Design, Fundamental Principles of Fabrication and Applications of Microreactors

Opportunities and Challenges in the Synthesis of Noble Metal Nanoparticles via the Chemical Route in Microreactor Systems

The process of noble metal nanoparticle synthesis is complex and consists of at least two steps: slow nucleation and fast autocatalytic growth. The kinetics of these two processes depends on the reductant "power" and the addition of stabilizers, as well as other factors (e.g., temperature, pH, ionic strength). Knowing these parameters, it is possible to synthesize materials with appropriate physicochemical properties, which can be simply adjusted by the type of the used metal, particle morphology and surface property. This, in turn, affects the possibility of their applications in various areas of life, including medicine, catalysis, engineering, fuel cells, etc. However, in some cases, the standard route, i.e., the chemical reduction of a metal precursor carried out in the batch reactor, is not sufficient due to problems with temperature control, properties of reagents, unstable or dangerous intermediates and products, etc. Therefore, in this review, we focused on an alternative approach to their chemical synthesis provided by microreactor systems. The use of microreactors for the synthesis of noble metal nanomaterials (e.g., Ag, Au, Pt, Pd), obtained by chemical reduction, is analyzed, taking into account investigations carried out in recent years. A particular emphasis is placed on the processes in which the use of microreactors removed the limitations associated with synthesis in a batch reactor. Moreover, the opportunities and challenges related to the synthesis of noble nanomaterials in the microreactor system are underlined. This review discusses the advantages as well as the problems of nanoparticle synthesis in microreactors.

Review on Microreactors for Photo-Electrocatalysis Artificial Photosynthesis Regeneration of Coenzymes

In recent years, with the outbreak of the global energy crisis, renewable solar energy has become a focal point of research. However, the utilization efficiency of natural photosynthesis (NPS) is only about 1%. Inspired by NPS, artificial photosynthesis (APS) was developed and utilized in applications such as the regeneration of coenzymes. APS for coenzyme regeneration can overcome the problem of high energy consumption in comparison to electrocatalytic methods. Microreactors represent a promising technology. Compared with the conventional system, it has the advantages of a large specific surface area, the fast diffusion of small molecules, and high efficiency. Introducing microreactors can lead to more efficient, economical, and environmentally friendly coenzyme regeneration in artificial photosynthesis. This review begins with a brief introduction of APS and microreactors, and then summarizes research on traditional electrocatalytic coenzyme regeneration, as well as photocatalytic and photo-electrocatalysis coenzyme regeneration by APS, all based on microreactors, and compares them with the corresponding conventional system. Finally, it looks forward to the promising prospects of this technology.

Factors affecting the preparation of nanocrystals: characterization, surface modifications and toxicity aspects

INTRODUCTION

The fabrication of well-defined nanocrystals in size and form is the focus of much investigation. In this work, we have critically reviewed several recent instances from the literature that shows how the production procedure affects the physicochemical properties of the nanocrystals.

AREAS COVERED

Scopus, MedLine, PubMed, Web of Science, and Google Scholar were searched for peer-review articles published in the past few years using different key words. Authors chose relevant publications from their files for this review. This review focuses on the range of techniques available for producing nanocrystals. We draw attention to several recent instances demonstrating the impact of various process and formulation variables that affect the nanocrystals' physicochemical properties. Moreover, various developments in the characterization techniques explored for nanocrystals concerning their size, morphology, etc. have been discussed. Last but not least, recent applications, the effect of surface modifications, and the toxicological traits of nanocrystals have also been reviewed.

EXPERT OPINION

The selection of an appropriate production method for the formation of nanocrystals, together with a deep understanding of the relationship between the drug's physicochemical properties, unique features of the various formulation alternatives, and anticipated in-vivo performance, would significantly reduce the risk of failure during human clinical trials that are inadequate.

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.

Application of Spectroscopy Techniques for Monitoring (Bio)Catalytic Processes in Continuously Operated Microreactor Systems

In the last twenty years, the application of microreactors in chemical and biochemical industrial processes has increased significantly. The use of microreactor systems ensures efficient process intensification due to the excellent heat and mass transfer within the microchannels. Monitoring the concentrations in the microchannels is critical for a better understanding of the physical and chemical processes occurring in micromixers and microreactors. Therefore, there is a growing interest in performing in-line and on-line analyses of chemical and/or biochemical processes. This creates tremendous opportunities for the incorporation of spectroscopic detection techniques into production and processing lines in various industries. In this work, an overview of current applications of ultraviolet–visible, infrared, Raman spectroscopy, NMR, MALDI-TOF-MS, and ESI-MS for monitoring (bio)catalytic processes in continuously operated microreactor systems is presented. The manuscript includes a description of the advantages and disadvantages of the analytical methods listed, with particular emphasis on the chemometric methods used for spectroscopic data analysis.

Advanced oxidation processes in microreactors for water and wastewater treatment: Development, challenges, and opportunities

The miniaturization of reaction processes by microreactors offers many significant advantages over the use of larger, conventional reactors. Microreactors' interior structures exhibit comparatively higher surface area-to-volume ratios, which reduce reactant diffusion distances, enable faster and more efficient heat and mass transfer, and better control over process conditions. These advantages can be exploited to significantly enhance the performance of advanced oxidation processes (AOPs) commonly used for the removal of water pollutants. This comprehensive review of the rapidly emerging area of environmental microfluidics describes recent advances in the development and application of microreactors to AOPs for water and wastewater treatment. Consideration is given to the hydrodynamic properties, construction materials, fabrication techniques, designs, process features, and upscaling of microreactors used for AOPs. The use of microreactors for various AOP types, including photocatalytic, electrochemical, Fenton, ozonation, and plasma-phase processes, showcases how microfluidic technology enhances mass transfer, improves treatment efficiency, and decreases the consumption of energy and chemicals. Despite significant advancements of microreactor technology, organic pollutant degradation mechanisms that operate during microscale AOPs remain poorly understood. Moreover, limited throughput capacity of microreactor systems significantly restrains their industrial-scale applicability. Since large microreactor-inspired AOP systems are needed to meet the high-throughput requirements of the water treatment sector, scale-up strategies and recommendations are suggested as priority research opportunities. While microstructured reactor technology remains in an early stage of development, this work offers valuable insight for future research and development of AOPs in microreactors for environmental purposes.

Photocatalytic Oxidative Bromination of 2,6-Dichlorotoluene to 2,6-Dichlorobenzyl Bromide in a Microchannel Reactor

Photocatalytic oxidative benzylic bromination with hydrobromic acid (HBr) and hydrogen peroxide (H₂O₂) is a green process for the synthesis of benzyl bromides, but suffers from the risk of explosion when performing it in a batch reactor. This disadvantage could be overcome by running the reaction in a microchannel reactor. In this work, a green and safe process for the synthesis of 2,6-dichlorobenzyl bromide (DCBB) was developed by conducting selective benzylic bromination of 2,6-dichlorotoluene (DCT) with H₂O₂ as an oxidant and HBr as a bromine source in a microchannel reactor under light irradiation. The reaction parameters were optimized, and the conversion of DCT reached up to 98.1% with a DCBB yield of 91.4% under the optimal reaction conditions.

Hydrogenation of carbon dioxide (CO2) to fuels in microreactors: a review of set-ups and value-added chemicals production

A review of CO2 hydrogenation to fuels and value-added chemicals in microreactors.

Computational Study of the Dynamics of the Taylor Bubble

We perform high-resolution numerical simulations of three-dimensional dynamics of an elongated bubble in a microchannel at moderate Reynolds numbers up to 1800. For this purpose, we use the coupled Brinkman penalization and volume of fluid methods implemented in the open-source framework Basilisk. The new results are validated with available experimental data and compared with previous numerical and theoretical predictions. We extend existing results to regimes with significant inertia, which are characterized by intense deformations of the bubble, including cases with azimuthal symmetry breaking. Various dynamical features are analyzed in terms of their spatiotemporal characteristics, such as frequencies and wavelengths of the bubble surface undulations and vortical structures in the flow.

Metal-Free Fabrication of Fused Silica Extended Nanofluidic Channel to Remove Artifacts in Chemical Analysis

In microfluidics, especially in nanofluidics, nanochannels with functionalized surfaces have recently attracted attention for use as a new tool for the investigation of chemical reaction fields. Molecules handled in the reaction field can reach the single-molecule level due to the small size of the nanochannel. In such surroundings, contamination of the channel surface should be removed at the single-molecule level. In this study, it was assumed that metal materials could contaminate the nanochannels during the fabrication processes; therefore, we aimed to develop metal-free fabrication processes. Fused silica channels 1000 nm-deep were conventionally fabricated using a chromium mask. Instead of chromium, electron beam resists more than 1000 nm thick were used and the lithography conditions were optimized. From the results of optimization, channels with 1000 nm scale width and depth were fabricated on fused silica substrates without the use of a chromium mask. In nanofluidic experiments, an oxidation reaction was observed in a device fabricated by conventional fabrication processes using a chromium mask. It was found that Cr⁶⁺ remained on the channel surfaces and reacted with chemicals in the liquid phase in the extended nanochannels; this effect occurred at least to the micromolar level. In contrast, the device fabricated with metal-free processes was free of artifacts induced by the presence of chromium. The developed fabrication processes and results of this study will be a significant contribution to the fundamental technologies employed in the fields of microfluidics and nanofluidics.

Process Intensification Approach Using Microreactors for Synthesizing Nanomaterials-A Critical Review

Nanomaterials have found many applications due to their unique properties such as high surface-to-volume ratio, density, strength, and many more. This review focuses on the recent developments on the synthesis of nanomaterials using process intensification. The review covers the designing of microreactors, design principles, and fundamental mechanisms involved in process intensification using microreactors for synthesizing nanomaterials. The microfluidics technology operates in continuous mode as well as the segmented flow of gas–liquid combinations. Various examples from the literature are discussed in detail highlighting the advantages and disadvantages of microfluidics technology for nanomaterial synthesis.

Monolithically Integrated Diffused Silicon Two-Zone Heaters for Silicon-Pyrex Glass Microreactors for Production of Nanoparticles: Heat Exchange Aspects

We present the design, simulation, fabrication and characterization of monolithically integrated high resistivity p-type boron-diffused silicon two-zone heaters in a model high temperature microreactor intended for nanoparticle fabrication. We used a finite element method for simulations of the heaters’ operation and performance. Our experimental model reactor structure consisted of a silicon wafer anodically bonded to a Pyrex glass wafer with an isotropically etched serpentine microchannels network. We fabricated two separate spiral heaters with different temperatures, mutually thermally isolated by barrier apertures etched throughout the silicon wafer. The heaters were characterized by electric measurements and by infrared thermal vision. The obtained results show that our proposed procedure for the heater fabrication is robust, stable and controllable, with a decreased sensitivity to random variations of fabrication process parameters. Compared to metallic or polysilicon heaters typically integrated into microreactors, our approach offers improved control over heater characteristics through adjustment of the Boron doping level and profile. Our microreactor is intended to produce titanium dioxide nanoparticles, but it could be also used to fabricate nanoparticles in different materials as well, with various parameters and geometries. Our method can be generally applied to other high-temperature microsystems.