Hallmarks of mechanochemistry: from nanoparticles to technology

Main group mechanochemistry

Over the past decade, mechanochemistry has emerged as a powerful methodology in the search for sustainable alternatives to conventional solvent-based synthetic routes. Mechanochemistry has already been successfully applied to the synthesis of active pharmaceutical ingredients (APIs), organic compounds, metal oxides, coordination compounds and organometallic complexes. In the main group arena, examples of synthetic mechanochemical methodologies, whilst still relatively sporadic, are on the rise. This short review provides an overview of recent advances and achievements in this area that further validate mechanochemistry as a credible alternative to solution-based methods for the synthesis of main group compounds and frameworks.

Mechanically induced oxidation of alcohols to aldehydes and ketones in ambient air: Revisiting TEMPO-assisted oxidations

The present work addresses the development of an eco-friendly and cost-efficient protocol for the oxidation of primary and secondary alcohols to the corresponding aldehydes and ketones by mechanical processing under air. Ball milling was shown to promote the quantitative conversion of a broad set of alcohols into carbonyl compounds with no trace of an over-oxidation to carboxylic acids. The mechanochemical reaction exhibited higher yields and rates than the classical, homogeneous, TEMPO-based oxidation.

Mechanochemical synthesis of small organic molecules

With the growing interest in renewable energy and global warming, it is important to minimize the usage of hazardous chemicals in both academic and industrial research, elimination of waste, and possibly recycle them to obtain better results in greener fashion. The studies under the area of mechanochemistry which cover the grinding chemistry to ball milling, sonication, etc. are certainly of interest to the researchers working on the development of green methodologies. In this review, a collection of examples on recent developments in organic bond formation reactions like carbon–carbon (C–C), carbon–nitrogen (C–N), carbon–oxygen (C–O), carbon–halogen (C–X), etc. is documented. Mechanochemical syntheses of heterocyclic rings, multicomponent reactions and organometallic molecules including their catalytic applications are also highlighted.

Recycling of spent lithium-ion battery with polyvinyl chloride by mechanochemical process

In the present study, cathode materials (C/LiCoO₂) of spent lithium-ion batteries (LIBs) and waste polyvinyl chloride (PVC) were co-processed via an innovative mechanochemical method, i.e. LiCoO₂/PVC/Fe was co-grinded followed by water-leaching. This procedure generated recoverable LiCl from Li by the dechlorination of PVC and also generated magnetic CoFe₄O₆ from Co. The effects of different additives (e.g. alkali metals, non-metal oxides, and zero-valent metals) on (i) the conversion rates of Li and Co and (ii) the dechlorination rate of PVC were investigated, and the reaction mechanisms were explored. It was found that the chlorine atoms in PVC were mechanochemically transformed into chloride ions that bound to the Li in LiCoO₂ to form LiCl. This resulted in reorganization of the Co and Fe crystals to form the magnetic material CoFe₄O₆. This study provides a more environmentally-friendly, economical, and straightforward approach for the recycling of spent LIBs and waste PVC compared to traditional processes.

Thiourea sensor development based on hydrothermally prepared CMO nanoparticles for environmental safety

Low-dimensional cobalt oxide codoped manganese oxide nanoparticles (CMO NPs; dia. ~ 25.6nm) were synthesized using the hydrothermal method in alkaline phase. The optical, morphological, and structural properties of CMO NPs were characterized in details using FT-IR, UV/vis., FESEM, XEDS, XPS, TEM, and XRD techniques. Glassy carbon electrode (GCE) was fabricated with a thin-layer of CMO NPs by conducting coating binders for the development of selective and sensitive thiourea (TU) sensors. Electrochemical responses along with higher sensitivity, large-dynamic-range, and long-term stability towards TU were performed by electrochemical I-V approach. The calibration curve was found linear over a wide linear dynamic range (LDR) of TU concentration. From the gradient of the calibration plot, limit of detection (LOD), and sensitivity were calculated as 12.0±0.05pM and 3.3772nAnM^-1cm^-2 respectively. It is an organized route for the development of chemical sensor based on very low-dimensional CMO NPs/GCE using electrochemical reduction phenomena. As far as we know, this report is the maiden publication on highly sensitive TU sensor based on the CMO NPs/GCE. This method could be a pioneer developer in TU sensitive chemical sensor development using doped NPs in the simple I-V method for the important sensor applications with useful doped materials coupled nano-technological systems for environmental safety.

Tandem In Situ Monitoring for Quantitative Assessment of Mechanochemical Reactions Involving Structurally Unknown Phases

We report herein quantitative in situ monitoring by simultaneous PXRD and Raman spectroscopy of the mechanochemical reaction between benzoic acid and nicotinamide, affording a rich polymorphic system with four new cocrystal polymorphs, multiple phase transformations, and a variety of reaction pathways. After observing polymorphs by in situ monitoring, we were able to isolate and characterize three of the four polymorphs, most of which are not accessible from solution. Relative stabilities among the isolated polymorphs at ambient conditions were established by slurry experiments. Using two complementary methods for in situ monitoring enabled quantitative assessment and kinetic analysis of each studied mechanochemical reaction, even when involving unknown crystal structures, and short-lived intermediates. In situ Raman monitoring was introduced here also as a standalone laboratory technique for quantitative assessment of mechanochemical reactions and understanding of mechanochemical reactivity. Our results provide an important step toward a complete and high-throughput quantitative approach to mechanochemical reaction kinetics and mechanisms, necessary for the development of the mechanistic framework of milling reactions.

Screening for new pharmaceutical solid forms using mechanochemistry: A practical guide

Within the pharmaceutical industry, and elsewhere, the screening for new solid forms is a mandatory exercise for both existing and new chemical entities. This contribution focuses on mechanochemistry as a versatile approach for discovering new and alternative solid forms. Whilst a series of recently published extensive reviews exist which focus on mechanistic aspects and potential areas of development, in this review we focus on particular practical aspects of mechanochemistry in order to allow full optimisation of the approach in searches for new solid forms including polymorphs, salts and cocrystals as well as their solvated/hydrated analogues. As a consequence of the apparent experimental simplicity of the method (compared to more traditional protocols e.g. solvent-based methods), the high efficiency and range of conditions available in a mechanochemical screen, mechanochemistry should not be considered simply as an alternative method when other screening methods are not successful, but rather as a key strategy in any fully effective solid form screen providing reduced effort and time as well as the potential of requiring reduced amounts of material.

Advanced methodologies for cocrystal synthesis

Pharmaceutical cocrystals are multicomponent systems composed of two or more molecules and held together by H-bonding. Currently, cocrystals provide exciting opportunities in the pharmaceutical industry for the development and manufacturing of new medicines by improving poor physical properties of Active Pharmaceutical Ingredients (APIs) such as processability, solubility, stability and bioavailability. According to the recent reclassification, cocrystals are considered as drug polymorph rather a new API which has a significant impact on drug development, regulatory submissions and intellectual property protection. This review summarizes recent trends and advances in synthesis, manufacturing and scale - up of cocrystals. The operational principles of several cocrystals manufacturing technologies are discussed including their advantages and disadvantages in terms of crystal quality, purity stability, throughput and limitations in large scale production.

De novo formation of dioxins from milled model fly ash

Municipal solid waste incineration (MSWI) fly ash has been classified as hazardous waste and needs treatment in an environmentally safe manner. Mechanochemical (MC) treatment is such a detoxification method, since it destroys dioxins and solidifies heavy metals. Milling, however, also introduces supplemental metals (Fe, Ni, Cr, Mn…), following wear of both steel balls and housing. Milling moreover reduces the particle size of fly ash and disperses catalytic metal, potentially rising the reactivity of fly ash to form and destroy 'dioxins', i.e. polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD + PCDF or PCDD/F). To test this issue, model fly ash (MFA) samples were composed by mixing of silica, sodium chloride, and activated carbon, and doped with CuCl₂. Then, these samples were first finely milled without any additives for 0 h (original sample), 1 h and 8 h, and the effect of milling time (and hence particle size) was investigated on the formation of polycyclic aromatic hydrocarbons (PAHs), and of polychlorinated phenols (CP), benzenes (CBz), biphenyls (PCB) and dioxins (PCDD + PCDF) during de novo tests at 300 °C for 1 h, thus simulating the conditions prevailing in the post-combustion zone of an incinerator, where dioxins are formed and destroyed. These compounds are all characterized by their rate of generation (ng/g MFA) and their signature, i.e. internal distribution over congeners as a means of gathering mechanistic indications. PAH and CBz total yield did not decrease in MC treated MFA with milling time, while total pentachlorophenol (PeCP), PCB and PCDD/F yield decreased up to 86, 94 and 97%, respectively. International Toxic Equivalents (I-TEQ) concentration decreased more than 90%, while degree of chlorination varied inconsistently for PCB and PCDD/F, and average congener patterns of PCDD/F do not vary considerably with milling time for both gas and solid phase.

From Flatland to Spaceland: Higher Dimensional Patterning with Two-Dimensional Materials

The creation of three-dimensional (3D) structures from two-dimensional (2D) nanomaterial building blocks enables novel chemical, mechanical or physical functionalities that cannot be realized with planar thin films or in bulk materials. Here, we review the use of emerging 2D materials to create complex out-of-plane surface topographies and 3D material architectures. We focus on recent approaches that yield periodic textures or patterns, and present four techniques as case studies: (i) wrinkling and crumpling of planar sheets, (ii) encapsulation by crumpled nanosheet shells, (iii) origami folding and kirigami cutting to create programmed curvature, and (iv) 3D printing of 2D material suspensions. Work to date in this field has primarily used graphene and graphene oxide as the 2D building blocks, and we consider how these unconventional approaches may be extended to alternative 2D materials and their heterostructures. Taken together, these emerging patterning and texturing techniques represent an intriguing alternative to conventional materials synthesis and processing methods, and are expected to contribute to the development of new composites, stretchable electronics, energy storage devices, chemical barriers, and biomaterials.

In Situ Monitoring of the Mechanosynthesis of the Archetypal Metal-Organic Framework HKUST-1: Effect of Liquid Additives on the Milling Reactivity

We have applied in situ monitoring of mechanochemical reactions by high-energy synchrotron powder X-ray diffraction to study the role of liquid additives on the mechanochemical synthesis of the archetypal metal-organic framework (MOF) HKUST-1, which was one of the first and is still among the most widely investigated MOF materials to be synthesized by solvent-free procedures. It is shown here how the kinetics and mechanisms of the mechanochemical synthesis of HKUST-1 can be influenced by milling conditions and additives, yielding on occasion two new and previously undetected intermediate phases containing a mononuclear copper core, and that finally rearrange to form the HKUST-1 architecture. On the basis of in situ data, we were able to tune and direct the milling reactions toward the formation of these intermediates, which were isolated and characterized by spectroscopic and structural means and their magnetic properties compared to those of HKUST-1. The results have shown that despite the relatively large breadth of analysis available for such widely investigated materials as HKUST-1, in situ monitoring of milling reactions can help in the detection and isolation of new materials and to establish efficient reaction conditions for the mechanochemical synthesis of porous MOFs.

Analysis of the Acting Forces in a Theory of Catalysis and Mechanochemistry

The theoretical description of a chemical process resulting from the application of mechanical or catalytical stress to a molecule is performed by the generation of an effective potential energy surface (PES). Changes for minima and saddle points by the stress are described by Newton trajectories (NTs) on the original PES. From the analysis of the acting forces we postulate the existence of pulling corridors built by families of NTs that connect the same stationary points. For different exit saddles of different height we discuss the corresponding pulling corridors; mainly by simple two-dimensional surface models. If there are different exit saddles then there can exist saddles of index two, at least, between. Then the case that a full pulling corridor crosses a saddle of index two is the normal case. It leads to an intrinsic hysteresis of such pullings for the forward or the backward reaction. Assuming such relations we can explain some results in the literature. A new finding is the existence of roundabout corridors that can switch between different saddle points by a reversion of the direction. The findings concern the mechanochemistry of molecular systems under a mechanical load as well as the electrostatic force and can be extended to catalytic and enzymatic accelerated reactions. The basic and ground ansatz includes both kinds of forces in a natural way without an extra modification.

Rapid and direct synthesis of complex perovskite oxides through a highly energetic planetary milling

The search for a new and facile synthetic route that is simple, economical and environmentally safe is one of the most challenging issues related to the synthesis of functional complex oxides. Herein, we report the expeditious synthesis of single-phase perovskite oxides by a high-rate mechanochemical reaction, which is generally difficult through conventional milling methods. With the help of a highly energetic planetary ball mill, lead-free piezoelectric perovskite oxides of (Bi, Na)TiO₃, (K, Na)NbO₃ and their modified complex compositions were directly synthesized with low contamination. The reaction time necessary to fully convert the micron-sized reactant powder mixture into a single-phase perovskite structure was markedly short at only 30-40 min regardless of the chemical composition. The cumulative kinetic energy required to overtake the activation period necessary for predominant formation of perovskite products was ca. 387 kJ/g for (Bi, Na)TiO₃ and ca. 580 kJ/g for (K, Na)NbO₃. The mechanochemically derived powders, when sintered, showed piezoelectric performance capabilities comparable to those of powders obtained by conventional solid-state reaction processes. The observed mechanochemical synthetic route may lead to the realization of a rapid, one-step preparation method by which to create other promising functional oxides without time-consuming homogenization and high-temperature calcination powder procedures.

Synergy Effects in the Chemical Synthesis and Extensions of Multicomponent Reactions (MCRs)-The Low Energy Way to Ultra-Short Syntheses of Tailor-Made Molecules

Several novel methods, catalysts and reagents have been developed to improve organic synthesis. Synergistic effects between reactions, reagents and catalysts can lead to minor heats of reaction and occur as an inherent result of multicomponent reactions (MCRs) and their extensions. They enable syntheses to be performed at a low energy level and the number of synthesis steps to be drastically reduced in comparison with ‘classical’ two-component reactions, fulfilling the rules of Green Chemistry. The very high potential for variability, diversity and complexity of MCRs additionally generates an extremely diverse range of products, thus bringing us closer to the aim of being able to produce tailor-made and extremely low-cost materials, drugs and compound libraries.

Synthesis and Supercapacitor Application of Alkynyl Carbon Materials Derived from CaC2 and Polyhalogenated Hydrocarbons by Interfacial Mechanochemical Reactions

The discovery of new carbon materials and the reactive activation of CaC₂ are challenging subjects. In this study, a series of alkynyl carbon materials (ACMs) were synthesized by the interfacial mechanochemical reaction of CaC₂ with four typical polyhalogenated hydrocarbons. Their properties and structures were characterized, and their electrochemical performances were examined. The reaction was rapid and efficient arising from the intense mechanical activation of CaC₂. The ACMs are micro-mesoporous materials with distinct layered structure, specific graphitization degree, and clear existence of sp-C. In addition, the ACMs exhibit high specific capacitance in the range of 57-133 F g^-1 and thus can be ideal candidates for active materials used in supercapacitors. The results may imply an alternative synthesis of carbon allotropes, as well as an efficient approach for the activation of CaC₂.

Graphite-to-Graphene: Total Conversion

The rush to develop graphene applications mandates mass production of graphene sheets. However, the currently available complex and expensive production technologies are limiting the graphene commercialization. The addition of a protective diluent to graphite during ball-milling is demonstrated to result in a game-changer yield (>90%) of defect-free graphene, whose size is controlled by the milling energy and the diluent type.

Noble-Metal-Free Photocatalytic Hydrogen Evolution Activity: The Impact of Ball Milling Anatase Nanopowders with TiH2

Ball milling TiO₂ anatase together with TiH₂ can create an effective photocatalyst. The process changes the lattice and electronic structure of anatase. Lattice deformation created by mechanical impact combined with hydride incorporation yield electronic gap-states close to the conduction band of anatase. These provide longer lifetimes of photogenerated charge carriers and lead to an intrinsic cocatalytic activation of anatase for H₂ evolution.

Mechanochemistry at Solid Surfaces: Polymerization of Adsorbed Molecules by Mechanical Shear at Tribological Interfaces

Polymerization of allyl alcohol adsorbed and sheared at a silicon oxide interface is studied using tribo-tests in vapor phase lubrication conditions and reactive molecular dynamics simulations. The load dependences of product formation obtained from experiments and simulations were consistent, indicating that the atomic-scale processes observable in the simulations were relevant to the experiments. Analysis of the experimental results in the context of mechanically assisted thermal reaction theory, combined with the atomistic details available from the simulations, suggested that the association reaction pathway of allyl alcohol molecules induced by mechanical shear is quite different from chemically induced polymerization reactions. Findings suggested that some degree of distortion of the molecule from its equilibrium state is necessary for mechanically induced chemical reactions to occur and such a distortion occurs during mechanical shear when molecules are covalently anchored to one of the sliding surfaces.

Mechanochemistry: A Force of Synthesis

The past decade has seen a reawakening of solid-state approaches to chemical synthesis, driven by the search for new, cleaner synthetic methodologies. Mechanochemistry, i.e., chemical transformations initiated or sustained by mechanical force, has been advancing particularly rapidly, from a laboratory curiosity to a widely applicable technique that not only enables a cleaner route to chemical transformations but offers completely new opportunities in making and screening for molecules and materials. This Outlook provides a brief overview of the recent achievements and opportunities created by mechanochemistry, including access to materials, molecular targets, and synthetic strategies that are hard or even impossible to access by conventional means.

Mechanochemical Lignin-Mediated Strecker Reaction

A mechanochemical Strecker reaction involving a wide range of aldehydes (aromatic, heteroaromatic and aliphatic), amines, and KCN afforded a library of α-aminonitriles upon mechanical activation. This multicomponent process was efficiently activated by lignocellulosic biomass as additives. Particularly, commercially available Kraft lignin was found to be the best activator for the addition of cyanide to the in situ formed imines. A comparative study of the ³¹P-NMR (Nuclear Magnetic Resonance) along with IR (Infrared) data analysis for the Kraft lignin and methylated Kraft lignin samples ascertained the importance of the free hydroxyl groups in the activation of the mechanochemical reaction. The solvent-free mechanochemical Strecker reaction was then coupled with a lactamization process leading to the formation of the N-benzylphthalimide (5a) and the isoindolinone derivative 6a.

Advances in Solid-State Transformations of Coordination Bonds: From the Ball Mill to the Aging Chamber

Controlling the formation of coordination bonds is pivotal to the development of a plethora of functional metal-organic materials, ranging from coordination polymers, metal-organic frameworks (MOFs) to metallodrugs. The interest in and commercialization of such materials has created a need for more efficient, environmentally-friendly routes for making coordination bonds. Solid-state coordination chemistry is a versatile greener alternative to conventional synthesis, offering quantitative yields, enhanced stoichiometric and topological selectivity, access to a wider range of precursors, as well as to molecules and materials not readily accessible in solution or solvothermally. With a focus on mechanochemical, thermochemical and “accelerated aging” approaches to coordination polymers, including pharmaceutically-relevant materials and microporous MOFs, this review highlights the recent advances in solid-state coordination chemistry and techniques for understanding the underlying reaction mechanisms.

Separation of Cu(ii) from Cd(ii) in sulfate solution using CaCO3 and FeSO4 based on mechanochemical activation

Mechanochemical activation of CaCO₃ was applied to separate Cu–Cd ions, using FeSO₄·7H₂O as a selective precipitation agent.

The effect of the ball to reactant ratio on mechanochemical reaction times studied by in situ PXRD

The effect of the ball to reactant ratio on reaction times for a cocrystal formation was studied by in situ PXRD.

Warming up for mechanosynthesis – temperature development in ball mills during synthesis

We present a first direct measurement of the temperature during milling combined with in situ Raman spectroscopy monitoring.

Divalent metal phosphonates – new aspects for syntheses, in situ characterization and structure solution

Divalent metal phosphonates are promising hybrid materials with a broad field of application. The rich coordination chemistry of the phosphonate linkers enables the formation of structures with different dimensionalities ranging from isolated complexes and layered structures to porous frameworks incorporating various functionalities through the choice of the building blocks. In brief, metal phosphonates offer an interesting opportunity for the design of multifunctional materials. Here, we provide a short review on the class of divalent metal phosphonates discussing their syntheses, structures, and applications. We present the advantages of the recently introduced mechanochemical pathway for the synthesis of divalent phosphonates as a possibility to generate new, in certain cases metastable compounds. The benefits of

Synthesis and characterization of metal–organic frameworks fabricated by microwave-assisted ball milling for adsorptive removal of Congo red from aqueous solutions

In this study, four metal–organic frameworks (MOFs) were prepared using a simple, low-cost, and high-efficiency technique utilizing simple carboxylic acids and metal salts by microwave-assisted ball milling.

Melt-driven mechanochemical phase transformations in moderately exothermic powder mixtures

Usually, mechanochemical reactions between solid phases are either gradual (by deformation-induced mixing), or self-propagating (by exothermic chemical reaction). Here, by means of a systematic kinetic analysis of the Bi-Te system reacting to Bi₂Te₃, we establish a third possibility: if one or more of the powder reactants has a low melting point and low thermal effusivity, it is possible that local melting can occur from deformation-induced heating. The presence of hot liquid then triggers chemical mixing locally. The molten events are constrained to individual particles, making them distinct from self-propagating reactions, and occur much faster than conventional gradual reactions. We show that the mechanism is applicable to a broad variety of materials systems, many of which have important functional properties. This mechanistic picture offers a new perspective as compared to conventional, gradual mechanochemical synthesis, where thermal effects are generally ignored.

The geochemically-analogous process of metal recovery from second-hand resources via mechanochemistry: An atom-economic case study and its implications

In the context of recycling metal to embrace the sustainability challenge, this work proposes a geochemically-analogous process of metal recovery through mechanochemistry for the first time, to avoid the limitations of on-going methods and to establish an innovative technology philosophy. This work systematically investigates this geochemically-analogous process, to keep it green and to generalize it further. Copper recovery from waste printed circuit boards (WPCBs), a typical copper-rich waste, is chosen as a case study in this work. Nearly 98% of the copper in the WPCBs can be recycled in the optimized conditions and 82.3% of the sulfur can be reused, by means of the process. Based on the experimental result, this paper purports a closed-loop route of copper recovery which follows the green chemistry principles (high yield, high atom economy and no secondary pollution). This route can be generalized into other second-hand resources that are rich in copper. Some other metals (e.g. lead) that are commonly present as corresponding sulfides in nature can be taken into consideration in this geochemically-analogous process as well.

Advances in Quantum Mechanochemistry: Electronic Structure Methods and Force Analysis

In quantum mechanochemistry, quantum chemical methods are used to describe molecules under the influence of an external force. The calculation of geometries, energies, transition states, reaction rates, and spectroscopic properties of molecules on the force-modified potential energy surfaces is the key to gain an in-depth understanding of mechanochemical processes at the molecular level. In this review, we present recent advances in the field of quantum mechanochemistry and introduce the quantum chemical methods used to calculate the properties of molecules under an external force. We place special emphasis on quantum chemical force analysis tools, which can be used to identify the mechanochemically relevant degrees of freedom in a deformed molecule, and spotlight selected applications of quantum mechanochemical methods to point out their synergistic relationship with experiments.