Channel-fouling is a pervasive problem in continuous flow chemistry, causing poor product control and reactor failure. Droplet chemistry, in which the reaction mixture flows as discrete droplets inside an immiscible carrier liquid, prevents fouling by isolating the reaction from the channel walls. Unfortunately, the difficulty of controllably adding new reagents to an existing droplet stream has largely restricted droplet chemistry to simple reactions in which all reagents are supplied at the time of droplet formation. Here we describe an effective method for repeatedly adding controlled quantities of reagents to droplets. The reagents are injected into a multiphase fluid stream, comprising the carrier liquid, droplets of the reaction mixture and an inert gas that maintains a uniform droplet spacing and suppresses new droplet formation. The method, which is suited to many multistep reactions, is applied to a five-stage quantum dot synthesis wherein particle growth is sustained by repeatedly adding fresh feedstock.

The past decade has seen a steady rise in the use of microfluidic reactors for nanocrystal synthesis, with numerous studies reporting improved reaction control relative to conventional batch chemistry. However, flow synthesis procedures continue to lag behind batch methods in terms of chemical sophistication and the range of accessible materials, with most reports having involved simple one- or two-step chemical procedures directly adapted from proven batch protocols. Here we examine the current status of microscale methods for nanocrystal synthesis, and consider what role microreactors might ultimately play in laboratory-scale research and industrial production.

This study compares the performance of a microfluidic technique and a conventional bulk method to manufacture conjugated polymer nanoparticles (CPNs) embedded within a biodegradable poly(ethylene glycol) methyl ether-blockpoly(lactide-co-glycolide) (PEG5K-PLGA55K) matrix. The influence of PEG5K-PLGA55K and conjugated polymers cyanosubstituted poly(p-phenylene vinylene) (CN-PPV) and poly(9,9-dioctylfluorene-2,1,3-benzothiadiazole) (F8BT) on the physicochemical properties of the CPNs was also evaluated. Both techniques enabled CPN production with high end product yields (~70-95%). However, while the bulk technique (solvent displacement) under optimal conditions generated small nanoparticles (~70-100 nm) with similar optical properties (quantum yields ~35%), the microfluidic approach produced larger CPNs (140-260 nm) with significantly superior quantum yields (49-55%) and tailored emission spectra. CPNs containing CN-PPV showed smaller size distributions and tuneable emission spectra compared to F8BT systems prepared under the same conditions. The presence of PEG5K-PLGA55K did not affect the size or optical properties of the CPNs and provided a neutral net electric charge as is often required for biomedical applications. The microfluidics flowbased device was successfully used for the continuous preparation of CPNs over a 24 hour period. On the basis of the results presented here, it can be concluded that the microfluidic device used in this study can be used to optimize the production of bright CPNs with tailored properties with good reproducibility.

We report the use of a porous polytetrafluoroethylene capillary for the inline separation of liquid-liquid segmented flows, based on the selective wetting and permeation of the porous capillary walls by one of the liquids. Insertion of a narrow flow restriction at the capillary outlet allows the back pressure to be tuned for multiple liquid-liquid combinations and flow conditions. In this way, efficient separation of aqueous-organic, aqueous-fluorous and organic-fluorous segmented flows can be readily achieved over a wide range of flow rates. The porous-capillary-separator enables the straightforward regeneration of a continuous flow from a segmented flow, and may be applied to various applications, including inline analysis, biphasic reactions, and purification. As a demonstration of the latter, we performed a simple inline aqueous-organic extraction of the pH indicator 2,6-dichloroindophenol. An aqueous solution of the conjugate base was mixed with hydrochloric acid in continuous flow to protonate the indicator and render it organic-soluble. The indicator was then extracted from the aqueous feed into chloroform using a segmented flow. The two liquids were finally separated inline using a porous PTFE capillary, with the aqueous phase emerging as a continuous stream from the separator outlet. UV-visible absorption spectroscopy showed the concentration of indicator in the outflowing aqueous phase to be less than one percent of its original value, confirming the efficacy of the extraction and separation process.

PAPER deMello et al. Microscale separation of immiscible liquids using a porous capillary