screening micro- devices,micromixersare analyticaltoolsforinformation gatheringandsynthetictoolsfor providing minute quantities ofproducts. In micromixers for analysis, information gained from this product is the purpose of the mixing process and the reaction. The amount of the reaction product only needs to fulfill the delectability requirements.Incontrast,reactionproductsinsynthesisapplicationsareusedtomakematerialswith improvedpropertiesatfavorableconditionsgivenbymicromixers.Alargeamountoftheproductmay 6 CHAPTER 1 Introduction beneeded.Thus,thedesignofmicromixersforsynthesisshouldbereadyfornumberingupinthecase ofa large-scaleproduction [4]. Micromixers as microreactors will potentially have a large impact on chemical technology. Because of their small size, micromixers allow control over a number of parameters of production processes in chemistry and the pharmaceutical industry. Reaction conditions that are unusual in macroscalearetechnicallypossibleinmicromixers.Theadvantagesofreactioninmicromixersare small thermal inertia, uniform temperature, high gradient of the different physical fields, short residence time, and a high surface-to-volume ratio. The small thermal inertia allows fast and precise temperature control in micromixers. Miniaturization leads to higher rates of heat and mass transfer. Compared to their macroscale counterparts, micromixers can offer more aggressive reaction conditions. The large surface-to-volume ratio allows for an effective suppression of homogenoussidereactionsinheterogeneouslycatalyzedgas-phasereactions.Thesmallsizemakes reaction in micromixers safe because of the suppression of flames and explosions. Explosions can be suppressed by using mixing channels with hydraulic diameter less than the quenching distance (cid:2) [5]. For instance, the fluorination of toulene with fluorine can be carried out at –10 C in micro- (cid:2) mixers.Conventionalreactorswouldrequireatemperatureof–70 Cduetotheexplosivenatureof thereaction[5].Inthecaseofaccidents,thesmallamountsofhazardousreactionproductsareeasy to contain. Micromixers as microreactors enable a faster transfer of research results into production. Since scalingupthemixerdesignisnotpossible,labsetupcanimmediatelybetransferredintolarge-scale productionbynumberingup.Sincenumberingupistheonlyoptionformicromixers,scalinglawleads to high ratio between device material and reaction volume. This means, fixed production costs will increase with miniaturization because of the higher costs of materials and infrastructure. If micro- reactors deliver a similar performance to their conventional macroscale counterparts, the higher production costs will make micromixers unprofitable for chemical production. However, for some particular products, the smaller production capacity may save costs through other factors such as replacingabatchprocessbyacontinuousprocess.Forinstance,duetoslowmassandheattransferin macroscalereactors,reactiontimeforfinechemicalsisdeterminedbymixingandismuchlongerthan needed for reaction kinetics. Replacing a batch-based macroscale reactor by a continuous-flow microreactor can significantly reduce the reaction time. The reactor volume is smaller, but the total throughputper unittimeishigher.Asaresult,forthe same amount ofproductsthe reaction process wouldbe carriedout faster inmicroreactors. In addition, as illustrated in Fig. 1.2, selectivity of the reaction may increase with micromixers. Productionyields of microreactors could exceed those of batch-basedmacroscale reactors. The next cost-saving factor of micromixers for chemical production is the intensification process. The larger surface-to-volumeratioprovidesmoresurfaceforcatalystincorporation.Comparedtoitsmacroscale counterpart,theamountofcatalystneededinamicroreactorcanbedecreasedbyafactorof1000.If thecostofthecatalystsissignificantintheoverallproduction,savingcatalystscancompensateforthe largeamountof constructionmaterials needed for numbering-up microreactors. Micromixershaveanindirectimpactonnationalsecurityduetothepossibilityofon-sideportable detection systemsfor chemical weaponsand explosive.However, due to its portability, micromixers couldbemisusedbycriminalsandterrorists[5].Aminiaturechemicalplantfittedintoasuitcasecould be misused for the production of drugs and hazardous gases. Raw chemicals may not be detectable prior to reactions in these miniature plants. Lethal nerve gases could be formed by two primary 1.3 Organization of the book 7 less-toxiccompoundsinmicromixers.Detectionfacilitiesshouldbeextendedtothesepre-compounds to counter this potential misuse. 1.3 ORGANIZATION OF THE BOOK This book offers a wide spectrum for the study of the mixing processes in microscale, from funda- mentaltransporteffectstoavarietyofdesignstospecificapplicationsinchemistryandlifesciences. AftertheintroductioninChapter1,Chapters2and3discussthebasicterminologyandfundamental physicsoftransporteffectsthatwillbeusedfordesigningmicromixers.Chapter2discussesindetail thethreekeymasstransporteffectsoftenusedinmicromixers:moleculardiffusion,Taylordispersion, andchaoticadvection.Thechallengesandadvantagesofminiaturizationinmixingarehighlightedin this chapter with the help of scaling laws. The scaling laws are discussed based on nondimensional numbers which represent relationships between different transport effects. Chapter 3 discusses the fundamentals of the different numerical schemes for modeling the transport phenomena in micromixers. Chapter 4 gives an overview on available microtechnologies for making micromixers. Basic techniques of conventional silicon-based microtechnologies are covered. Since polymers are chemi- cally and biologically compatible, polymeric micromachining is the focus of this chapter. Technol- ogiesforbondingandsealingarenecessaryformakingamicromixer.Thischapteralsodiscussesthe design and fabrication of fluidic interconnects that are needed for interfacing micromixer to larger- scale devices and equipments. Different concepts and designs for micromixers are discussed in Chapters 5 to 7. Although all mixing concepts involve molecular diffusion, Chapter 5 only discusses concepts where molecular diffusionistheprimarymasstransferprocess.Basedonthearrangementofthemixedphases,thefour mixertypesdiscussedinthischapterareparallelmixer,serialmixer,sequentialmixer,andinjection mixer. Chapter6isdedicatedtomicromixersbasedonchaoticadvection.Incontrasttothemicromixers discussedinChapter5,thisclassofmicromixersreliesonbulkmasstransportformixing.Thegeneral conceptsforgeneratingchaoticadvectionarestretchingandfoldingoffluidstreams.Thesestretching andfoldingactionscanbeimplementedinaplanardesignorinacomplexthree-dimensionalchannel structure. A special case of chaotic advection is mixing in microdroplets. Manipulation of the flow fieldinsideadropletcanleadtothesamestretchingandfoldingeffectsasachievedinacontinuous- flowplatform. Chapter 7 discusses activemixers, where mixing is achievedwith energyinduced by an external source.Activemixersaresimilartoconventionalmacroscalemixerswherefluidmotionisdrivenbyan impeller.However,asdiscussedinSection1.1,miniaturizationoftheimpellerconceptwouldnotwork because of the dominant viscous force in microscale. This chapter discusses different concepts for inducing a disturbance into the flow field. The use of electrohydrodynamic, dielectrophoretic, elec- trokinetic, magnetohydrodynamic, acoustic,and thermal effects inmicromixersis discussed here. Chapter8summarizeskeydiagnosticstechniquesforcharacterizationofmicromixers.Sinceboth velocityfieldandconcentrationfieldareimportantforgoodmixing,diagnosticstechniquesforthese fields are the focus of this chapter. The quantification of the extent of mixing is important for the evaluation ofperformance as well asthe design optimizationof micromixers. 8 CHAPTER 1 Introduction Chapter9discussesthecurrentapplicationsofmicromixers.Differentapplicationsneeddifferent designrequirements. Thechapterdiscussesapplications fromthe two major areas: lab-on-a-chip for chemicalandbiochemicalanalysisandchemicalproduction.Thischapteralsorecommendsmaterials andmixertypes for each application area. References [1] E.L.Paul, V.A.Atiemo-Oberg,S.M.Kresta, Handbookof IndustrialMixing, Wiley,New York,2004. [2] N.T.Nguyen,Z.G.Wu,“Micromixers–areview”,JournalofMicromechanicsandMicroengineeringvol. 15 (2005), R1–R16. [3] J.RBourne,“MixingandSelectivityofChemical Reactions”,OrganicProcessResearch &Development, vol. 7 (2003),471–508. [4] K.F.Jensen,TheImpactofMEMSonthechemicalandpharmaceuticalindustries,in:TechnicalDigestof theIEEESolidStateSensorandActuatorWorkshop,HiltonHeadIsland,SC,4–8June,2000,pp.105–110. [5] H. Lo¨we, V. Hessel, A. Muller, “Microreactors. Prospects already achieved and possible misuse”, Pure AppliedChemistryvol.74(2002),2271–2276. CHAPTER 2 Fundamentals of mass transport in the microscale CHAPTER OUTLINE 2.1 TransportPhenomena.....................................................................................................................10 2.1.1 Molecularlevel............................................................................................................10 2.1.2 Continuumlevel..........................................................................................................14 2.1.2.1 Conservationofmass...............................................................................................14 2.1.2.2 Conservationofmomentum.....................................................................................15 2.1.2.3 Conservationofenergy.............................................................................................21 2.1.2.4 Conservationofspecies...........................................................................................22 2.2 MolecularDiffusion........................................................................................................................22 2.2.1 RandomwalkandBrownianmotion...............................................................................22 2.2.2 Stokes–Einsteinmodelofdiffusion...............................................................................23 2.2.3 Diffusioncoefficient.....................................................................................................24 2.2.3.1 Diffusioncoefficientingases....................................................................................24 2.2.3.2 Diffusioncoefficientinliquids..................................................................................25 2.2.3.3 Diffusioncoefficientofelectrolytes...........................................................................26 2.3 TaylorDispersion...........................................................................................................................28 2.3.1 Two-dimensionalanalysis.............................................................................................28 2.3.2 Three-dimensionalanalysis...........................................................................................34 2.4 ChaoticAdvection..........................................................................................................................36 2.4.1 Basicterminologies.....................................................................................................36 2.4.2 Examplesofchaoticadvection......................................................................................40 2.4.2.1 Lorentz’sconvectionflow.........................................................................................40 2.4.2.2 Deanflowincurvedpipes........................................................................................40 2.4.2.3 Flowinhelicalpipes................................................................................................46 2.4.2.4 Flowintwistedpipes...............................................................................................47 2.4.2.5 Flowinadroplet......................................................................................................50 2.5 Viscoelasticeffects........................................................................................................................53 2.6 ElectrokineticEffects.....................................................................................................................55 2.6.1 Electroosmosis............................................................................................................55 2.6.1.1 TheDebyelayer......................................................................................................55 2.6.1.2 Electroosmotictransporteffect.................................................................................57 2.6.1.3 Electrokineticflowbetweentwoparallelplates..........................................................58 2.6.1.4 Electrokineticflowinacylindricalcapillary...............................................................60 2.6.1.5 Electrokineticflowinarectangularmicrochannel......................................................61 9 Nam-TrungNguyen:Micromixers,Secondedition.DOI:10.1016/B978-1-4377-3520-8.00002-4 Copyright(cid:1)2012ElsevierInc.Allrightsreserved. 10 CHAPTER 2 Fundamentals of mass transport in the microscale 2.6.1.6 Ohmicmodelforelectrolytesolutions.......................................................................63 2.6.2 Electrophoresis............................................................................................................64 2.6.3 Dielectrophoresis.........................................................................................................65 2.7 MagneticandElectromagneticEffects.............................................................................................66 2.7.1 Magneticeffects..........................................................................................................66 2.7.1.1 Electromagneticeffects............................................................................................68 2.8 ScalingLawandFluidFlowinMicroscale.......................................................................................68 References...........................................................................................................................................71 2.1 TRANSPORT PHENOMENA Transport phenomena in micromixers can be described theoretically at two basic levels: molecular levelandcontinuumlevel.Thetwodifferentlevelsofdescriptioncorrespondtothetypicallengthscale involved. Continuum model can describe most transport phenomena in micromixers with a length scalerangingfrommicrometerstocentimeters.Mostmicromixersforpracticalapplicationsareinthis rangeoflengthscale.Molecularmodelsinvolvetransportphenomenaintherangeofonenanometerto one micrometer. Mixers with length scale in this range should be called “nanomixer.” The term “micromixer” in thisbook will cover devices with submillimeter length dimension. At the continuum level, the fluid is considered as a continuum. Fluid properties are defined continuously throughout the space. At this level, fluid properties, such as viscosity, density, and conductivity,areconsideredasmaterialproperties.Transportphenomenacanbedescribedbyasetof conservation equations for mass, momentum, and energy. These equations of change are partial differentialequations,whichcanbesolvedforphysicalfieldsinamicromixer,suchasconcentration, velocity, andtemperature. Miniaturizationtechnologieshavepushedthelengthscaleofmicrodevicesfurther.Intheeventof nanotechnology, scientistsandengineerswillencountermorephenomena at molecularlevel. Atthis level, transport phenomena can be described through molecular structure and intermolecular forces. Because many micromixers are used as microreactors, a fundamental understanding of molecular processesisimportantfordesigningdeviceswithlengthscaleinthemicrometertocentimeterrange. 2.1.1 Molecular level Atmolecularlevel,thesimplestdescriptionoftransportphenomenaisbasedonthekinetictheoryof dilutedmonatomicgases,whichisalsocalledtheChapman–Enskogtheory.Theinteractionbetween nonpolar molecules isrepresented by the Lennard–Jones potential, which hasan empirical form of: (cid:1) (cid:5) (cid:3) (cid:4) (cid:3) (cid:4) s 12 s 6 f ðrÞ ¼ 43 c (cid:2)d ; (2.1) ij ij r ij r wheresisthecharacteristicdiameterofthemolecule,risthedistancebetweenthetwomolecules,and 3 is the characteristic energy, which is the maximum energy of attraction between the molecules. In (2.1),theterm(s/r)12representstherepulsionpotential,whiletheterm(s/r)6representstheattraction potentialbetweenthepairofmolecules.Thecoefficientsc andd aredeterminedbymoleculetypes ij ij

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