Abstract The need for eco-friendly and energy saving processes which are substantially compact and give higher efficiency has led to the concept of process intensification (PI). Curved microchannel is such innovative device, which has potential for the intensification of processes currently carried out in conventional straight or T-type microchannels. Curved microchannels utilize the benefits of centrifugal force to its advantage. The present study deals with the numerical simulation of the Taylor flow in curved microchannels, particularly on gas and liquid slugs with varying curvature ratios (i.e., coil to tube diameter = 5 , 10, 20 and 30). The three-dimensional, unsteady slug flow development in the curved microchannel was carried out using control volume finite difference method (CVFDM). The gas and liquid slug lengths at various operating and fluid conditions were obtained. The slug flow development for different inlet conditions and geometries (premixed feed, T-type and Y-type inlets) was also studied in the curved microchannels. It was found that for low curvature ratio ( D / d = 3 ) , the phenomenon of flow reversal and slug freezing takes place due to centrifugal and buoyancy forces. For the similar process conditions, with an increase in curvature ratio to 5 and 10, the phenomenon of flow reversal and slug freezing observed was very minor. The non-uniformity in the slug formation was observed for low curvature ratio as compared to the higher curvature ratios. Further the influence of surface tension, viscosity and wall adhesion was studied on slug flow development in the curved microchannels. From the results it was observed that the surface tension, viscosity and wall adhesion have significant influence on slug flow development in curved microchannels.