Continuous nanoparticle production by microfluidic-based emulsion, mixing and crystallization

Microreactor-based micro/nanomaterials: fabrication, advances, and outlook

Micro/nanomaterials are widely used in optoelectronics, environmental materials, bioimaging, agricultural industries, and drug delivery owing to their marvelous features, such as quantum tunneling, size, surface and boundary, and Coulomb blockade effects. Recently, microreactor technology has opened up broad prospects for green and sustainable chemical synthesis as a powerful tool for process intensification and microscale manipulation. This review focuses on recent progress in the microreactor synthesis of micro/nanomaterials. First, the fabrication and design principles of existing microreactors for producing micro/nanomaterials are summarized and classified. Afterwards, typical examples are shown to demonstrate the fabrication of micro/nanomaterials, including metal nanoparticles, inorganic nonmetallic nanoparticles, organic nanoparticles, Janus particles, and MOFs. Finally, the future research prospects and key issues of microreactor-based micro/nanomaterials are discussed. In short, microreactors provide new ideas and methods for the synthesis of micro/nanomaterials, which have huge potential and inestimable possibilities in large-scale production and scientific research.

Recent Advances in the Preparation of Barium Sulfate Nanoparticles: A Mini-Review

The potential for barium sulphate nanoparticles to be used in a variety of important fields has sparked a lot of attention. Methods for obtaining this material by milling (top-down approach) are not very popular due to the difficulty of controlling the size and shape of particles, as well as changes in their physicochemical properties during milling. More promising is the bottom-up approach, which is the interaction of Ba2+ and SO42− ions in a liquid environment. Direct precipitation is the simplest method; however, it does not allow control of the particle size. Microemulsions, microreactors membrane dispersion, as well as spinning disc reactors are used to overcome drawbacks of direct precipitation and allow control of particle size and shape. This is ensured mainly by intensive controlled micromixing of the precursors with concentrations close to saturated ones. The present review focuses on recent advances in the production of barium sulfate nanoparticles using various approaches, as well as their advantages and limitations. The issues of scaling up the techniques are also considered, and promising methods for obtaining BaSO4 nanoparticles are also discussed.

Liquid Flow and Mass Transfer Behaviors in a Butterfly-Shaped Microreactor

Based on the split-and-recombine principle, a millimeter-scale butterfly-shaped microreactor was designed and fabricated through femtosecond laser micromachining. The velocity fields, streamlines and pressure fields of the single-phase flow in the microreactor were obtained by a computational fluid dynamics simulation, and the influence of flow rates on the homogeneous mixing efficiency was quantified by the mixing index. The flow behaviors in the microreactor were investigated using water and n-butanol, from which schematic diagrams of various flow patterns were given and a flow pattern map was established for regulating the flow behavior via controlling the flow rates of the two-phase flow. Furthermore, effects of the two-phase flow rates on the droplet flow behavior (droplet number, droplet size and standard deviation) in the microreactor were investigated. In addition, the interfacial mass transfer behaviors of liquid-liquid flow were evaluated using the standard low interfacial tension system of "n-butanol/succinic acid/water", where the dependence between the flow pattern and mass transfer was discussed. The empirical relationship between the volumetric mass transfer coefficient and Reynold number was established with prediction error less than 20%.

Study on the Technology of Monodisperse Droplets by a High-Throughput and Instant-Mixing Droplet Microfluidic System

In this study, we report a novel high-throughput and instant-mixing droplet microfluidic system that can prepare uniformly mixed monodisperse droplets at a flow rate of mL/min designed for rapid mixing between multiple solutions and the preparation of micro-/nanoparticles. The system is composed of a magneton micromixer and a T-junction microfluidic device. The magneton micromixer rapidly mixes multiple solutions uniformly through the rotation of the magneton, and the mixed solution is sheared into monodisperse droplets by the silicone oil in the T-junction microfluidic device. The optimal conditions of the preparation of monodisperse droplets for the system have been found and factors affecting droplet size are analyzed for correlation; for example, the structure of the T-junction microfluidic device, the rotation speed of the magneton, etc. At the same time, through the uniformity of the color of the mixed solution, the mixing performance of the system is quantitatively evaluated. Compared with mainstream micromixers on the market, the system has the best mixing performance. Finally, we used the system to simulate the internal gelation broth preparation of zirconium broth and uranium broth. The results show that the system is expected to realize the preparation of ceramic microspheres at room temperature without cooling by the internal gelation process.

Microfluidics for pharmaceutical nanoparticle fabrication: The truth and the myth

Using micro-sized channels to manipulate fluids is the essence of microfluidics which has wide applications from analytical chemistry to material science and cell biology research. Recently, using microfluidic-based devices for pharmaceutical research, in particular for the fabrication of micro- and nano-particles, has emerged as a new area of interest. The particles that can be prepared by microfluidic devices can range from micron size droplet-based emulsions to nano-sized drug loaded polymeric particles. Microfluidic technology poses unique advantages in terms of the high precision of the mixing regimes and control of fluids involved in formulation preparation. As a result of this, monodispersity of the particles prepared by microfluidics is often recognised as being a particularly advantageous feature in comparison to those prepared by conventional large-scale mixing methods. However, there is a range of practical drawbacks and challenges of using microfluidics as a direct micron- and nano-particle manufacturing method. Technological advances are still required before this type of processing can be translated for application by the pharmaceutical industry. This review focuses specifically on the application of microfluidics for pharmaceutical solid nanoparticle preparation and discusses the theoretical foundation of using the nanoprecipitation principle to generate particles and how this is translated into microfluidic design and operation.

Continuous Synthesis of Nanocrystals via Flow Chemistry Technology

Modern nanotechnologies bring humanity to a new age, and advanced methods for preparing functional nanocrystals are cornerstones. A considerable variety of nanomaterials has been created over the past decades, but few were prepared on the macro scale, even fewer making it to the stage of industrial production. The gap between academic research and engineering production is expected to be filled by flow chemistry technology, which relies on microreactors. Microreaction devices and technologies for synthesizing different kinds of nanocrystals are discussed from an engineering point of view. The advantages of microreactors, the important features of flow chemistry systems, and methods to apply them in the syntheses of salt, oxide, metal, alloy, and quantum dot nanomaterials are summarized. To further exhibit the scaling-up of nanocrystal synthesis, recent reports on using microreactors with gram per hour and larger production rates are highlighted. Finally, an industrial example for preparing 10 tons of CaCO₃ nanoparticles per day is introduced, which shows the great potential for flow chemistry processes to transfer lab research to industry.

Microfluidic Generation of Nanomaterials for Biomedical Applications

As nanomaterials (NMs) possess attractive physicochemical properties that are strongly related to their specific sizes and morphologies, they are becoming one of the most desirable components in the fields of drug delivery, biosensing, bioimaging, and tissue engineering. By choosing an appropriate methodology that allows for accurate control over the reaction conditions, not only can NMs with high quality and rapid production rate be generated, but also designing composite and efficient products for therapy and diagnosis in nanomedicine can be realized. Recent evidence implies that microfluidic technology offers a promising platform for the synthesis of NMs by easy manipulation of fluids in microscale channels. In this Review, a comprehensive set of developments in the field of microfluidics for generating two main classes of NMs, including nanoparticles and nanofibers, and their various potentials in biomedical applications are summarized. Furthermore, the major challenges in this area and opinions on its future developments are proposed.

Progress of crystallization in microfluidic devices

Microfluidic technology provides a unique environment for the investigation of crystallization processes at the nano or meso scale. The convenient operation and precise control of process parameters, at these scales of operation enabled by microfluidic devices, are attracting significant and increasing attention in the field of crystallization. In this paper, developments and applications of microfluidics in crystallization research including: crystal nucleation and growth, polymorph and cocrystal screening, preparation of nanocrystals, solubility and metastable zone determination, are summarized and discussed. The materials used in the construction and the structure of these microfluidic devices are also summarized and methods for measuring and modelling crystal nucleation and growth process as well as the enabling analytical methods are also briefly introduced. The low material consumption, high efficiency and precision of microfluidic crystallizations are of particular significance for active pharmaceutical ingredients, proteins, fine chemicals, and nanocrystals. Therefore, it is increasingly adopted as a mainstream technology in crystallization research and development.

Emerging Droplet Microfluidics

Droplet microfluidics generates and manipulates discrete droplets through immiscible multiphase flows inside microchannels. Due to its remarkable advantages, droplet microfluidics bears significant value in an extremely wide range of area. In this review, we provide a comprehensive and in-depth insight into droplet microfluidics, covering fundamental research from microfluidic chip fabrication and droplet generation to the applications of droplets in bio(chemical) analysis and materials generation. The purpose of this review is to convey the fundamentals of droplet microfluidics, a critical analysis on its current status and challenges, and opinions on its future development. We believe this review will promote communications among biology, chemistry, physics, and materials science.

Size Control in the Nanoprecipitation Process of Stable Iodine (¹²⁷I) Using Microchannel Reactor-Optimization by Artificial Neural Networks

In this study, nanosuspension of stable iodine ((127)I) was prepared by nanoprecipitation process in microfluidic devices. Then, size of particles was optimized using artificial neural networks (ANNs) modeling. The size of prepared particles was evaluated by dynamic light scattering. The response surfaces obtained from ANNs model illustrated the determining effect of input variables (solvent and antisolvent flow rate, surfactant concentration, and solvent temperature) on the output variable (nanoparticle size). Comparing the 3D graphs revealed that solvent and antisolvent flow rate had reverse relation with size of nanoparticles. Also, those graphs indicated that the solvent temperature at low values had an indirect relation with size of stable iodine ((127)I) nanoparticles, while at the high values, a direct relation was observed. In addition, it was found that the effect of surfactant concentration on particle size in the nanosuspension of stable iodine ((127)I) was depended on the solvent temperature. Nanoprecipitation process of stable iodine (127I) and optimization of particle size using ANNs modeling.

Reaction engineering strategies for the production of inorganic nanomaterials

The rapid expansion of nanotechnology requires scaled-up production rates to cope with increased nanomaterials demand. However, in many cases, the final uses of nanomaterials impose strict requisites on their physical and chemical characteristics including size, shape, chemical composition and type of functional groups on their surface. Frequently, additional features such as a limited degree of agglomeration are also demanded. These requisites represent a serious challenge to present-day synthesis methods when nanomaterials must be produced in large amounts. Some of the possible solutions from the reaction engineering perspective are discussed in this work for both gas and liquid phase production processes. Special attention will be devoted to enabling technologies, which allow the production of engineered nanoparticles with limited aggregation and with a good control on their nano-scale characteristics.

Investigation of design parameters in ultrasound reactors with confined channels

This paper presents a three-dimensional numercial simulation of sonochemical degradation upon cavitational activity. The model relates the simulation of the acoustic pressure distribution to the sonochemical reaction rate. As a case study, the thermal degradation of carbon tetrachloride during sonication is studied in a tubular milliscale reactor. The model is used to optimize the reactor diameter, ultrasound frequency and power dissipated to the ultrasound transducers. The results indicate that multiple transducers at a moderate power level are more efficient than one transducer with high power level. Furthermore, the average cavity volume fraction is proposed as a reaction independent parameter to estimate the optimal reactor design. Within the results obtained in this paper, it appears possible to optimise reactor design based on this parameter.

Microfluidic and lab-on-a-chip preparation routes for organic nanoparticles and vesicular systems for nanomedicine applications

In recent years, advancements in the fields of microfluidic and lab-on-a-chip technologies have provided unique opportunities for the implementation of nanomaterial production processes owing to the miniaturisation of the fluidic environment. It has been demonstrated that microfluidic reactors offer a range of advantages compared to conventional batch reactors, including improved controllability and uniformity of nanomaterial characteristics. In addition, the fast mixing achieved within microchannels, and the predictability of the laminar flow conditions, can be leveraged to investigate the nanomaterial formation dynamics. In this article recent developments in the field of microfluidic production of nanomaterials for drug delivery applications are reviewed. The features that make microfluidic reactors a suitable technological platform are discussed in terms of controllability of nanomaterials production. An overview of the various strategies developed for the production of organic nanoparticles and colloidal assemblies is presented, focusing on those nanomaterials that could have an impact on nanomedicine field such as drug nanoparticles, polymeric micelles, liposomes, polymersomes, polyplexes and hybrid nanoparticles. The effect of microfluidic environment on nanomaterials formation dynamics, as well as the use of microdevices as tools for nanomaterial investigation is also discussed.

Segmented flow reactors for nanocrystal synthesis

In the past decade microreactors have emerged as a compelling technology for the highly controlled synthesis of colloidal nanocrystals, offering multiple advantages over conventional batch synthesis methods (including improved levels of control, reproducibility, and automation). Initial work in the field employed simple continuous phase reactors that manipulate miscible streams of a single reagent phase. Recently, however, there has been increasing interest in segmented flow reactors that use an immiscible fluid to divide the reagent phase into discrete slugs or droplets. Key advantages of segmented flow include the elimination of velocity dispersion (a significant cause of polydispersity) and greatly reduced susceptibility to reactor fouling. In this progress report we review the operation of segmented flow microreactors, their application to the controlled synthesis of nanocrystals, and some of the principal challenges that must be addressed before they can become a mainstream technology for the controlled production of nanomaterials.

The use of artificial neural networks for optimizing polydispersity index (PDI) in nanoprecipitation process of acetaminophen in microfluidic devices

Artificial neural networks (ANNs) were used in this study to determine factors that control the polydispersity index (PDI) in an acetaminophen nanosuspension which was prepared using nanoprecipitation in microfluidic devices. The PDI of prepared formulations was measured by dynamic light scattering. Afterwards, the ANNs were applied to model the data. Four independent variables, namely, surfactant concentration, solvent temperature, and flow rate of solvent and antisolvent were considered as input variables, and the PDI of acetaminophen nanosuspension was taken as the output variable. The response surfaces, generated as 3D graphs after modeling, were used to survey the interactions happening between the input variables and the output variable. Comparison of the response surfaces indicated that the antisolvent flow rate and the solvent temperature have reverse effect on the PDI, whereas solvent flow rate has direct relation with PDI. Also, the effect of the concentration of the surfactant on the PDI was found to be indirect and less influential. Overall, it was found that minimum PDI may be obtained at high values of antisolvent flow rate and solvent temperature, while the solvent flow rate should be kept to a minimum.

Fabrication of advanced particles and particle-based materials assisted by droplet-based microfluidics

Recent advances in the fabrication of complex particles and particle-based materials assisted by droplet-based microfluidics are reviewed. Monodisperse particles with expected internal structures, morphologies, and sizes in the range of nanometers to hundreds of micrometers have received a good deal of attention in recent years. Due to the capability of generating monodisperse emulsions and of executing precise control and operations on the suspended droplets inside the microchannels, droplet-based microfluidic devices have become powerful tools for fabricating complex particles with desired properties. Emulsions and multiple-emulsions generated in the microfluidic devices can be composed of a variety of materials including aqueous solutions, gels, polymers and solutions containing functional nanoparticles. They are ideal microreactors or fine templates for synthesizing advanced particles, such as polymer particles, microcapsules, nanocrystals, and photonic crystal clusters or beads by further chemical or physical operations. These particles are promising materials that may be applicable for many fields, such as photonic materials, drug delivery systems, and bio-analysis. From simple to complex, from spherical to nonspherical, from polymerization and reaction crystallization to self-assembly, this review aims to help readers be aware of the many aspects of this field.

A stable droplet reactor for high temperature nanocrystal synthesis

We report a versatile capillary-based droplet reactor for the controlled synthesis of nanoparticles over a wide range of flow conditions and temperatures. The reactor tolerates large flow-rate differentials between individual reagent streams, and allows droplet composition to be varied independently of residence time and volume. The reactor was successfully applied to the synthesis of metal (Ag), metal-oxide (TiO(2)) and compound semiconductor (CdSe) nanoparticles, and in each case exhibited stable droplet flow over many hours of operation without fouling, even for reactions involving solid intermediates. For CdSe formed by the reaction of Cd oleate and Se, highly controlled growth could be achieved at temperatures of up to 250 °C, with emission spectra varying smoothly and reproducibly with temperature and flow-rate. The droplet reactor showed exceptional stability when operated under constant flow-rate and temperature conditions, yielding particles with well-defined band-edge emission spectra that did not vary over the course of a full day's continuous operation.

Hierarchically nanostructured barium sulfate fibers

BaSO(4) nanostructures with controlled morphologies were successfully produced via one-step process through precipitation of BaSO(4) in aqueous and organic media. The synthesis is carried out by mixing solutions of BaCl(2) and Na(2)SO(4) in presence of EDTA (disodium ethylenediaminetetraacetic acid) at room temperature. The influence of the reaction conditions such as initial reactants concentration, pH, EDTA/[Ba(2+)] ratio and aging on the BaSO(4) nanoparticles organization is studied. Using EDTA in aqueous media, spherical secondary particles of 500 nm diameter are obtained, which are formed by 4 nm size primary particles. With dimethyl sulfoxide and small amounts of water (5%) and EDTA, the aging process allows the production of long homogeneous fibers, related to hierarchical organization of BaSO(4) nanoparticles. Direct observation of self-assembling of primary particles by HRTEM allows proposing a mechanism for fiber formation, which is based on multipolar attractions that lead to a brick-by-brick organization along a preferential orientation. Results evidence the role of EDTA as controlling agent of the morphology and primary and secondary mean particle size.

Multiscale materials from microcontinuous-flow synthesis: ZnO and Au nanoparticle-filled uniform and homogeneous polymer microbeads

Tri(propylene glycol) diacrylate (TPGDA) was found to be an excellent monomer for the stabilization and dispersion of inorganic nanoparticles. Uniform nano-Au/poly(TPGDA) and nano-ZnO/poly(TPGDA) composite microbeads were synthesized in situ using a designed axisymmetric capillary-based flow-focusing microfluidic device without any additional surfactant or coupling agent. Using the designed mixing-enhanced microfluidic device, homogeneous nano-inorganic/polymer composites with a high content of nanoparticles were obtained. Morphologies of the composites were characterized by SEM, TEM, surface microscopy, dark-field microscopy and internal fluorescence.

Preparation of evaporation-resistant aqueous microdroplet arrays as a model system for the study of molecular order at the liquid/air interface

Aqueous arrays of microdroplets typically sized between 2 and 10 microm were generated by microfluid contact printing and stabilized with respect to evaporation by incorporation of poly(ethylene oxide). The arrays are used as a model system for the study of structure formation at liquid/air or liquid/liquid interfaces. In particular, we demonstrated the self-organization of fatty acids with photopolymerizable diacetylene units (10,12-pentacosadiynoic acid) at the liquid/air interface of the microdroplets. Topochemical polymerization behavior of this compound and the autofluorescence property of the resulting polyconjugated polymer are appropriate features to prove the molecular order of the amphiphilic molecules at the interface.

Preparation of hydrocortisone nanosuspension through a bottom-up nanoprecipitation technique using microfluidic reactors

In this work, the possibility of bottom-up creation of a relatively stable aqueous hydrocortisone nanosuspension using microfluidic reactors was examined. The first part of the work involved a study of the parameters of the microfluidic precipitation process that affect the size of generated drug particles. These parameters included flow rates of drug solution and antisolvent, microfluidic channel diameters, microreactors inlet angles and drug concentrations. The experimental results revealed that hydrocortisone nano-sized dispersions in the range of 80-450 nm were obtained and the mean particle size could be changed by modifying the experimental parameters and design of microreactors. The second part of the work studied the possibility of preparing a hydrocortisone nanosuspension using microfluidic reactors. The nano-sized particles generated from a microreactor were rapidly introduced into an aqueous solution of stabilizers stirred at high speed with a propeller mixer. A tangential flow filtration system was then used to concentrate the prepared nanosuspension. The nanosuspension produced was then characterized using photon correlation spectroscopy (PCS), Zeta potential measurement, transmission electron microscopy (TEM), differential scanning calorimetry (DSC) and X-ray analysis. Results showed that a narrow sized nanosuspension composed of amorphous spherical particles with a mean particle size of 500+/-64 nm, a polydispersity index of 0.21+/-0.026 and a zeta potential of -18+/-2.84 mV was obtained. Physical stability studies showed that the hydrocortisone nanosuspension remained homogeneous with slight increase in mean particle size and polydispersity index over a 3-month period.