From microchannels to high shear reactors: process intensification strategies for controlled nanomaterial synthesis

Area of Science:

• Materials Science and Engineering
• Chemical Engineering
• Nanotechnology

Background:

• Nanomaterials (NMs) possess unique properties driving technological advancements.
• Scalable and controlled synthesis of NMs is challenging due to complex nucleation and growth dynamics.
• Traditional batch synthesis methods face limitations in efficiency and control.

Purpose of the Study:

• To review and analyze process intensification (PI) strategies for nanomaterial synthesis.
• To systematically examine seven representative PI reactors and their applicability.
• To provide guidance for selecting and engineering PI reactors for advanced NM manufacturing.

Main Methods:

• Comprehensive review of seven PI reactors: microreactors, confined impinging jet reactors, rotating packed beds, high shear mixers, spinning disk reactors, ultrasonic reactors, and microwave reactors.
• Systematic examination of operating principles, enhancement mechanisms, advantages, and limitations.
• Critical review of applications in biomedicine, adsorption, catalysis, coatings, optics, and electrochemistry.

Main Results:

• Detailed analysis of the performance and suitability of various PI reactors for NM synthesis.
• Identification of specific PI reactor advantages and limitations for different NM applications.
• Establishment of synthesis-structure-function correlations for rational reactor selection.

Conclusions:

• Process intensification offers a viable approach to overcome limitations in traditional NM synthesis.
• The selection of appropriate PI reactors is crucial for controllable, sustainable, and high-throughput NM manufacturing.
• This review provides essential guidance for advancing precision nanotechnology through optimized reactor engineering.