Synthesis of Submicron CaCO₃ Particles in 3D-Printed Microfluidic Chips Supporting Advection and Diffusion Mixing

Microfluidic technology provides a solution to the challenge of continuous CaCO₃ particle synthesis. In this study, we utilized a 3D-printed microfluidic chip to synthesize CaCO₃ micro- and nanoparticles in vaterite form. Our primary focus was on investigating a continuous one-phase synthesis method tailored for the crystallization of these particles. By employing a combination of confocal and scanning electron microscopy, along with Raman spectroscopy, we were able to thoroughly evaluate the synthesis efficiency. This evaluation included aspects such as particle size distribution, morphology, and polymorph composition. The results unveiled the existence of two distinct synthesis regimes within the 3D-printed microfluidic chips, which featured a channel cross-section of 2 mm². In the first regime, which was characterized by chaotic advection, particles with an average diameter of around 2 μm were produced, thereby displaying a broad size distribution. Conversely, the second regime, marked by diffusion mixing, led to the synthesis of submicron particles (approximately 800-900 nm in diameter) and even nanosized particles (70-80 nm). This research significantly contributes valuable insights to both the understanding and optimization of microfluidic synthesis processes, particularly in achieving the controlled production of submicron and nanoscale particles.