Shear-assisted liquid exfoliation is a primary candidate for producing defect-free two-dimensional (2D) materials. A range of approaches that delaminate nanosheets from layered precursors in solution have emerged in recent years. Diverse hydrodynamic conditions exist across these methods, and combined with low-throughput, high-cost characterization techniques, strongly contribute to the wide variability in performance and material quality. Nanosheet concentration and production rate are usually correlated against operating parameters unique to each production method, making it difficult to compare, optimize and predict scale-up performance. Here, we reveal the shear exfoliation mechanism from precursor to 2D material and extract the derived hydrodynamic parameters and scaling relationship that are key to nanomaterial output and common to all shear exfoliation processes. Our investigations use conditions created from two different hydrodynamic instabilities-Taylor vortices and interfacial waves-and combine materials characterization, fluid dynamics experiments and numerical simulations. Using graphene as the prototypical 2D material, we find that scaling of concentration of few-layer nanosheets depends on local strain rate distribution, relationship to the critical exfoliation criterion, and precursor residence time. We report a transmission-reflectance method to measure concentration profiles in real-time, using low-cost optoelectronics and without the need to remove the layered precursor material from the dispersion. We show that our high-throughput, in situ approach has broad uses by controlling the number of atomic layers on-the-fly, rapidly optimizing green solvent design to maximize yield, and viewing live production rates. Combining the findings on the hydrodynamics of exfoliation with this monitoring technique, we unlock targeted process intensification, quality control, batch traceability and individually customizable 2D materials on-demand.

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The development of adsorbents into structured and robust forms remains a challenge for emerging porous materials. In the context of porous boron nitride (BN), studies point to a tradeoff between...

In the past decade, porous boron nitride (BN) has proven promising as a novel class of inorganic materials in the field of separations and particularly adsorption. Owing to its high surface area and thermal stability, porous BN has been researched for CO2 capture and water cleaning, for instance. However, most research remains at laboratory scale due to a lack of understanding of the formation mechanism of porous BN, which is still largely a 'black box' and prevents scale-up. Partial reaction pathways have been unveiled, but they omit critical steps in the formation, including the porosity development, which is key to adsorption. To unlock the potential of porous BN at a larger scale, we have investigated its formation from the perspective of both chemical formation and porosity development. We have characterised reaction intermediates obtained at different temperatures with a range of analytical and spectroscopic tools. Using these analyses, we propose a mechanism that highlights the key stages of BN formation and its porosity, including the intermediates and gaseous species formed in the process. We identified that the formation of non-porous carbon nitride is crucial to form porous BN with release of porogens, such as HCN and CO2. This work paves the way for scaled-up processes to use porous BN to its full potential at industrial level for gas and liquid separations.