Dial-a-particle: model-driven self-optimised manufacturing platform of nanoparticles
Lead Research Organisation:
University of Cambridge
Department Name: Chemical Engineering and Biotechnology
Abstract
Their surface asymmetry, high surface-to-volume ratios and confinement quantum effects of nanoparticles result in unprecedented properties for applications in healthcare, diagnosis, energy storage, electronics, sensors, catalysis, etc. However, the full impact of these nanomaterials to overcome some of the most pressing global challenges, is hindered by the lack of a manufacturing technology capable of their production in a continuous and reproducible manner in large scale. A plethora of nanoparticle syntheses has been developed over the last decades, aiming for the control of the size, shape and composition of nanoparticles as property-determining parameters. Conventionally, nanoparticles are synthesised in poorly characterised batch reactors. Flow systems enable the continuous synthesis, but they are currently limited to rapid processes (ms to a few minutes) due to their inherent instability issues. This project will deliver a novel model-driven self-optimised manufacturing technology for on-demand size- and composition-customised nanoparticles. The dial-a-particle platform will integrate, for the first time, real-time characterisation and hydrodynamic understanding to enable the development of mathematical predictive algorithms. They will be the pillar for the autonomous identification of the most interesting manufacturing route. The distinguishing novelty features of this approach are i. On-demand synthesis with a wide range size (2-100 nm) and composition (core-shell, hollow, multicomponent), ii. Self-control to mitigate instability sources associated to multi-stage continuous processes (extending the current state-of-the-art from seconds to minutes/hours) and iii. Universality, thanks to the mechanistic knowledge underpinning the mathematical models.
Organisations
- University of Cambridge (Lead Research Organisation)
- Astrazeneca (Collaboration)
- University of Cambridge (Collaboration)
- King Juan Carlos University (Collaboration)
- University of Bern (Collaboration)
- Corning SAS (Project Partner)
- Ocean Optics (Project Partner)
- Johnson Matthey (United Kingdom) (Project Partner)
Publications
Casado C
(2024)
Predicting the size of silver nanoparticles synthesised in flow reactors: Coupling population balance models with fluid dynamic simulations
in Chemical Engineering Journal
El-Kadi J
(2024)
Continuous synthesis of ruthenium nanoparticles with tuneable sizes using ruthenium nitrosyl nitrate precursor
in Reaction Chemistry & Engineering
Gao Y
(2022)
Tailoring the size of silver nanoparticles by controlling mixing in microreactors
in Chemical Engineering Journal
Pinho B
(2022)
Importance of Monitoring the Synthesis of Light-Interacting Nanoparticles - A Review on In Situ, Ex Situ, and Online Time-Resolved Studies
in Advanced Optical Materials
Pinho B
(2023)
Enhancing mixing efficiency in curved channels: A 3D study of bi-phasic Dean-Taylor flow with high spatial and temporal resolution
in Chemical Engineering Journal
Zhang K
(2023)
The importance of transport phenomena on the flow synthesis of monodispersed sharp blue-emitting perovskite CsPbBr3 nanoplatelets
in Chemical Engineering Journal
| Description | In this project, we study the continuous synthesis of metal nanoparticles to enable their large-scale production for deployment in a number of applications from catalysis, bio-imaging, lightening, etc. The focus of this work was the development of automated platforms able to produced the desired materials with the desired physical and chemical properties (e.g. tunable sizes and narrow distributions) in a self-sufficient manner. In other words, the user would be able to select the desired size and the platform, based on a number of algorithms, will be able to adapt the conditions automatically to achieve it in a short period of time. In addition to this, we have demonstrated how fundamental mechanistic understanding of materials synthesis can be reveal using flow reactors which enable the fast mixing of precursors to achieve homogeneous reaction conditions. |
| Exploitation Route | Our work has revealed fundamental understanding on the formation of metal nanoparticles including the effect of mass transfer on the resulting size and distribution. These findings will have a key impact on guiding the design of flow reactors according to the kinetics of the desired materials. We have also developed new optical cells to enable the real-time characterisation of colloidal suspensions using UV-vis and photoluminence spectroscopy. This new capabilities have an impact in understanding the early-stage kinetics of the formation of nanomaterials. This project has demonstrated the potential of flow reactors not only as manufacturing tools but also as a way of revealing key mechanistic understanding of the synthesis of materials. We are further developing this expertise and capabilities with industry for the synthesis of polymers and drugs. |
| Sectors | Chemicals Energy Environment Healthcare Manufacturing including Industrial Biotechology |
| Description | We have used the outcomes of this project in a number of public engagement activities where we have showcased to the public the importance of size of the materials in their interaction with the light. For example, we have shown how the colour of gold nanoparticles change with size form red to purple when their size ranges from 2 to 5 nm. We have also done a similar demonstration to show the fluorescent properties of perovskite materials with different shapes under UV-vis light |
| First Year Of Impact | 2022 |
| Sector | Chemicals,Education,Energy,Environment,Healthcare,Manufacturing, including Industrial Biotechology |
| Impact Types | Cultural Societal |
| Description | International advisory board for the CSIC Institute for Materials in Seville (Spain) |
| Geographic Reach | Local/Municipal/Regional |
| Policy Influence Type | Participation in a guidance/advisory committee |
| Description | Policy briefing - Green Carbon for the Chemical Industry by Royal Society |
| Geographic Reach | National |
| Policy Influence Type | Participation in a guidance/advisory committee |
| Description | AstraZeneca (Sophie Jabon) |
| Organisation | AstraZeneca |
| Country | United Kingdom |
| Sector | Private |
| PI Contribution | PhD project starting on October 2025 |
| Collaborator Contribution | Funding, supervision and expertise on crystallisation |
| Impact | TBA |
| Start Year | 2023 |
| Description | Eva Hevia |
| Organisation | University of Bern |
| Country | Switzerland |
| Sector | Academic/University |
| PI Contribution | This is a collaboration project together. They are developing new chemistries using deep eutectic solvents which we are translating into continuous flow systems for their adaptation in industry. |
| Collaborator Contribution | They are exploring the use of deep eutectic solvents in organic reactions using air-sensitive catalysts. Two members of Prof Hevia's group have been visiting Cambridge for different periods of time including Florian Mulks and Andrew Platten |
| Impact | We have demonstrated for the first time the synthesis of organometallic reactions in flow at room temperature assisted by deep eutectic solvents in a stable and safe manner (Chem 8 (2022) 3382-3394, DOI: 10.1016/j.chempr.2022.11.004) |
| Start Year | 2019 |
| Description | Jeremy Baumberg |
| Organisation | University of Cambridge |
| Department | Cavendish Laboratory |
| Country | United Kingdom |
| Sector | Academic/University |
| PI Contribution | This project is enabling a collaboration to provide metal nanoparticles with tuneable sizes for the development of responsive functional polymers |
| Collaborator Contribution | They are opening up new applications for these nanoparticles |
| Impact | This is a multi-disciplinary collaboration between physics and engineering. |
| Start Year | 2017 |
| Description | Prof Akshay Rao (University of Cambridge, UK) |
| Organisation | University of Cambridge |
| Department | Department of Physics |
| Country | United Kingdom |
| Sector | Academic/University |
| PI Contribution | Potential Kinetic Study with detailed discussions to CPT company |
| Collaborator Contribution | Synthesis of AgSe QDs |
| Impact | TBA |
| Start Year | 2024 |
| Description | Prof Clare Grey (University of Cambridge, UK) |
| Organisation | University of Cambridge |
| Department | Department of Chemistry |
| Country | United Kingdom |
| Sector | Academic/University |
| PI Contribution | Synthesis of Perovksite quantum dots |
| Collaborator Contribution | Solid State NMR experiements (1D/2D) |
| Impact | TBA |
| Start Year | 2024 |
| Description | Prof Hugo Bronstein (University of Cambridge, UK) |
| Organisation | University of Cambridge |
| Department | Department of Physics |
| Country | United Kingdom |
| Sector | Academic/University |
| PI Contribution | We have performed ligand exchange studies on CdSe quantum dots |
| Collaborator Contribution | Organic synthesis of TADF ligand and photonic measurements |
| Impact | TBA |
| Start Year | 2024 |
| Description | Prof Hugo Bronstein (University of Cambridge, UK) |
| Organisation | University of Cambridge |
| Department | Department of Physics |
| Country | United Kingdom |
| Sector | Academic/University |
| PI Contribution | Kinetic Study of differing phosphine oxide ligands on the crystllisation of metal halide QDs |
| Collaborator Contribution | DFT simulation of inorganic complexes |
| Impact | TBA |
| Start Year | 2024 |
| Description | Prof Javier Marugan (URJC, Spain) |
| Organisation | King Juan Carlos University |
| Country | Spain |
| Sector | Academic/University |
| PI Contribution | Our group has hosted a post-doctoral researcher from Prof Marugán's group (Dr Cintia Casado) during 2 summers (2016 and 2020). We have provided training and development in the areas of reactor design and modelling. |
| Collaborator Contribution | Dr Casado's visits have had a profound impact on our expertise, leading to an onset of our interest in coupling fluid dynamic simulations and population balance to achieve predictive capabilities in the synthesis of metal nanoparticles in flow reactors. |
| Impact | This collaboration has resulted in a publication in the Chemical Engineering Journal (https://doi.org/10.1016/j.cej.2023.147684) where we brought together our complementary expertise in fluid dynamics and population balance disciplines. In addition, this collaboration has led to a Marie Curie Industrial Doctorate Training Account (REWATERGY) where we have trained 8 PhD students in the nexus of water-energy. Two of these students were graduated in Cambridge in collaborations with a wastewater company (Aqualia, Spain) and a materials atom layer deposition start-up (Delft IMP, The Netherlands). |
| Start Year | 2015 |
| Description | Prof Sam Stranks' group |
| Organisation | University of Cambridge |
| Department | Department of Chemical Engineering and Biotechnology |
| Country | United Kingdom |
| Sector | Academic/University |
| PI Contribution | Prof Sam Stranks is an expert on the developing and understanding of perovskite materials for photovoltaics and lightening applications. His group, as many others with roots in physics and chemistry, synthesis these materials using hot injection methods in flow. While this approach is perfectly fitted for the fast discovery of materials, the mass transfer (e.g. mixing) and heat transfer (e.g. temperature profiles) are difficult to control, in addition to the issues associated to scale-up. Our group has partner with them to develop flow reactors for the synthesis of these materials to understand the effects of mass and heat transfer. This collaboration is leading to new fundamental understanding on the mechanism of formation of materials by fast co-precipitation. In addition, we are also developing new sustainable routes to replace the toxic organic solvents (e.g. octene) normally used in these high-temperature synthesis with deep eutectic ones following the outcomes of a EPSRC project (EP/S021019/1). |
| Collaborator Contribution | As an expert on the development of perovskite materials, Prof Strank's lab is equipped with advanced characterisation techniques that are contributing to our new understanding of the mechanism of these materials in addition to their knowledge to interpret the results. |
| Impact | We have supervised 2 PhD students: - Kaiwen Wang - who graduated in 2023 and he is now working for Helios display technologies start-up in Oxford - Tariq Hussein - who has started with PhD in 2023 as part of the EPSRC NanoCDT (Cambridge) We have published a number of papers where we have brought together physics and material development and characterisation (Stranks) with reactor design, flow systems and fluid dynamics (Torrente) expertise. - Chemical Engineering Journal 451 (2023) 138752, DOI: 10.1016/j.cej.2022.138752 - where we demonstrate the importance of transport phenomena (e.g mixing) on the flow synthesis of monodispersed sharp blue-emitting perovskite CsPbBr3 nanoplatelets - Nature Photonics, (2014) 1-9, DOI: 10.1038/s41566-024-01398-y - where we contributed to the characterisation of the pervoskite nanoplatelet |
| Start Year | 2019 |
| Title | Enhancing Mixing Efficiency in Curved Channels: A 3D Study of Bi-Phasic Dean-Taylor Flow with High Spatial and Temporal Resolution |
| Description | Two-phase (Taylor flow) and curved reactors (Dean flow) are conventionally used to improve mixing in flow systems by reducing axial dispersion and narrowing residence time distributions. However, when the two flow regimes are superposed in bi-phasic flow in curved channels (Dean-Taylor flow), the result is poorly understood due to experimental and computational limitations, despite its widespread practical implementation. In this study, we introduce a novel high-efficient computational strategy to investigate Dean-Taylor flow providing highly detailed spatial and time-resolved data of the fluid dynamics of this flow regime. Here we share the fluent journals (code) to create the Dean-Taylor inside Ansys fluent. |
| Type Of Technology | Software |
| Year Produced | 2023 |
| Impact | Other researchers will be able to use our fluent journals to replicate Dean-Taylor flow using Ansys fluent. |
| URL | https://www.repository.cam.ac.uk/handle/1810/349466 |
| Description | Arkwright Scholars Visit |
| Form Of Engagement Activity | Participation in an open day or visit at my research institution |
| Part Of Official Scheme? | No |
| Geographic Reach | Local |
| Primary Audience | Schools |
| Results and Impact | Presentation on the catalysis and nanoparticles research of our lab group to Year 12 students on scholarships to study Engineering |
| Year(s) Of Engagement Activity | 2022,2023 |
| Description | Cambridge Festival - Art using Nanoparticles |
| Form Of Engagement Activity | Participation in an open day or visit at my research institution |
| Part Of Official Scheme? | No |
| Geographic Reach | Regional |
| Primary Audience | Public/other audiences |
| Results and Impact | Demonstration of art designs using nanoparticles |
| Year(s) Of Engagement Activity | 2021,2024 |
| Description | Outreach event at Christ's College, Cambridge |
| Form Of Engagement Activity | Participation in an open day or visit at my research institution |
| Part Of Official Scheme? | No |
| Geographic Reach | Local |
| Primary Audience | Schools |
| Results and Impact | Prepared an interactive presentation session for Y10-Y12 students giving them an introduction to quantum mechanics and its applications to quantum dots. |
| Year(s) Of Engagement Activity | 2022,2023,2024 |
| Description | Outreach event in Christ College, Cambridge |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | Local |
| Primary Audience | Schools |
| Results and Impact | Prepared an interactive presentation session for Y10-Y12 students giving them an introduction to quantum mechanics and its applications to quantum dots. |
| Year(s) Of Engagement Activity | 2024 |