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This review provides a holistic description of flow reactor fouling for wet-chemical nanomaterial syntheses. Fouling origins and consequences are discussed together with the variety of flow reactors for its prevention.

Microfluidic produced nanogels provide an alternative to standard transfection reagents for the manufacture of adeno-associated viral vectors (AAVs), with equivelant viral titres demonstrated.

A modular platform designed for gas–liquid–liquid segmented flow allows to robustly feed reagents into droplets/slugs, enabling fouling-free multi-step flow syntheses. This was showcased for a partial oxidation synthesis of iron oxide nanoparticles.

A continuous manufacturing platform was developed for the synthesis of aqueous colloidal 10–20 nm gold nanoparticles (Au NPs) in a flow reactor using chloroauric acid, sodium citrate and citric acid at 95 oC and 2.3 bar(a) pressure. The use of a two-phase flow system – using heptane as the continuous phase – prevented fouling on the reactor walls, while improving the residence time distribution. Continuous syntheses for up to 2 h demonstrated its potential application for continuous manufacturing, while live quality control was established using online UV-Vis photospectrometry that monitored the particle size and process yield. The synthesis was stable and reproducible over time for gold precursor concentration above 0.23 mM (after mixing), resulting in average particle size between 12 and 15 nm. A hydrophobic membrane separator provided successful separation of the aqueous and organic phases and collection of colloidal Au NPs in flow. Process yield increased at higher inlet flow rates (from 70 % to almost 100 %), due to lower residence time of the colloidal solution in the separator resulting in less fouling in the PTFE membrane. This study addresses the challenges for the translation of the synthesis from batch to flow and provides tools for the development of a continuous manufacturing platform for gold nanoparticles.Graphical abstract

Among the unconventional approaches of supporting catalyst nanoparticles, the layer-by-layer assembly of polyelectrolyte multilayers for nanoparticle adsorption represents an easy and convenient method. It enables the deposition of singularly adsorbed nanoparticles and prevents them from aggregating. In this work, polydopamine was grafted onto the internal surface of a Teflon AF-2400 tubular membrane, known for its excellent permeability to light gases and inertness to chemicals. Poly(acrylic acid) and poly(allylamine hydrochloride) were sequentially adsorbed onto the modified surface of the membrane. Ex situ synthesized spherical, cubical, truncated octahedral palladium or dendritic platinum-palladium nanoparticles were then incorporated. The catalytic membranes were assembled in a tube-in-tube configuration and tested over 6 h of continuous nitrobenzene hydrogenation with molecular hydrogen. Stable conversion was observed for the truncated octahedral and dendritic nanoparticles, while a progressive deactivation occurred for the other nanoparticles. Due to their small size, the 3.7 nm spherical nanoparticles exhibited the highest reaction rate, 629molreactant/(molcatalyst⋅h), while the cubical nanoparticles showed the highest turnover frequency, ∼3000 h−1. The reactor concept developed in this work demonstrates how such a design can serve as a platform for conducting continuous multiphase catalytic reactions in flow using singularly adsorbed and finely tuned nanoparticles. The small volume of pressurized gas present in the tube-in-tube reactor offers improved process safety compared to a batch process, while the Teflon AF-2400 membrane provides control over the gas permeation during reaction.

Ionic gelation is commonly used to generate nanogels but often results in poor control over size and polydispersity. In this work we present a novel approach to the continuous manufacture of protein-loaded chitosan nanogels using microfluidics whereby we demonstrate high control and uniformity of the product characteristics. Specifically, a coaxial flow reactor (CFR) was employed to control the synthesis of the nanogels, comprising an inner microcapillary of internal diameter (ID) 0.595 mm and a larger outer glass tube of ID 1.6 mm. The CFR successfully facilitated the ionic gelation process via chitosan and lysozyme flowing through the inner microcapillary, while cross-linkers sodium tripolyphosphate (TPP) and 1-ethyl-2-(3-dimethylaminopropyl)-carbodiimide (EDC) flowed through the larger outer tube. In conjunction with the CFR, a four-factor three-level face-centered central composite design (CCD) was used to ascertain the relationship between various factors involved in nanogel production and their responses. Specifically, four factors including chitosan concentration, TPP concentration, flow ratio and lysozyme concentration were investigated for their effects on three responses (size, polydispersity index (PDI) and encapsulation efficiency (% EE)). A desirability function was applied to identify the optimum parameters to formulate nanogels in the CFR with ideal characteristics. Nanogels prepared using the optimal parameters were successfully produced in the nanoparticle range at 84 ± 4 nm, showing a high encapsulation efficiency of 94.6 ± 2.9% and a high monodispersity of 0.26 ± 0.01. The lysis activity of the protein lysozyme was significantly enhanced in the nanogels at 157.6% in comparison to lysozyme alone. Overall, the study has demonstrated that the CFR is a viable method for the synthesis of functional nanogels containing bioactive molecules.

Despite the wide usage of magnetic nanoparticles, it remains challenging to synthesise particles with properties that exploit each application's full potential. Time consuming experimental procedures and particle analysis hinder process development, which is commonly constrained to a handful of experiments without considering particle formation kinetics, reproducibility and scalability. Flow reactors are known for their potential of large-scale production and high-throughput screening of process parameters. These advantages, however, have not been utilised for magnetic nanoparticle synthesis where particle characterisation is performed, with a few exceptions, post-synthesis. To overcome this bottleneck, we developed a highly sensitive magnetometer for flow reactors to characterise magnetic nanoparticles in solution in-line and in real-time using alternating current susceptometry. This flow magnetometer enriches the flow-chemistry toolbox by facilitating continuous quality control and high-throughput screening of magnetic nanoparticle syntheses. The sensitivity required to monitor magnetic nanoparticle syntheses at the typically low concentrations (

Anisotropic nanoparticles (NPs) have garnered a great deal of attention for their applications in catalysis, magnetism and biomedicine. However, synthetic strategies to grow such NPs are still limited as their growth mechanisms are poorly understood. This work presents the synthesis of iron oxide nanoparticles (IONPs) based on the decomposition of iron(III) acetylacetonate in organic solvents to form anisotropic IONPs that are branched or multiply branched. We fully explore their growth parameters to understand the effect of varying amounts of oleylamine (OAm), as well as a nitrogen purge on particle morphology. We show here the synthetic relationship between a wide range of sizes and shapes of IONPs that are both isotropic and anisotropic. Of all the parameters, the amount of oleylamine in the reaction is the key to tune the particle size while the effect of a nitrogen gas purge during synthesis was shown to be crucial for the formation of the branched and multiply branched NPs. Two multiply branched NP systems with only a small difference in the synthetic conditions were shown to have radically different magnetic properties, such as heating in an alternating magnetic field. This was attributed to the defects found in the structure of one and not in the other. By following their development during growth, crystal defects were observed in both systems during the early stages of the reaction. However, for the multiply branched structure that became single crystalline, the aggregation of the nuclei occurred earlier in the reaction, allowing more time for growth and crystallite rearrangement to occur. These results have wide ranging implications for controlling the properties of anisotropic nanomaterials with similar structures, including their magnetic behavior.

The quantitative analysis of nanomaterials synthesis kinetics is valuable both for understanding the synthesis and for development of manufacturing processes, and it usually requires the use of syn...

The advancement of analytical methods for nanoparticle measurements is critical both for the growing industrial exploitation of engineered nanoparticles and for developing robust strategies to understand and control the concentration of nanomaterials in humans and the environment. For high value nanoparticles, the measurement of nanoparticle number concentration in a liquid directly impacts the ability to assess the scale and reproducibility of the production process, it allows optimisation of efficiency and supports regulatory compliance. This measurement is also useful to monitor and control the intentional or accidental release of engineered nanoparticles into the environment at the production plant, as well as by end-users., peer-reviewed

Thiolate-gold nanoclusters have various applications. However, most of the synthesis methods require prolonged synthesis times from several hours to days. In the present study, we report a rapid synthesis method for [Au25(Cys)18] nanoclusters and their application for photobactericidal enhancement. For [Au25(Cys)18] synthesis, we employed a tube-in-tube membrane reactor using CO as a reducing agent at elevated temperatures. This approach allows continuous generation of high-quality [Au25(Cys)18] within 3 min. Photobactericidal tests against Staphylococcus aureus showed that crystal violet-treated polymer did not have photobactericidal activity, but addition of [Au25(Cys)18] in the treated polymer demonstrated a potent photobactericidal activity at a low white light flux, resulting in >4.29 log reduction in viable bacteria numbers. Steady-state and time-resolved photoluminescence spectroscopies demonstrated that after light irradiation, photoexcited electrons in crystal violet flowed to [Au25(Cys)18] in the silicone, suggesting that redox reaction from [Au25(Cys)18] enhanced the photobactericidal activity. Stability tests revealed that leaching of crystal violet and [Au25(Cys)18] from the treated silicone was negligible and cyclic testing showed that the silicone maintained a strong photobactericidal activity after repeated use.

A millifluidic reactor with a 0.76 mm internal diameter was utilized for the synthesis of monodisperse, high magnetic moment, iron carbide (FexCy) nanoparticles by thermal decomposition of iron pentacarbonyl (Fe­(CO)5) in 1-octadecene in the presence of oleylamine at 22 min nominal residence time. The effect of reaction conditions (temperature and pressure) on the size, morphology, crystal structure, and magnetic properties of the nanoparticles was investigated. The system developed facilitated the thermal decomposition of precursor at reaction conditions (up to 265 °C and 4 bar) that cannot be easily achieved in conventional batch reactors. The degree of carbidization was enhanced by operating at elevated temperature and pressure. The nanoparticles synthesized in the flow reactor had size 9–18 nm and demonstrated high saturation magnetization (up to 164 emu/gFe). They further showed good stability against oxidation after 2 months of exposure in air, retaining good saturation magnetization values with a change of no more than 10% of the initial value. The heating ability of the nanoparticles in an alternating magnetic field was comparable with other ferrites reported in the literature, having intrinsic loss power values up to 1.52 nHm2 kg–1.

Antibiotics lose their effectiveness over time due to antimicrobial resistance. The increasing risk of hospital-acquired infections from contaminated surfaces and medical interventions requires the development of new antimicrobial materials. We report the first example of a modified ultra high molecular weight polyethylene that showed good antibacterial properties on light activation. Its efficacy was due to the production of reactive oxygen species under low-intensity white light sources (ca. 375 lux). Crystal violet and cysteine capped gold nanoclusters were successfully incorporated into the polymer using a readily available solvent as a dispersing agent followed by the process of compression moulding at 200 °C, 4.5 MPa for 1 min. This modified ultra-high molecular weight polyethylene demonstrates excellent robustness with regards to dye and metal leaching as well as photostability. Despite incorporating antimicrobial agents, the modified ultra-high molecular weight polyethylene retained its mechanical properties and showed >99% reduction in bacterial numbers against Escherichia coli and. To our knowledge, this paper reports the first use of compression moulding to create a light-activated antimicrobial surface which has distinct processing advantages over the widely used “swell-encapsulation-shrink” method and is potentially scalable.

With recent advances in automated flow reactors and online analysis techniques, transient flow experiments are attracting significant interest as methods for rapidly gathering kinetic data. However, the design of these experiments is challenging and non-intuitive. This work addresses this challenge by using model-based design of experiments (MBDoE) to design optimum transient experiments for the purpose of identifying kinetic parameters with maximum precision. Using the case study of benzoic acid and ethanol esterification with sulfuric acid as the catalyst, the flowrate and temperature of a plug flow reactor were linearly ramped in time to create transient flow experiments. Two types of experiments were conducted, one where only flowrate was ramped while all other variables were held constant, and one where flowrate and temperature were ramped simultaneously. In both cases, model-based design of experiments (MBDoE) methods were used to design the transient experiments in order to choose the initial value and ramp rate of all ramped process variables, as well as choosing the fixed value of process variables that were not being ramped (feed concentration). The model-based designed experiments were compared against equivalent experiments designed by researcher intuition and standard design of experiments approaches, such as trying to cover a wide area of the design space. It is shown that MBDoE led to significantly more precise parameter estimates, and that the identified model was then able to predict with high accuracy the outlet concentration of other experiments.

Operando X-ray absorption spectroscopy (XAS), diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) and mass spectrometry (MS) provide complementary information on the catalyst structure, surface reaction mechanisms and activity relationships. The powerful combination of the techniques has been the driving force to design and engineer suitable spectroscopic operando reactors that can mitigate limitations inherent to conventional reaction cells and facilitate experiments under kinetic regimes. Microreactors have recently emerged as effective spectroscopic operando cells due to their plug-flow type operation with no dead volume and negligible mass and heat transfer resistances. Here we present a novel microfabricated reactor that can be used for both operando XAS and DRIFTS studies. The reactor has a glass-silicon-glass sandwich-like structure with a reaction channel (3000 μm × 600 μm; width × depth) packed with a catalyst bed (ca. 25 mg) and placed sideways to the X-ray beam, while the infrared beam illuminates the catalyst bed from the top. The outlet of the reactor is connected to MS for continuous monitoring of the reactor effluent. The feasibility of the microreactor is demonstrated by conducting two reactions: i) combustion of methane over 2 wt% Pd/Al2O3 studied by operando XAS at the Pd K-edge and ii) CO oxidation over 1 wt% Pt/Al2O3 catalyst studied by operando DRIFTS. The former shows that palladium is in an oxidised state at all studied temperatures, 250, 300, 350, 400 °C and the latter shows the presence of linearly adsorbed CO on the platinum surface. Furthermore, temperature-resolved reduction of palladium catalyst with methane and CO oxidation over platinum catalyst are also studied. Based on these results, the catalyst structure and surface reaction dynamics are discussed, which demonstrate not only the applicability and versatility of the microreactor for combined operando XAS and DRIFTS studies, but also illustrate the unique advantages of the microreactor for high space velocity and transient response experiments.

From all of the iron oxide nanoparticle (IONP) syntheses, thermal decomposition methods are the most developed for controlling particle properties, but suffer from poor reproducibility at larger scale. An alternative solution for large scale production is continuous synthesis, where the production volume can be increased with longer operation times. However, continuous thermal decomposition synthesis is not trivial as it requires oxygen and water removal from the precursor solution, reaction temperatures above 230 °C, and the formation of particles is likely to cause reactor fouling. This work presents a continuous thermal decomposition synthesis of IONPs using a tubular flow reactor, which provides inert reaction conditions at temperatures of up to 290 °C, and heating/cooling at rates which cannot be achieved in standard batch systems. This makes it possible to define the start and endpoint accurately, hence, allowing for a well-controlled and scalable thermal decomposition synthesis. A simple synthetic protocol was chosen using only ferric acetylacetonate, oleylamine, and 1-octadecene as a solvent, but no additives to minimise costs. In this flow reactor residence times of less than 10 min were shown to be sufficient to synthesise monodisperse IONPs of 5–7 nm and achieve precursor conversion between 10–70% depending on the reaction temperature. For all synthesis conditions tested, there was no indication of reactor fouling. Since the precursor conversion correlated to the residence time and reaction temperature, but particle sizes were comparable for all reaction conditions studied, the particle formation is proposed to follow mechanisms other than classical nucleation and growth. To examine possible economic advantages of such a continuous thermal decomposition process as compared to a conventional batch synthesis, a cost analysis, comparing costs assigned to chemicals, reactor equipment, energy and labour, was performed.

Recent advances in automation and digitization enable the close integration of physical devices with their virtual counterparts, facilitating the real-time modeling and optimization of a multitude of processes in an automatic way. The rich and continuously updated data environment provided by such systems makes it possible for decisions to be made over time to drive the process toward optimal targets. In many manufacturing processes, in order to achieve an overall optimal process, the simultaneous assessment of multiple objective functions related to process performance and cost is necessary. In this work, a multi-objective optimal experimental design framework is proposed to enhance the efficiency of online model-identification platforms. The proposed framework permits flexibility in the choice of trade-off experimental design solutions, which are calculated online—that is, during the execution of experiments. The application of this framework to improve the online identification of kinetic models in flow reactors is illustrated using a case study in which a kinetic model is identified for the esterification of benzoic acid and ethanol in a microreactor. Keywords: Multi-objective optimization, Optimal design of experiments, Online

An autonomous reactor platform was developed to rapidly identify a kinetic model for the esterification of benzoic acid with ethanol with the heterogeneous Amberlyst-15 catalyst. A five-step methodology for kinetic studies was employed to systematically reduce the number of experiments required to identify a practical kinetic model. This included (i) initial screening using traditional factorial designed steady-state experiments, (ii) proposing and testing candidate kinetic models, (iii) performing an identifiability analysis to reject models whose model parameters cannot be estimated for a given experimental budget, (iv) performing online Model-Based Design of Experiments (MBDoE) for model discrimination to identify the best model from a list of candidates, and (v) performing online MBDoE for improving parameter precision for the chosen model. This methodology combined with the reactor platform, which conducted all kinetic experiments unattended, reduces the number of experiments and time required to identify kinetic models, significantly increasing lab productivity.

Magnetic nanoparticles are researched intensively not only for biomedical applications, but also for industrial applications including wastewater treatment and catalytic processes. Although these particles have been shown to have interesting surface properties in their bare form, their magnetisation remains a key feature, as it allows for magnetic separation. This makes them a promising carrier for precious materials and enables recovery via magnetic fields that can be turned on and off on demand, rather than using complex (nano)filtration strategies. However, designing a magnetic separator is by no means trivial, as the magnetic field and its gradient, the separator dimensions, the particle properties (such as size and susceptibility), and the throughput must be coordinated. This is showcased here for a simple continuous electromagnetic separator design requiring no expensive materials or equipment and facilitating continuous operation. The continuous electromagnetic separator chosen was based on a current-carrying wire in the centre of a capillary, which generated a radially symmetric magnetic field that could be described using cylindrical coordinates. The electromagnetic separator design was tested in-silico using a Lagrangian particle-tracking model accounting for hydrodynamics, magnetophoresis, as well as particle diffusion. This computational approach enabled the determination of separation efficiencies for varying particle sizes, magnetic field strengths, separator geometries, and flow rates, which provided insights into the complex interplay between these design parameters. In addition, the model identified the separator design allowing for the highest separation efficiency and determined the retention potential in both single and multiple separators in series. The work demonstrated that throughputs of ~1/4 L/h could be achieved for 250–500 nm iron oxide nanoparticle solutions, using less than 10 separator units in series.

Small iron oxide nanoparticles (IONPs) were synthesised in water via co-precipitation by quenching particle growth after the desired magnetic iron oxide phase formed. This was achieved in a millifluidic multistage flow reactor by precisely timed addition of an acidic solution. IONPs (≤5 nm), a suitable size for positive T1 magnetic resonance imaging (MRI) contrast agents, were obtained and stabilised continuously. This novel flow chemistry approach facilitates a reproducible and scalable production, which is a crucial paradigm shift to utilise IONPs as contrast agents and replace currently used Gd complexes. Acid addition had to be timed carefully, as the inverse spinel structure formed within seconds after initiating the co-precipitation. Late quenching allowed IONPs to grow larger than 5 nm, whereas premature acid addition yielded undesired oxide phases. Use of a flow reactor was not only essential for scalability, but also to synthesise monodisperse and non-agglomerated small IONPs as (i) co-precipitation and acid addition occurred at homogenous environment due to accurate temperature control and rapid mixing and (ii) quenching of particle growth was possible at the optimum time, i.e., a few seconds after initiating co-precipitation. In addition to the timing of growth quenching, the effect of temperature and dextran present during co-precipitation on the final particle size was investigated. This approach differs from small IONP syntheses in batch utilising either growth inhibitors (which likely leads to impurities) or high temperature methods in organic solvents. Furthermore, this continuous synthesis enables the low-cost (£10 per g) and large-scale production of highly stable small IONPs without the use of toxic reagents. The flow-synthesised small IONPs showed high T1 contrast enhancement, with transversal relaxivity (r2) reduced to 20.5 mM-1 s-1 and longitudinal relaxivity (r1) higher than 10 mM-1 s-1, which is among the highest values reported for water-based IONP synthesis.

The interaction of methylene blue and crystal violet dyes with a range of gold nanoparticles (AuNPs), gold nanoclusters and gold/silver nanoclusters is reported. It is found that 20 nm citrate-capped AuNPs have strong interactions with these two dyes that result in red-shifted absorption peaks in their electronic absorption spectra. Transmission electron microscopy and dynamic light scattering measurements show that this can be attributed to these AuNPs combining into large agglomerates. Eventually, precipitation is observed. The agglomeration process is triggered when the dye reaches or exceeds a threshold concentration and then does not stop until all the AuNPs have agglomerated into large particles and precipitated. Calculations suggest that the threshold concentration corresponds to having sufficient dye molecules to form a monolayer on the surface of AuNPs. We also observe similar red-shifting in the absorption peaks of the electronic absorption spectra of 11–50 nm citrate-capped AuNPs formed by both single step and seeded growth methods. No such interactions were observed in the UV-vis spectra of the dyes with Tris-capped AuNPs, gold nanoclusters or gold/silver nanoclusters.

Automated model identification platforms were recently employed to identify parametric models online in the course of unmanned experimental campaigns. The algorithms controlling these platforms include two computational elements: i) a tool for parameter estimation; ii) a tool for model-based experimental design. Both tools require the solution of complex optimisation problems and their effective outcome relies on their respective objective functions being well-conditioned. Ill-conditioned objective functions may arise when the model is characterised by a weak parametrisation, i.e. the model parameters are practically non-identifiable and/or extremely correlated. In this work, a robust reparametrisation technique is proposed and tested both in-silico and in an automated model identification platform. The benefit of reparametrisation is demonstrated on a case study for the identification of a kinetic model of catalytic esterification of benzoic acid with ethanol in a flow microreactor.

Parameter estimation algorithms integrated in automated platforms for kinetic model identification are required to solve two optimization problems: i) a parameter estimation problem given the available samples; ii) a model-based design of experiments problem to select the conditions for collecting future samples. These problems may be ill-posed, leading to numerical failures when optimization routines are applied. In this work, an approach of online reparametrization is introduced to enhance the robustness of model identification algorithms towards ill-posed parameter estimation problems.

A microfluidic reactor was developed to enhance the speed (reaction time

Co-precipitation is the most ubiquitous method for forming iron oxide nanoparticles. For a typical co-precipitation synthesis, the pH of a ferrous and/or ferric ion solution is increased via the addition of a base. The latter can be added either slowly (a steady addition over either minutes or hours) or fast (a one-time addition) resulting in an abrupt increase in the pH. However, understanding the mechanism of particle formation is still lacking, which limits the reproducibility of the co-precipitation reaction due to intermediate phases still being present in the final product. In this work, we study in detail a co-precipitation synthesis with an abrupt increase in pH via the addition of sodium carbonate. Fast and reproducible mixing at defined precursor and base solution temperatures was achieved utilising a flow reactor. Transmission electron microscopy, electron diffraction and room temperature 57Fe Mössbauer spectroscopy showed a distinct transition from an amorphous ferrihydrite phase to a mixture of magnetite-maghemite (Fe3O4/γ-Fe2O3). Synchrotron X-ray diffraction revealed the initial formation of crystalline iron hydroxide carbonate (green rust) plates occurring before the Fe3O4/γ-Fe2O3 appeared. The ferrihydrite particles increase in size over time as the proportion of iron hydroxide carbonate plates are re-dissolved into solution, until the ferrihydrite particles crystallise into Fe3O4/γ-Fe2O3.

An autonomous flow microreactor platform was developed that was able to conduct reaction experiments and measure the outlet reactant and product concentrations using HPLC without user supervision. The platform performed unmanned kinetic experiments with the aim of precisely estimating the parameters of a kinetic model for the esterification between benzoic acid and ethanol catalysed by sulfuric acid. The capabilities of the autonomous platform were demonstrated on three different experimental scenarios: 1) performing steady-state experiments, where the experimental reaction conditions were pre-defined by the user; 2) performing steady-state experiments, where the conditions were optimised online by Model-Based Design of Experiments (MBDoE) algorithms, with the aim of improving parameter precision; 3) executing transient experiments, where the conditions were pre-selected by the user. For the steady-state experiments, the platform automatically performed online parameter estimation and MBDoE with a pre-selected kinetic model. It was demonstrated that a campaign of steady-state experiments designed using online MBDoE algorithms led to more precise parameter estimates than a campaign of experiments designed by the traditional factorial design. Transient experiments were shown to expedite kinetic parameter estimation and use less reagents than campaigns of steady-state experiments, as it was no longer necessary to wait for the system to reach steady-state. In general, the transient experiments offered less precise parameter estimates than the steady-state campaigns, however the experiments could be completed in just 2 h instead of the 8 h required for a campaign of steady-state experiments.

CO2 absorption in solutions of sodium hydroxide (NaOH) was performed in three membrane/mesh microstructured contactors: a single-channel polytetrafluoroethylene (PTFE) membrane contactor, a nickel mesh contactor and an eight-channel PTFE membrane contactor. A membrane/mesh was used to achieve gas/liquid mass transfer without dispersion of one phase within the other. The PTFE membrane consisted of a pure PTFE layer 20 μm thick laminated onto a polypropylene (PP) layer of 80 μm thickness. The pure PTFE layer contained pores of ~0.5 to 5 μm diameter and was hydrophobic, while the PP layer consisted of rectangular openings of 0.8 mm×0.324 mm and was hydrophilic. The nickel mesh was 25 μm thick and contained pores of 25 μm diameter and was hydrophilic. Experiments were performed with a 2 m NaOH solution and an inlet feed of 20 vol % CO2/N2 gas mixture. Numerical simulations matched reasonably well the experimental data. CO2 removal efficiency increased by increasing the NaOH concentration, the gas residence time and the exchange area between gas and liquid. Higher removal of CO2 was achieved when the PP was in the gas side rather than in the liquid side, due to lower mass transfer resistance of the gas phase. For the same reason, CO2 removal efficiency was higher for the eight-channel PTFE contactor compared to the nickel mesh contactor. Average CO2 flux was higher for the eight-channel contactor (8×10−3 mol/min·cm2 with PP on the gas side) compared to the nickel mesh contactor (3×10−3 mol/min·cm2) for the same gas and liquid residence times. The eight-channel PTFE membrane contactor removed around 72% of CO2 in 1.2 s gas residence time, demonstrating the potential for CO2 absorption using flat membrane contactors.

The volumetric liquid-solid (L-S) mass transfer coefficient under gas-liquid (G-L) two-phase flow in a silicon-chip-based micropacked bed reactor (MPBR) was studied using the copper dissolution method and was related to the reactor hydrodynamic behavior. Using a high-speed camera and a robust computational image analysis method that selectively analyzed the bed voidage around the copper particles, the observed hydrodynamics were directly related to the L-S mass transfer rates in the MPBR. This hydrodynamic study revealed different pulsing structures inside the packed copper bed depending on the flow patterns established preceding the packed bed upon increasing gas velocity. A "liquid-dominated slug" flow regime was associated with an upstream slug flow feed. A "sparse slug" flow regime developed with an upstream slug-annular flow feed. At higher gas velocity, a "gas continuous with pulsing" regime developed with an annular flow feed, which had similar features to the pulsing flow in macroscale packed beds, but it was sensitive and easily destabilized by disturbances from upstream or downstream pressure fluctuations. The volumetric L-S mass transfer coefficient decreased with increasing gas velocity under the liquid-dominated slug flow regime and became rather less affected under the sparse slug flow regime. By resolving the transition from the liquid-dominated slug flow to the sparse slug flow and capturing the onset of the gas-continuous with pulsing regime, we gained new insights into the hydrodynamic effects of G-L flows on the L-S mass transfer rates in a MPBR.

Small iron oxide nanoparticles (IONPs) were synthesised in water via co-precipitation by quenching particle growth after the desired magnetic iron oxide phase formed. This was achieved in a millifluidic multistage flow reactor by precisely timed addition of an acidic solution. IONPs (≤5 nm), a suitable size for positive T1 magnetic resonance imaging (MRI) contrast agents, were obtained and stabilised continuously. This novel flow chemistry approach facilitates a reproducible and scalable production, which is a crucial paradigm shift to utilise IONPs as contrast agents and replace currently used Gd complexes. Acid addition had to be timed carefully, as the inverse spinel structure formed within seconds after initiating the co-precipitation. Late quenching allowed IONPs to grow larger than 5 nm, whereas premature acid addition yielded undesired oxide phases. Use of a flow reactor was not only essential for scalability, but also to synthesise monodisperse and non-agglomerated small IONPs as (i) co-precipitation and acid addition occurred at homogenous environment due to accurate temperature control and rapid mixing and (ii) quenching of particle growth was possible at the optimum time, i.e., a few seconds after initiating co-precipitation. In addition to the timing of growth quenching, the effect of temperature and dextran present during co-precipitation on the final particle size was investigated. This approach differs from small IONP syntheses in batch utilising either growth inhibitors (which likely leads to impurities) or high temperature methods in organic solvents. Furthermore, this continuous synthesis enables the low-cost (

Thiolate-gold nanoclusters have various applications. However, most of the synthesis methods require prolonged synthesis times from several hours to days. In the present study, we report a rapid synthesis method for [Au

A millifluidic reactor with a 0.76 mm internal diameter was utilized for the synthesis of monodisperse, high magnetic moment, iron carbide (FexCy) nanoparticles by thermal decomposition of iron pentacarbonyl (Fe(CO)5) in 1-octadecene in the presence of oleylamine at 22 min nominal residence time. The effect of reaction conditions (temperature and pressure) on the size, morphology, crystal structure, and magnetic properties of the nanoparticles was investigated. The system developed facilitated the thermal decomposition of precursor at reaction conditions (up to 265 °C and 4 bar) that cannot be easily achieved in conventional batch reactors. The degree of carbidization was enhanced by operating at elevated temperature and pressure. The nanoparticles synthesized in the flow reactor had size 9–18 nm and demonstrated high saturation magnetization (up to 164 emu/gFe). They further showed good stability against oxidation after 2 months of exposure in air, retaining good saturation magnetization values with a change of no more than 10% of the initial value. The heating ability of the nanoparticles in an alternating magnetic field was comparable with other ferrites reported in the literature, having intrinsic loss power values up to 1.52 nHm2 kg–1.

The emergence of antibiotic resistant bacteria is a major threat to the practice of modern medicine. Photobactericidal agents have obtained significant attention as promising candidates to kill bacteria, and they have been extensively studied. However, to obtain photobactericidal activity, an intense white light source or UV-activation is usually required. Here we report a photobactericidal polymer containing crystal violet (CV) and thiolated gold nanocluster ([Au25(Cys)18]) activated at a low flux levels of white light. It was shown that the polymer encapsulated with CV do not have photobactericidal activity under white light illumination of an average 312 lux. However, encapsulation of [Au25(Cys)18] and CV into the polymer activates potent photobactericidal activity. The study of the photobactericidal mechanism shows that additional encapsulation of [Au25(Cys)18] into the CV treated polymer promotes redox reactions through generation of alternative electron transfer pathways, while it reduces photochemical reaction type-ІІ pathways resulting in promotion of hydrogen peroxide (H2O2) production., Antibiotic resistant bacteria have increased the interest in the development of antibacterial surfaces to reduce the risk of infection. Here, the authors report on a thiolated gold nanocluster enhanced crystal violet polymer with bactericidal properties under low level white light illumination.

Reproducibility in the synthesis of nanomaterials is a crucial aspect for their real-life applications. It is particularly pertinent in the context of gold nanoparticles, where a plethora of seeded-growth methods are being developed to control particle morphology and size. The translation of such methods to manufacturing can be hindered by poor reproducibility of the seed production step. This study focuses on the development of a highly reproducible platform for the synthesis of gold nanoparticles, as potential substrates for glucose sensing. A flow reactor was designed, starting from a detailed study of the synthesis in batch. The well-established Turkevich synthesis was investigated via in situ time-resolved UV-vis spectroscopy. In order to enhance the reproducibility of the synthesis the effect of passivating the gold precursor stock before its use in the synthesis was investigated. It is shown that starting from a pre-passivated precursor provided improved control over the initial reaction stage, at the expense of a small increase in the reaction time. At the optimal reaction conditions, the proposed modified Turkevich method allowed for the synthesis in batch of ∼12 nm monodisperse (RSD ∼10%) particles, with a variability from batch to batch of only ∼5%. The information gathered from the batch study, in particular the reaction time, was used to translate the synthesis from batch to flow. The system utilized for the flow synthesis consisted of a segmented flow reactor, where an organic stream was employed to segment the reactive aqueous stream to avoid reactor fouling and improve monodispersity. The use of segmented flow enables treating each droplet as a “travelling batch”, hence allowing the direct use of the kinetic data obtained in batch to design the flow reactor, leading to the rapid identification of the minimum residence time to allow for reaction completion. The flow reactor enabled the synthesis of ∼11 nm monodisperse (RSD ∼10%) particles, with full precursor conversion and reproducibility between reactor runs higher than that obtained in batch (variability of ∼2%). The flow-produced gold nanoparticles were tested for glucose sensing, exploiting their glucose oxidase-mimicking behaviour and demonstrated satisfactory glucose detection in the range of 1–10 mM.

Co-precipitation is by far the most common synthesis for magnetic iron oxide nanoparticles (IONPs), as cheap and environmentally friendly precursors and simple experimental procedures facilitate IONP production in many labs. Optimising co-precipitation syntheses remains challenging however, as particle formation mechanisms are not well understood. This is partly due to the rapid particle formation (within seconds) providing insufficient time to characterise initial precipitates. To overcome this limitation, a flow chemistry approach has been developed using steady-state operation to “freeze” transient reaction states locally. This allowed for the first time a comprehensive analysis of the early stages of co-precipitation syntheses via in-situ Small Angle X-ray Scattering and in-situ synchrotron X-Ray Diffraction. These studies revealed that after mixing the ferrous/ferric chloride precursor with the NaOH base solution, the most magnetic iron oxide phase forms within 5 s, the particle size changes only marginally afterwards, and co-precipitation and agglomeration occur simultaneously. As these agglomerates were too large to achieve colloidal stability via subsequent stabiliser addition, co-precipitated IONPs had to be de-agglomerated. This was achieved by adding the appropriate quantity of a citric acid solution which yielded within minutes colloidally stable IONP solutions around a neutral pH value. The new insights into the particle formation and the novel stabilisation procedure (not requiring any ultra-sonication or washing step) allowed to design a multistage flow reactor to synthesise and stabilise IONPs continuously with a residence time of less than 5 min. This reactor was robust against fouling and produced stable IONP solutions (of ~1.5 mg particles per ml) reproducibly via fast mixing ( 500 ml/h) for low materials cost.

A novel reactor that combines a catalyst slurry flowing inside a loop configuration, incorporating a tubular membrane (Teflon AF-2400) for controlled oxygen delivery was designed and employed for the aerobic oxidation of benzyl alcohol using a 1 wt% Au-Pd/TiO2 powdered catalyst. This reactor keeps the liquid phase saturated with oxygen, while avoiding the creation of bubbles in it, thus enhancing operation safety. Experimental results in batch mode compared with those of a conventional autoclave demonstrated that the slurry loop membrane reactor reached a similar oxidation turnover frequency (20,000–25,000 h−1) with comparable values of benzaldehyde selectivity (∼70%). Continuous operation was achieved by using a crossflow filter connected to the loop to keep the catalyst from exiting the reactor. Using a 60 cm long tubular membrane, with the slurry flow circulating at 10 mL/min, continuous reaction was performed at 100–120 °C, 0–5 bar oxygen pressure and 1.2–5.0 g/L catalyst loading. Selectivity to benzaldehyde increased by either decreasing the reaction temperature or increasing the external oxygen pressure. The oxygen consumption rate decreased linearly with the catalyst loading, suggesting negligible gas-liquid mass transfer resistance. This was further evidenced by doubling the length of the tubular membrane, which had no effect on the oxidation turnover frequency. The slurry loop membrane reactor showed significantly better performance than packed-bed membrane microchannel reactors, and similar performance as that of a trickle-bed capillary reactor. This reactor can be implemented for a wide range of applications, which rely on the use of powder catalyst, are limited by gaseous reactant availability and require safe operation.

© 2018, The Author(s). A catalytic membrane reactor with a Au–Pd catalyst, impregnated at the inner side of the membrane, was studied in the catalytic oxidation of benzyl alcohol in flow. The reactor comprised of four concentric sections. The liquid substrate flowed in the annulus created by an inner tube and the membrane. The membrane consisted of 3 layers of α-alumina and a titania top layer with 5 nm average pore size. Oxygen was fed on the outer side of the membrane, and its use allowed the controlled contact of the liquid and the gas phase. Experiments revealed excellent stability of the impregnated membrane and selectivities to benzaldehyde were on average > 95%. Increasing the pressure of the gas phase and decreasing liquid flowrates and benzyl alcohol concentration resulted in an increased conversion, while selectivities to benzaldehyde remained constant and in excess of 95%. ispartof: TOPICS IN CATALYSIS vol:62 issue:17-20 pages:1126-1131 ispartof: location:ENGLAND, Abingdon status: published