An improved rotating microchannel (IRM) separator was further explored in the intensification for demulsification and separation process. Oil-in-water (O/W) emulsion system of 2-ethylhexyl phosphoric acid-2-ethylhexyl ester (P507)–water without emulsifier was employed toevaluate the performance of the new equipment. In this experiment

the influence on demulsification separation process was explored by changing the geometrical structure and channel height of the microchannel and combining the liquid–liquid two-phase flow pattern

and the correlation general graph between demulsification efficiency and dimensionless parameters was established. The total demulsification effect of the IRM and the separation capacity of the clear organic phase recovered from demulsification are significantly improved. In addition

the liquid–liquid two-phase flow pattern of the clear organic phase after demulsification and the remaining emulsion in the IRM are observed and recorded by high-speed photography. The separation ability of organic phase from the upper outlet can be significantly improved when the total demulsification rate of IRM is up to 90%. There are 3 types and 6 kinds of flow patterns observed. The results demonstrated that the suitable demulsification performance is obtained when the liquid–liquid two-phase inside the IRM is in a parallel pattern. Finally

the relation map between total demulsification efficiency and the universal flow is drawn

which provides a basis for the accurate control of the IRM device.