01851nas a2200157 4500008004100000022001400041245008800055210006900143260000900212300001600221490000700237520129300244100002501537700002301562856010801585 2023 eng d a0888-588500aEffect of microwave heating on the residence time distribution in a tubular reactor0 aEffect of microwave heating on the residence time distribution i cAUG  a19381-193890 v623 a

Microwave(MW) heating has been revolutionary in various applications,including chemical synthesis. A nonconventional heating approach reducesthe reaction time significantly. For a continuous flow tubular reactorunder microwaves, the temperature would change from the inlet to theoutlet depending on the dielectric constant of the reaction mass,which would further change the physical properties, viz., the densityand viscosity of the material. Such changes in the physical propertieswould lead to nonideal flows and would affect the conversion as wellas selectivity for reactions. In order to understand the extent ofsuch a nonideality, here for the first time we have done systematicstudies of the residence time distribution in a helical coil reactor.The axial dispersion model has been modified to take into accountthe temperature-dependent physical properties of the fluid. The empiricalcorrelation for the dispersion number is obtained over the range of450 & LE; P (W) & LE; 1200 and 60 & LE; T (& DEG;C) & LE; 150. This study will help model thereaction kinetics as well as reactor design under microwave specificallyfor heat sensitive reactions where variations in the overall residencetime would affect the yield and selectivity of the end product.

1 aSonawane, Jayesh, R.1 aKulkarni, Amol, A. uhttps://library.ncl.res.in/content/effect-microwave-heating-residence-time-distribution-tubular-reactor01882nas a2200169 4500008004100000022001400041245010900055210006900164260000900233300001600242490000700258520125100265100002501516700001801541700002301559856013001582 2023 eng d a0888-588500aUnderstanding the nucleation and growth kinetics of the microwave-assisted synthesis of silver nanowires0 aUnderstanding the nucleation and growth kinetics of the microwav cSEP  a14199-142110 v623 a

Here, we present a detailed study of understanding the nucleation and growth kinetics of silver nanowire synthesis under microwave irradiation. The approach includes studying the effect of various parameters (viz., microwave power, reaction temperature, reaction time, substrate concentration, etc.) on the rate of nucleation and growth, as well as on the yield and morphology of silver nanowires. It is found that microwave power is the most important factor in leading to almost complete conversion of the substrate along with high aspect ratio nanowires in a short reaction time. Based on the observations, here, we have proposed a three-step growth kinetics mechanism for the synthesis of silver nanowires under the influence of microwaves. The approach comprises the autocatalytic growth of stable multiple twin particles after the nucleation process and their unidirectional growth to form nanowires. The FW autocatalytic model and the JMAK Avrami model were used to validate the proposed mechanism of AgNW formation based on our experimental results. The model predictions match very well with the conversion and yield of AgNWs. At the optimized conditions, wires with a 42 nm diameter and 94% yield were achieved within 4 min.

1 aSonawane, Jayesh, R.1 aPatil, Suneha1 aKulkarni, Amol, A. uhttps://library.ncl.res.in/content/understanding-nucleation-and-growth-kinetics-microwave-assisted-synthesis-silver-nanowires02470nas a2200205 4500008004100000022001400041245013200055210006900187260000800256300001100264490000800275520172700283653002502010653001402035653001902049653002102068100002502089700002302114856012702137 2024 eng d a1385-894700aModel predicted optimization of experimental set-up and process conditions for microwave-assisted synthesis of silver nanowires0 aModel predicted optimization of experimental setup and process c cOCT a1554830 v4983 a

This work presents simulations led optimization of choice of a reactor for an experimental set-up for the continuous production of silver nanowires with certain constraints in terms of yield, reaction time, and dimensions of nanowires. The choice of reactors based on the simulations of reaction kinetics for nucleation and growth phases of driving the optimization of an experimental set-up and subsequent optimization of process conditions to maximize the yield of nanowires of desired dimensions. The optimized reactor configuration is dictated by the reaction kinetics and using a microwave in continuous mode becomes unavoidable. This makes the approach highly reproducible as well as scalable. The integration of conventional and microwave heating is simulated and subsequently optimized experimentally to attain a significant increase in nanowire yield under steady-state conditions with less than 15 min of residence time. The precise control over the rate in different reactor configurations governing nucleation, accelerated growth followed by slow growth to complete the conversion of precursor enables higher selectivity of nanowires with controllable dimensions resulting in 100 gm production per day using simple set-up. We systematically examined key reaction parameters, including the concentration of metal ions, residence time, and different reactor configurations. Our approach successfully yielded AgNWs with 40-60 nm diameter and 15 mu m length. The cost associated with this process for synthesizing AgNWs is less than 10\$ per gram. This study highlights the potential of continuous, high-throughput processes for controlling nanowire size and yield through advanced reactor engineering.

10aContinuous synthesis10aMicrowave10aReactor design10aSilver Nanowires1 aSonawane, Jayesh, R.1 aKulkarni, Amol, A. uhttps://library.ncl.res.in/content/model-predicted-optimization-experimental-set-and-process-conditions-microwave-assisted02155nas a2200205 4500008004100000022001400041245011300055210006900168260000900237300001400246490000600260520141100266100002601677700002501703700002501728700002701753700002101780700002301801856012501824 2024 eng d a2058-988300aScaling-up continuous production of mesoporous silica particles at kg scale: design & operational strategies0 aScalingup continuous production of mesoporous silica particles a cJUN  a1914-19230 v93 a

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).

1 aJundale, Rajashri, B.1 aSonawane, Jayesh, R.1 aPalghadmal, Anil, V.1 aJaiswal, Hemant, Kumar1 aDeore, Hital, S.1 aKulkarni, Amol, A. uhttps://library.ncl.res.in/content/scaling-continuous-production-mesoporous-silica-particles-kg-scale-design-operational02599nas a2200169 4500008004100000022001400041245011000055210006900165260000800234300001200242490000700254520197700261100002502238700002202263700002302285856012102308 2025 eng d a2051-634700aContinuous flow synthesis of metal nanowires: protocols, engineering aspects of scale-up and applications0 aContinuous flow synthesis of metal nanowires protocols engineeri cJAN a364-4000 v123 a

This review comprehensively covers the translation from batch to continuous flow synthesis of metal nanowires (i.e., silver, copper, gold, and platinum nanowires) and their diverse applications across various sectors. Metal nanowires have attracted significant attention owing to their versatility and feasibility for large-scale synthesis. The efficacy of flow chemistry in nanomaterial synthesis has been extensively demonstrated over the past few decades. Continuous flow synthesis offers scalability, high throughput screening, and robust and reproducible synthesis procedures, making it a promising technology. Silver nanowires, widely used in flexible electronics, transparent conductive films, and sensors, have benefited from advancements in continuous flow synthesis aimed at achieving high aspect ratios and uniform diameters, though challenges in preventing agglomeration during large-scale production remain. Copper nanowires, considered as a cost-effective alternative to silver nanowires for conductive materials, have benefited from continuous flow synthesis methods that minimize oxidation and enhance stability, yet scaling up these processes requires precise control of reducing environments and copper ion concentration. A critical evaluation of various metal nanowire ink formulations is conducted, aiming to identify formulations that exhibit superior properties with lower metal solid content. This study delves into the intricacies of continuous flow synthesis methods for metal nanowires, emphasizing the exploration of engineering considerations essential for the design of continuous flow reactors. Furthermore, challenges associated with large-scale synthesis are addressed, highlighting the process-related issues. This review comprehensively covers the translation from batch to continuous flow synthesis of metal nanowires (i.e., silver, copper, gold, and platinum nanowires) and their diverse applications across various sectors.

1 aSonawane, Jayesh, R.1 aJundale, Rajashri1 aKulkarni, Amol, A. uhttps://library.ncl.res.in/content/continuous-flow-synthesis-metal-nanowires-protocols-engineering-aspects-scale-and