Production of MCM-41 Nanoparticles with Control of Particle Size and Structural Properties: Optimizing Operational...

Area of Science:

• Materials Science
• Nanotechnology
• Chemical Engineering

Background:

• MCM-41 mesoporous silica nanoparticles (MSNs) are crucial for biomedical applications.
• Controlling MSN size and porosity during synthesis is challenging, especially at larger scales.

Purpose of the Study:

• To develop and validate a scalable synthesis method for MCM-41 MSNs.
• To optimize synthesis parameters for controlled particle size and pore structure.
• To ensure process robustness and reproducibility from lab to pilot scale.

Main Methods:

• Taguchi experimental design at laboratory scale (1 L) to study key parameters (TEOS addition rate, maturation time, temperature, CTAB concentration).
• One-by-one optimization of conditions for scale-up.
• Pilot plant scale (5 L) validation using a cylindrical reactor to assess stirring speed, impeller type, TEOS addition, and maturation time.

Main Results:

• Optimized synthesis conditions achieved controlled MSN size (100-200 nm) and pore structure (3 nm).
• The process was successfully scaled to pilot plant level without significant particle enlargement or pore deformation.
• Identified robust and reproducible synthesis parameters: 60 °C, TEOS/CTAB molar ratio of 8, 2 g/L CTAB, 2 mL/min TEOS addition, 400 rpm stirring, and 60 min maturation time.

Conclusions:

• A scalable and robust method for synthesizing MCM-41 MSNs with controlled properties was established.
• The developed methodology is suitable for producing MSNs for biomedical applications.
• The process demonstrated reproducibility across different scales and reactor types.