Advances in scalable gas-phase manufacturing and processing of nanostructured solids: A review

Abstract

Although the gas-phase production of nanostructured solids has already been carried out in industry for decades, only in recent years has research interest in this topic begun to increase. Nevertheless, despite the remarkable scientific progress made recently, many long-established processes are still used in industry.Scientific advancements can potentially lead to the improvement of existing industrial processes, but also to the development of completely new routes. This paper aims to review state-of-the-art synthesis and processing technologies, as well as the recent developments academic research. Flame reactors that produce inorganic nanoparticles on industrial-and lab-scales are described, alongside a detailed overview of the different systems used for the production of carbon nanotubes and graphene. We discuss the problems of agglomeration and mixing of nanoparticles, which are strongly related to synthesis and processing. Finally, we focus on two promising processing techniques, namely nanoparticle fluidization and atomic layer deposition.

New development of atomic layer deposition: processes, methods and applications

“…Main ALD reactor types classified by their most important processing-related characteristics. (Adapted with permission from [165] Figure 7. Life cycle greenhouse gas emission and cumulative energy demand in an ALD process compared to other processes.…”

Developments and challenges in the manufacturing, characterization and scale-up of energetic nanomaterials – A review

“…Furthermore, functionalization of nanoparticles by applying a coating to improve their dispersion and wettability in a polymeric binder, to prevent coagulation or to modify their reactivity or ignitability could also enhance a more widespread application of energetic nanomaterials. A technique such as atomic layer deposition (ALD) combined with a fluidized bed reactor -which is well-suited for large scale operations -as a means to coat (nano)particles, has matured significantly over the past decade [65,66].…”

Experimental investigation on the microstructure of fluidized nanoparticle agglomerates by TEM image analysis

“…Gas fluidization is commonly used to disperse and process quantities of NPs because of its large gas‐solid contact area and excellent heat and mass transfer. [ 3,4 ] NPs fluidize as agglomerates, not individually due to strong interparticle forces. The fluidized nanoparticle agglomerates (FNPAs) have hierarchical structures and the structures of FNPAs are built up from the NPs by both aggregation and agglomeration mechanisms.…”