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Rapid mixing is a critical step in many nanoparticle syntheses that can impact the ability to scale production from bench to industrial levels. This study combines experimental and computational approaches to characterize mixing dynamics in crossflow jet mixing reactors (JMRs) with millimeter-scale internal dimensions. The Villermaux-Dushman reaction system is used to quantify experimental mixing times across different reactor sizes and flow rates. Complementary computational fluid dynamics (CFD) simulations assess changes in the state of the flow and estimate mixing times under varying operating conditions. Mixing times derived from CFD results agree well with the experimental results for mixing indices between 0.95 and 0.98. To demonstrate the impact of mixing on nanoparticle formation, we synthesize polybutylacrylate-b-polyacrylic acid (PBA-PAA) block co-polymer nanoparticles, confirming the existence of a critical flow rate beyond which particle size stabilizes. Additionally, we produce polylactic acid-co-glycolic acid (PLGA) nanoparticles incorporating a hydrophobic dye, achieving an average particle size below 300 nm at a throughput of ~1.3 kg/day. These results provide insights into optimizing JMRs for high-throughput, reproducible nanoparticle synthesis, bridging the gap between benchtop and industrial-scale production. 

This upload contains files supporting the paper;Experimental and computational investigation of mixing dynamics in millifluidic jet mixing reactors; Overview. Symmetric Paper Result workbook contains the computational results utilized for plots in the paper. Excel sheet tabs in the workbook have been organized based on Figure # in the submitted manuscript JMR-0.25-1.0mm and JMR-0.5-1.0mm contains the files for determining the computational mixing time calculations for each reactor. Software. COMSOL Multiphysics 

Superparamagnetic iron oxide nanoparticles (SPIONs) can align in polymer-stabilized aggregates, changing their properties. 

The formation of subcritical methanol clusters in the vapor phase is known to complicate the analysis of nucleation measurements. Here, we investigate how this process affects the onset of binary nucleation as dilute water–methanol mixtures in nitrogen carrier gas expand in a supersonic nozzle. These are the first reported data for water–methanol nucleation in an expansion device. We start by extending an older monomer–dimer–tetramer equilibrium model to include larger clusters, relying on Helmholtz free energy differences derived from Monte Carlo simulations. The model is validated against the pressure/temperature measurements of Laksmono et al. [Phys. Chem. Chem. Phys. 13, 5855 (2011)] for dilute methanol–nitrogen mixtures expanding in a supersonic flow prior to the appearance of liquid droplets. These data are well fit when the maximum cluster size imax is 6–12. The extended equilibrium model is then used to analyze the current data. On the addition of small amounts of water, heat release prior to particle formation is essentially unchanged from that for pure methanol, but liquid formation proceeds at much higher temperatures. Once water comprises more than ∼24 mol % of the condensable vapor, droplet formation begins at temperatures too high for heat release from subcritical cluster formation to perturb the flow. Comparing the experimental results to binary nucleation theory is challenged by the need to extrapolate data to the subcooled region and by the inapplicability of explicit cluster models that require a minimum of 12 molecules in the critical cluster. 

We generate water-rich aerosols containing 1-propanol and 1-pentanol in a supersonic nozzle to study the effects of these solutes on the freezing behavior of water. Condensation and freezing are characterized by two complementary techniques, pressure trace measurements and Fourier Transform Infrared spectroscopy. When 1-pentanol and 1-propanol are present, condensation occurs at higher temperatures because particle formation from the vapor phase is enhanced by the decrease in interfacial free energy of mixed aqueous-alcohol critical clusters relative to those of pure water. FTIR results suggest that when ∼6 nm radius droplets freeze, the tetrahedral structure of the ice is well preserved up to an overall alcohol mole fraction of 0.031 for 1-propanol and 0.043 for 1-pentanol. In this concentration range, the ice nucleation temperature decreases continuously with increasing 1-propanol concentration, whereas the onset of freezing is not significantly perturbed by 1-pentanol up to a mole fraction of 0.03. Furthermore, once freezing starts the ice nucleation rates in the aqueous-alcohol droplets are very close to those for pure water. In contrast, at the highest mole fractions of either alcohol it is not clear whether droplets freeze to form crystalline ice since the final state of the particles cannot be adequately characterized with the available experimental techniques.