Large Scale Nanomaterial Production Using Microfluidizer High Shear Processing
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Large Scale Nanomaterial Production Using Microfluidizer High Shear Processing Kenneth J. Chomistek and Thomai Panagiotou, Ph.D Microfluidics Corporation, 30 Ossipee Road Newton, MA 02464, U.S.A. ABSTRACT Microfluidics has developed scalable and low cost technologies, capable of producing nanomaterials with desirable properties for a wide variety of applications. Two main platforms are used for production of nanomaterials: (a) the “top down”, particle size reduction method, and (b) the “bottom up”, Microfluidics reaction Technology (MRT) for production of nanoparticles through multiphase chemical reactions and physical processes, such as crystallization. This technology received the Nano50 Award in 2007. Both technologies are continuous and can be used in line with upstream or downstream processes such as premixing, filtration, etc., and are consistent with process intensification principals. The produced materials can be in the form of nanoemulsions, liposomes, or suspensions. Highly crystalline nanoparticles of a desired polymorph, encapsulated or layered particles are possible. The industries served are pharmaceuticals and biotech, energy, specialty chemicals, cosmetics, and nutraceuticals. Microfluidics approach is based on an in-depth understanding of applications, unique design of high shear fluid processors, and development of processes tailored for each individual application. The heart of the technology is the interaction chamber which consists of “fixed geometry” microchannels. Flow through the chamber is characterized by high fluid velocities (up to 500 m/s), exposing the fluid to shear rates which are orders of magnitude higher than those of existing technologies. The unique “fixed geometry” feature combined with the high shear rates ensure that varied formulations (emulsions, liposomes and dispersions) achieve the smallest particle size and the narrowest particle size distribution when compared to other particle generation techniques. INTRODUCTION With the explosion of nanotechnology in recent years, there is a need to produce tailored high purity nanomaterials on a large scale, with a high level of repeatability and at low cost. However, current nanomaterials production takes place at a small scale, using insufficient mixing and techniques that cannot scale up or handle large solid content. As a result of the production methods used, product quality varies substantially, with low yields and therefore the price of the material remains high. To achieve the small particle size and the tailored properties, it is essential to precisely control the mechanisms responsible for formation and stabilization. For the process of crystallization; all particles should be formed under the same local shear levels, stoichiometric conditions, or degrees of supersaturation. Once the particles or nuclei are formed, the growth should be controlled and the particles stabilized at the desired size. Microfluidics has developed technologies for production of nanomaterials on a large scale. The technologies are for
