Understanding and controlling precipitation reactions is a major challenge for industrial crystallization. Calcium carbonate is a widely studied system: more than 3000 papers have been devoted to the subject over the past 10 years. The first step of the precipitation of calcium carbonate, from relatively concentrated solutions (0.01 mol/L), involves the formation of an initial gel phase which later transforms into calcite, vaterite, or a mixture of both phases. Our work aimed at controlling this first step. Nanosized seeds (8 nm), formed in situ, were used in order to control the often chaotic nucleation step which normally leads to poor phase selection and broad particle size distributions. Seeding has often been used to avoid spontaneous nucleation in metastable solutions for growth mechanism investigations of single-crystal calcium carbonate. Here the ability of a seeding method to control the precipitation reaction evolution even in the case of high supersaturation is demonstrated. The seeds and the presence of a polymeric additive (poly(acrylic acid)) allow the control of the precipitated polymorph and the specific surface area, while maintaining a narrow particle size distribution in the submicron range. Direct characterization methods did not succeed in identifying these nanoseeds; indirect methods using solubility calculations are used to demonstrate their existence and quantify size and number density of the nanosized seeds.
The synthesis of powders with controlled shape and narrow particle size distributions is still a major challenge for many industries. A continuous Segmented Flow Tubular Reactor (SFTR) has been developed to overcome homogeneity and scale‐up problems encountered when using batch reactors. Supersaturation is created by mixing the co‐reactants in a micromixer inducing precipitation; the suspension is then segmented into identical micro‐volumes by a non‐miscible fluid and sent through a tube. These micro‐volumes are more homogeneous when compared to large batch reactors leading to narrower size distributions, better particle morphology, polymorph selectivity and stoichiometry. All these features have been demonstrated on single tube SFTR for different chemical systems. To increase productivity for commercial application the SFTR is being “scaled‐out” by multiplying the number of tubes running in parallel instead of scaling‐up by increasing their size. The versatility of the multi‐tube unit will allow changes in type of precipitate with a minimum of new investment as new chemistry can be researched, developed and optimised in a single tube SFTR and then transferred to the multi‐tube unit for powder production.
scite is a Brooklyn-based organization that helps researchers better discover and understand research articles through Smart Citations–citations that display the context of the citation and describe whether the article provides supporting or contrasting evidence. scite is used by students and researchers from around the world and is funded in part by the National Science Foundation and the National Institute on Drug Abuse of the National Institutes of Health.