Insights in the Diffusion Controlled Interfacial Flow Synthesis of Au Nanostructures in a Microfluidic System.

Continuous segmented flow interfacial synthesis of Au nanostructures is demonstrated in a microchannel reactor. This study brings new insights into the growth of nanostructures at continuous interfaces. The size as well as the shape of the nanostructures showed significant dependence on the reactant concentrations, reaction time, temperature, and surface tension, which actually controlled the interfacial mass transfer. The microchannel reactor assisted in achieving a high interfacial area, as well as uniformity in mass transfer effects. Hexagonal nanostructures were seen to be formed in synthesis times as short as 10 min. The wettability of the channel showed significant effect on the particle size as well as the actual shape. The hydrophobic channel yielded hexagonal structures of relatively smaller size than the hydrophilic microchannel, which yielded sharp hexagonal bipyramidal particles (diagonal distance of 30 nm). The evolution of particle size and shape for the case of hydrophilic microchannel is also shown as a function of the residence time. The interfacial synthesis approach based on a stable segmented flow promoted an excellent control on the reaction extent, reduction in axial dispersion as well as the particle size distribution.

Synthesis, assembly and reaction of a nanocatalyst in microfluidic systems: a general platform.

We present a successive microfluidic approach to create and characterize hierarchical catalyst structures consisting of metal-decorated nanoparticles that are assembled into porous microparticles ("supraball" catalysts). First, using a silicon microreactor, platinum nanoparticles with a very narrow size distribution are grown and immobilized uniformly onto iron oxide/silica core-shell nanospheres. The Pt-decorated silica nanospheres are then assembled into uniform, spherical, micron-sized particles by using emulsion templates generated with a microfluidic drop generator. Finally, the assembled supraballs are loaded into a packed-bed microreactor for characterization of the catalytic reactivity. The prepared material showed excellent catalytic activity for the oxidation of aldehyde with only ~1 mg of material (containing ~50 µg of platinum nanoparticles). After the reactions, all the supraball catalysts are recovered by using the magnetic property of the underlying iron oxide/silica core-shell nanospheres.