Issue 7, 2024

Scaling-up continuous production of mesoporous silica particles at kg scale: design & operational strategies

Abstract

This paper demonstrates a continuous flow pilot-scale production of highly porous mesoporous silica particles (MSPs) via a soft template based technique. The study presents pilot scale reactor design, fabrication and production of mesoporous silica particles with a 1 kg per day production rate. The extent of mixing and overall performance of the system were evaluated by conducting a hydrodynamic study, including the estimation of the heat transfer coefficient and dispersion number. Nanoparticle synthesis in a clogging-free manner is the key challenge in moving towards large scale production and commercial applications. This article presents a comprehensive study on the effect of key parameters for successful scaling up of the process. We have also addressed challenges faced and how these are overcome by troubleshooting the process. Different strategies were used to prevent the clogging of the reactor, which involved reactant dilution, periodic pulsation and slug flow (two phase flow). Among them, slug flow allows us to operate the reactor continuously for several hours without clogging and wall-deposition problems. It helped produce morphologically well-defined and near-monodisperse particles. With this process, the production is validated at a scale of 85 times compared to that of a laboratory system (from 22 mL to >1.5 L), enabling a production rate of 20–50 g h−1.

Graphical abstract: Scaling-up continuous production of mesoporous silica particles at kg scale: design & operational strategies

Supplementary files

Article information

Article type
Paper
Submitted
25 Des 2023
Accepted
15 Mac 2024
First published
15 Mac 2024

React. Chem. Eng., 2024,9, 1914-1923

Scaling-up continuous production of mesoporous silica particles at kg scale: design & operational strategies

R. B. Jundale, J. R. Sonawane, A. V. Palghadmal, H. K. Jaiswal, H. S. Deore and A. A. Kulkarni, React. Chem. Eng., 2024, 9, 1914 DOI: 10.1039/D3RE00707C

To request permission to reproduce material from this article, please go to the Copyright Clearance Center request page.

If you are an author contributing to an RSC publication, you do not need to request permission provided correct acknowledgement is given.

If you are the author of this article, you do not need to request permission to reproduce figures and diagrams provided correct acknowledgement is given. If you want to reproduce the whole article in a third-party publication (excluding your thesis/dissertation for which permission is not required) please go to the Copyright Clearance Center request page.

Read more about how to correctly acknowledge RSC content.

Social activity

Spotlight

Advertisements