Scaling-up a Confined Jet Reactor for the Continuous Hydrothermal Manufacture of Nanomaterials

Continuous Hydrothermal Flow Synthesis and Characterization of ZrO2 Nanoparticles Doped with CeO2 in Supercritical Water

A confined jet mixing reactor operated in continuous hydrothermal flow synthesis was investigated for the synthesis of CeO₂-ZrO₂ (CZ) nanoparticles. The obtained ultrafine powders were characterized using scanning electron microscopy–energy dispersive spectrometry (SEM-EDS), inductively coupled plasma–atomic emission spectroscopy (ICP-AES), Fourier transform infrared spectroscopy (FTIR), Raman spectroscopy, X-ray diffraction analysis (XRD), transmission electron microscopy (TEM) coupled with selected area electron diffraction (SAED), a BET (Brunauer-Emmett-Teller)-specific surface area test and pore analysis, oxygen storage capacity (OSC) test, and a H₂ temperature programmed reduction (H₂-TPR) test. The XRD results show that all samples were composed of high-purity cubic CZ nanoparticles. High resolution transmission electron microscope (HR-TEM) analysis showed that CZ nanoparticles with uniform size and shape distributions were obtained in this investigation. The d-spacing values, determined based on the TEM-selected area electron diffraction (SAED) patterns, were in good agreements with the reference data. BET results showed that the prepared CZ samples had large specific surface areas. Pore volume and size distribution were obtained by pore analysis. Oxygen pulse adsorption technology was used to test the oxygen storage capacity of the sample. The redox capacity of the CZ material was determined by a H₂ temperature-programmed reduction test.

Continuous-flow syntheses of alloy nanoparticles

Alloy nanoparticles (NPs), including core-shell, segregated and solid-solution types, show a variety of attractive properties such as catalytic and optical properties and are used in a wide range of applications. Precise control and good reproducibility in the syntheses of alloy NPs are highly demanded because these properties are tunable by controlling alloy structures, compositions, particle sizes, and so on. To improve the efficiency and reproducibility of their syntheses, continuous-flow syntheses with various types of reactors have recently been developed instead of the current mainstream approach, batch syntheses. In this review, we focus on the continuous-flow syntheses of alloy NPs and first overview the flow syntheses of NPs, especially of alloy NPs. Subsequently, the details of flow reactors and their chemistry to synthesize core-shell, segregated, solid-solution types of alloy NPs, and high-entropy alloy NPs are introduced. Finally, the challenges and future perspectives in this field are discussed.

Revisiting aromatic diazotization and aryl diazonium salts in continuous flow: highlighted research during 2001–2021

Aryl diazonium salts play an important role in chemical transformations; however their explosive nature limits their applications in batch.

High Throughput Synthesis and Screening of Oxygen Reduction Catalysts in the MTiO3 (M = Ca, Sr, Ba) Perovskite Phase Diagram

A library of 66 perovskite Ba_xSr_yCa_zTiO₃ (x + y + z = 1) samples (ca. three grams per sample) was made in ca. 14 h using a high-throughput continuous hydrothermal flow synthesis system. The as-synthesized samples were collected from the outlet of the process and then cleaned and freeze-dried before being evaluated individually as oxygen reduction catalysts using a rotating disk electrode testing technique. To establish any correlations between physical and electrochemical characterization data, the as-synthesized samples were investigated using analytical methods including BET surface area, powder X-ray diffraction (PXRD) and in selected cases, transmission electron microscopy (TEM). The aforementioned approach was validated as being able to quickly identify oxygen reduction catalysts from new libraries of electrocatalysts.

Enhanced charge storage of nanometric ζ-V2O5 in Mg electrolytes

V2O5 is of interest as a Mg intercalation electrode material for Mg batteries, both in its thermodynamically stable layered polymorph (α-V2O5) and in its metastable tunnel structure (ζ-V2O5). However, such oxide cathodes typically display poor Mg insertion/removal kinetics, with large voltage hysteresis. Herein, we report the synthesis and evaluation of nanosized (ca. 100 nm) ζ-V2O5 in Mg-ion cells, which displays significantly enhanced electrochemical kinetics compared to microsized ζ-V2O5. This effect results in a significant boost in stable discharge capacity (130 mA h g-1) compared to bulk ζ-V2O5 (70 mA h g-1), with reduced voltage hysteresis (1.0 V compared to 1.4 V). This study reveals significant advancements in the use of ζ-V2O5 for Mg-based energy storage and yields a better understanding of the kinetic limiting factors for reversible magnesiation reactions into such phases.

Synthesis of Micro- and Nanoparticles in Sub- and Supercritical Water: From the Laboratory to Larger Scales

The use of micro- and nanoparticles is gaining more and more importance because of their wide range of uses and benefits based on their unique mechanical, physical, electrical, optical, electronic, and magnetic properties. In recent decades, supercritical fluid technologies have strongly emerged as an effective alternative to other numerous particle generation processes, mainly thanks to the peculiar properties exhibited by supercritical fluids. Carbon dioxide and water have so far been two of the most commonly used fluids for particle generation, the former being the fluid par excellence in this field, mainly, because it offers the possibility of precipitating thermolabile particles. Nevertheless, the use of high-pressure and -temperature water opens an innovative and very interesting field of study, especially with regards to the precipitation of particles that could hardly be precipitated when CO2 is used, such as metal particles with a considerable value in the market. This review describes an innovative method to obtain micro- and nanoparticles: hydrothermal synthesis by means of near and supercritical water. It also describes the differences between this method and other conventional procedures, the most currently active research centers, the types of particles synthesized, the techniques to evaluate the products obtained, the main operating parameters, the types of reactors, and amongst them, the most significant and the most frequently used, the scaling-up studies under progress, and the milestones to be reached in the coming years.

Probing Mg Intercalation in the Tetragonal Tungsten Bronze Framework V4Nb18O55

While commercial Li-ion batteries offer the highest energy densities of current rechargeable battery technologies, their energy storage limit has almost been achieved. Therefore, there is considerable interest in Mg batteries, which could offer increased energy densities in comparison to Li-ion batteries if a high-voltage electrode material, such as a transition-metal oxide, can be developed. However, there are currently very few oxide materials which have demonstrated reversible and efficient Mg²⁺ insertion and extraction at high voltages; this is thought to be due to poor Mg²⁺ diffusion kinetics within the oxide structural framework. Herein, the authors provide conclusive evidence of electrochemical insertion of Mg²⁺ into the tetragonal tungsten bronze V₄Nb₁₈O₅₅, with a maximum reversible electrochemical capacity of 75 mA h g^-1, which corresponds to a magnesiated composition of Mg₄V₄Nb₁₈O₅₅. Experimental electrochemical magnesiation/demagnesiation revealed a large voltage hysteresis with charge/discharge (1.12 V vs Mg/Mg²⁺); when magnesiation is limited to a composition of Mg₂V₄Nb₁₈O₅₅, this hysteresis can be reduced to only 0.5 V. Hybrid-exchange density functional theory (DFT) calculations suggest that a limited number of Mg sites are accessible via low-energy diffusion pathways, but that larger kinetic barriers need to be overcome to access the entire structure. The reversible Mg²⁺ intercalation involved concurrent V and Nb redox activity and changes in crystal structure, as confirmed by an array of complementary methods, including powder X-ray diffraction, X-ray absorption spectroscopy, and energy-dispersive X-ray spectroscopy. Consequently, it can be concluded that the tetragonal tungsten bronzes show promise as intercalation electrode materials for Mg batteries.

Bifunctionally active nanosized spinel cobalt nickel sulfides for sustainable secondary zinc–air batteries: examining the effects of compositional tuning on OER and ORR activity

Nanosized cobalt nickel sulfides were prepared via a continuous hydrothermal method and evaluated as electrocatalysts, with the catalytic activity being linked to the cationic composition.

Inorganic nanoparticle synthesis in flow reactors – applications and future directions

The use of flow technologies for obtaining nanoparticles can play an important role in the development of ecological and sustainable processes for obtaining inorganic nanomaterials, and the continuous methods are part of the Flow Chemistry trend.

Tailoring the electrochemical activity of magnesium chromium oxide towards Mg batteries through control of size and crystal structure

Chromium oxides with the spinel structure have been predicted to be promising high voltage cathode materials in magnesium batteries. Perennial challenges involving the mobility of Mg2+ and reaction kinetics can be circumvented by nano-sizing the materials in order to reduce diffusion distances, and by using elevated temperatures to overcome activation energy barriers. Herein, ordered 7 nm crystals of spinel-type MgCr2O4 were synthesized by a conventional batch hydrothermal method. In comparison, the relatively underexplored Continuous Hydrothermal Flow Synthesis (CHFS) method was used to make highly defective sub-5 nm MgCr2O4 crystals. When these materials were made into electrodes, they were shown to possess markedly different electrochemical behavior in a Mg2+ ionic liquid electrolyte, at moderate temperature (110 °C). The anodic activity of the ordered nanocrystals was attributed to surface reactions, most likely involving the electrolyte. In contrast, evidence was gathered regarding the reversible bulk deintercalation of Mg2+ from the nanocrystals made by CHFS. This work highlights the impact on electrochemical behavior of a precise control of size and crystal structure of MgCr2O4. It advances the understanding and design of new cathode materials for Mg-based batteries.

Chemistry in supercritical fluids for the synthesis of metal nanomaterials

The supercritical flow synthesis of metal nanomaterials is sustainable and scalable for the efficient production of materials.

Mechanistic insights of Li+ diffusion within doped LiFePO4 from Muon Spectroscopy

The Li⁺ ion diffusion characteristics of V- and Nb-doped LiFePO₄ were examined with respect to undoped LiFePO₄ using muon spectroscopy (µSR) as a local probe. As little difference in diffusion coefficient between the pure and doped samples was observed, offering D_Li values in the range 1.8–2.3 × 10⁻¹⁰ cm² s⁻¹, this implied the improvement in electrochemical performance observed within doped LiFePO₄ was not a result of increased local Li⁺ diffusion. This unexpected observation was made possible with the µSR technique, which can measure Li⁺ self-diffusion within LiFePO₄, and therefore negated the effect of the LiFePO₄ two-phase delithiation mechanism, which has previously prevented accurate Li⁺ diffusion comparison between the doped and undoped materials. Therefore, the authors suggest that µSR is an excellent technique for analysing materials on a local scale to elucidate the effects of dopants on solid-state diffusion behaviour.

Continuous Hydrothermal Synthesis of Inorganic Nanoparticles: Applications and Future Directions

Nanomaterials are at the leading edge of the emerging field of nanotechnology. Their unique and tunable size-dependent properties (in the range 1-100 nm) make these materials indispensable in many modern technological applications. In this Review, we summarize the state-of-art in the manufacture and applications of inorganic nanoparticles made using continuous hydrothermal flow synthesis (CHFS) processes. First, we introduce ideal requirements of any flow process for nanoceramics production, outline different approaches to CHFS, and introduce the pertinent properties of supercritical water and issues around mixing in flow, to generate nanoparticles. This Review then gives comprehensive coverage of the current application space for CHFS-made nanomaterials including optical, healthcare, electronics (including sensors, information, and communication technologies), catalysis, devices (including energy harvesting/conversion/fuels), and energy storage applications. Thereafter, topics of precursor chemistry and products, as well as materials or structures, are discussed (surface-functionalized hybrids, nanocomposites, nanograined coatings and monoliths, and metal-organic frameworks). Later, this Review focuses on some of the key apparatus innovations in the field, such as in situ flow/rapid heating systems (to investigate kinetics and mechanisms), approaches to high throughput flow syntheses (for nanomaterials discovery), as well as recent developments in scale-up of hydrothermal flow processes. Finally, this Review covers environmental considerations, future directions and capabilities, along with the conclusions and outlook.

Nano-sized Mo- and Nb-doped TiO2 as anode materials for high energy and high power hybrid Li-ion capacitors

Nano-sized Mo-doped titania (Mo_0.1Ti_0.9O₂) and Nb-doped titania (Nb_0.25Ti_0.75O₂) were directly synthesized via a continuous hydrothermal flow synthesis process. Materials characterization was conducted using physical techniques such as transmission electron microscopy, powder x-ray diffraction, x-ray photoelectron spectroscopy, Brunauer-Emmett-Teller specific surface area measurements and energy dispersive x-ray spectroscopy. Hybrid Li-ion supercapacitors were made with either a Mo-doped or Nb-doped TiO₂ negative electrode material and an activated carbon (AC) positive electrode. Cells were evaluated using electrochemical testing (cyclic voltammetry, constant charge discharge cycling). The hybrid Li-ion capacitors showed good energy densities at moderate power densities. When cycled in the potential window 0.5-3.0 V, the Mo_0.1Ti_0.9O₂/AC hybrid supercapacitor showed the highest energy densities of 51 Wh kg^-1 at a power of 180 W kg^-1 with energy densities rapidly declining with increasing applied specific current. In comparison, the Nb_0.25Ti_0.75O₂/AC hybrid supercapacitor maintained its energy density of 45 Wh kg^-1 at 180 W kg^-1 better, showing 36 Wh g^-1 at 3200 W kg^-1, which is a very promising mix of high energy and power densities. Reducing the voltage window to the range 1.0-3.0 V led to an increase in power density, with the Mo_0.1Ti_0.9O₂/AC hybrid supercapacitor giving energy densities of 12 Wh kg^-1 and 2.5 Wh kg^-1 at power densities of 6700 W kg^-1 and 14 000 W kg^-1, respectively.

Towards High Capacity Li-ion Batteries Based on Silicon-Graphene Composite Anodes and Sub-micron V-doped LiFePO4 Cathodes

Lithium iron phosphate, LiFePO₄ (LFP) has demonstrated promising performance as a cathode material in lithium ion batteries (LIBs), by overcoming the rate performance issues from limited electronic conductivity. Nano-sized vanadium-doped LFP (V-LFP) was synthesized using a continuous hydrothermal process using supercritical water as a reagent. The atomic % of dopant determined the particle shape. 5 at. % gave mixed plate and rod-like morphology, showing optimal electrochemical performance and good rate properties vs. Li. Specific capacities of >160 mAh g⁻¹ were achieved. In order to increase the capacity of a full cell, V-LFP was cycled against an inexpensive micron-sized metallurgical grade Si-containing anode. This electrode was capable of reversible capacities of approximately 2000 mAh g⁻¹ for over ¹50 cycles vs. Li, with improved performance resulting from the incorporation of few layer graphene (FLG) to enhance conductivity, tensile behaviour and thus, the composite stability. The cathode material synthesis and electrode formulation are scalable, inexpensive and are suitable for the fabrication of larger format cells suited to grid and transport applications.

Mapping Structure-Composition-Property Relationships in V- and Fe-Doped LiMnPO4 Cathodes for Lithium-Ion Batteries

A series of LiMn_1-x-yFe_xV_yPO₄ (LMFVP) nanomaterials have been synthesized using a pilot-scale continuous hydrothermal synthesis process (CHFS) and evaluated as high voltage cathodes in Li-ion batteries at a production rate of 0.25 kg h^-1. The rapid synthesis and screening approach has allowed the specific capacity of the high Mn content olivines to be optimized, particularly at high discharge rates. Consistent and gradual changes in the structure and performance are observed across the compositional region under investigation; the doping of Fe at 20 at% (with respect to Mn) into lithium manganese phosphate, rather than V or indeed codoping of Fe and V, gives the best balance of high capacity and high rate performance.

High-Throughput Synthesis, Screening, and Scale-Up of Optimized Conducting Indium Tin Oxides

A high-throughput optimization and subsequent scale-up methodology has been used for the synthesis of conductive tin-doped indium oxide (known as ITO) nanoparticles. ITO nanoparticles with up to 12 at % Sn were synthesized using a laboratory scale (15 g/hour by dry mass) continuous hydrothermal synthesis process, and the as-synthesized powders were characterized by powder X-ray diffraction, transmission electron microscopy, energy-dispersive X-ray analysis, and X-ray photoelectron spectroscopy. Under standard synthetic conditions, either the cubic In2O3 phase, or a mixture of InO(OH) and In2O3 phases were observed in the as-synthesized materials. These materials were pressed into compacts and heat-treated in an inert atmosphere, and their electrical resistivities were then measured using the Van der Pauw method. Sn doping yielded resistivities of ∼ 10(-2) Ω cm for most samples with the lowest resistivity of 6.0 × 10(-3) Ω cm (exceptionally conductive for such pressed nanopowders) at a Sn concentration of 10 at %. Thereafter, the optimized lab-scale composition was scaled-up using a pilot-scale continuous hydrothermal synthesis process (at a rate of 100 g/hour by dry mass), and a comparable resistivity of 9.4 × 10(-3) Ω cm was obtained. The use of the synthesized TCO nanomaterials for thin film fabrication was finally demonstrated by deposition of a transparent, conductive film using a simple spin-coating process.

Towards scalable and controlled synthesis of metal–organic framework materials using continuous flow reactors

Continuous flow synthesis offers potential for large-scale production of metal–organic frameworks with control of composition and microstructure for practical applications.

Direct and continuous synthesis of VO2 nanoparticles

Monoclinic VO2 nanoparticles are of interest due to the material's thermochromic properties, however, direct synthesis routes to VO2 nanoparticles are often inaccessible due to the high synthesis temperatures or long reaction times required. Herein, we present a two-step synthesis route for the preparation of monoclinic VO2 nanoparticles using Continuous Hydrothermal Flow Synthesis (CHFS) followed by a short post heat treatment step. A range of particle sizes, dependent on synthesis conditions, were produced from 50 to 200 nm by varying reaction temperatures and the residence times in the process. The nanoparticles were characterised by powder X-ray diffraction, Raman and UV/Vis spectroscopy, transmission electron microscopy (TEM), scanning electron microscopy (SEM) and differential scanning calorimetry (DSC). The nanoparticles were highly crystalline with rod and sphere-like morphologies present in TEM micrographs, with the size of both the rod and spherical particles being highly dependent on both reaction temperature and residence time. SEM micrographs showed the surface of the powders produced from the CHFS process to be highly uniform. The samples were given a short post synthesis heat treatment to ensure that they were phase pure monoclinic VO2, which led to them exhibiting a large and reversible switch in optical properties (at near-IR wavelengths), which suggests that if such materials can be incorporated into coatings or in composites, they could be used for fenestration in architectural applications.

Functionalised gold and titania nanoparticles and surfaces for use as antimicrobial coatings

We report the preparation, characterisation and antimicrobial functional testing of various titanium dioxide and gold modified titanium dioxide nanoparticles embedded into a polysiloxane polymer by a swell dip-coating procedure. We show that the surfaces are effective in killing both Gram-positive (Staphylococcus aureus) and Gram-negative (Escherichia coli) bacteria under different lighting conditions. The presence of the nanoparticles was of critical importance in improving the functional properties of the surface. These materials have the potential to reduce hospital-acquired infection, by killing bacteria on the polymer surface.

Structure-property-composition relationships in doped zinc oxides: enhanced photocatalytic activity with rare earth dopants

In this paper, we demonstrate the use of continuous hydrothermal flow synthesis (CHFS) technology to rapidly produce a library of 56 crystalline (doped) zinc oxide nanopowders and two undoped samples, each with different particle properties. Each sample was produced in series from the mixing of an aqueous stream of basic zinc nitrate (and dopant ion or modifier) solution with a flow of superheated water (at 450 °C and 24.1 MPa), whereupon a crystalline nanoparticle slurry was rapidly formed. Each composition was collected in series, cleaned, freeze-dried, and then characterized using analytical methods, including powder X-ray diffraction, transmission electron microscopy, Brunauer-Emmett-Teller surface area measurement, X-ray photoelectron spectroscopy, and UV-vis spectrophotometry. Photocatalytic activity of the samples toward the decolorization of methylene blue dye was assessed, and the results revealed that transition metal dopants tended to reduce the photoactivity while rare earth ions, in general, increased the photocatalytic activity. In general, low dopant concentrations were more beneficial to having greater photodecolorization in all cases.