Feasibility and Advantages of Continuous Synthesis of Bioinspired Silica Using CO₂ as an Acidifying Agent

In this work, we present a method for the continuous synthesis of bioinspired porous silica (BIS) particles using carbon dioxide (CO₂) as an acidifying agent. Typical BIS synthesis uses strong mineral acids (e.g., HCl) to initiate the hydrolysis and subsequent condensation reactions. The use of strong acids leads to challenges in controlling the reaction pH. The synthesis approach proposed in this work offers for the first time CO₂ as an attractive alternative for the synthesis of BIS and demonstrates the continuous process. The developed method leverages the mild acidic and the self-buffering nature of the CO₂ combined with additional options for controlling mass transfer rates to facilitate enhanced control of pH, which is crucial for controlling the properties of synthesized BIS. Proof of concept experiments conducted in continuous mode demonstrated a yield of over 70% and a surface area exceeding 500 m²/g. These results indicate the successful synthesis of BIS using CO₂ with properties in the desired range. The enhanced pH control offered by this CO₂-based process will facilitate the implementation of a sustainable and robust continuous process for BIS synthesis.