Continuous Hydrothermal Synthesis of Nanomaterials: From Laboratory to Pilot Plant
Lead Research Organisation:
University of Leeds
Department Name: Inst of Particle Science & Engineering
Abstract
Summary: A novel laboratory scale continuous hydrothermal flow synthesis (CHFS) system has been developed for the controlled synthesis of inorganic nano-materials (particles <100nm) with potential commercial applications from sunscreens and battery materials to fuel cell components and photocatalysts. The CHFS system has many advantages; it is a green technology (using supercritical water as the reagent), which utilises inexpensive precursors (metal nitrate salts) and can controllably produce high quality, technologically important functional nano-materials in an efficient single step (or fewer steps than conventionally). This project seeks to move the existing laboratory scale CHFS system (developed over the past few years at QMUL) towards a x10 pilot scale-up (nano-powder production of up to 500g per 12h depending on variables). The proposed research will initially compare the ability to control particle characteristics of the CHFS system at the laboratory scale over a large range of process variables (flow rates, temperatures, pressures, etc), building full operational envelopes that will describe reactor variables versus particle properties for each material. In particular, we will utilise on-line measurement of dynamic laser light scattering particle sizing, and at-line analytical methods. This data will help develop univariate and multivariate understanding of the temporal operational spaces and interactions between process variables and product quality. On-line sensing and chemometrics incorporated with combined computational fluid dynamics modelling of hydrodynamics/mixing and population balance modelling of particle size evolution via nano-precipitation will be used to study alternative nozzles designs and other potential bottleneck factors. This will lead to a generic strategy for scaling up and controlled manufacture of nanomaterials with consistent, reproducible and predictable quality. The scale up quantities of nano-powders from the pilot plant will allow industrial partners to perform prototyping or comprehensive commercial evaluation of nano-powders in a range of applications which they have hitherto not been able to conduct due to lack of sufficient high quality material. Importantly, the know-how acquired on the project and the proposed feasibility studies will reduce the risk and commercial barriers for industry that might consider building a larger industrial scale CHFS plant in the future.
Organisations
- University of Leeds (Lead Research Organisation)
- KTN for Resource Efficiency (Project Partner)
- Sun Chemical (United Kingdom) (Project Partner)
- Nanoforce Technology (United Kingdom) (Project Partner)
- Corin (United Kingdom) (Project Partner)
- AMR Ltd (Project Partner)
- Spectris (United Kingdom) (Project Partner)
- Johnson Matthey (United Kingdom) (Project Partner)
Publications
Boonkhao B
(2010)
Making use of process tomography data for multivariate statistical process control
in AIChE Journal
Chen M
(2011)
Modelling and simulation of continuous hydrothermal flow synthesis process for nano-materials manufacture
in The Journal of Supercritical Fluids
Chen M
(2012)
Population Balance Modelling and Experimental Study for Synthesis of TiO2 Nanoparticles using Continuous Hydrothermal Process
in IFAC Proceedings Volumes
Liu W
(2016)
Continuous reactive crystallization of pharmaceuticals using impinging jet mixers
in AIChE Journal
Ma C
(2014)
Modelling and simulation of counter-current and confined jet reactors for hydrothermal synthesis of nano-materials
in Chemical Engineering Science
Ma C
(2015)
Simulation for scale-up of a confined jet mixer for continuous hydrothermal flow synthesis of nanomaterials
in The Journal of Supercritical Fluids
Ma C
(2011)
Numerical modelling of hydrothermal fluid flow and heat transfer in a tubular heat exchanger under near critical conditions
in The Journal of Supercritical Fluids
Tighe C
(2012)
Investigation of counter-current mixing in a continuous hydrothermal flow reactor
in The Journal of Supercritical Fluids
Wang XZ
(2014)
Principal component and causal analysis of structural and acute in vitro toxicity data for nanoparticles.
in Nanotoxicology
Description | - Modelling techniques developed are used in scale-up of the process - The novel process was scale-up 25 times, a pilot plan was built |
Exploitation Route | - stimulate new research - built commercial process for production of new nanomaterials |
Sectors | Agriculture Food and Drink Chemicals Electronics Energy Environment Healthcare Manufacturing including Industrial Biotechology Pharmaceuticals and Medical Biotechnology |