Microjet Reactor Spray Drying Nanoparticle Size Control
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Solution Overview
Problem
Current methods for producing nanoparticles, particularly in the pharmaceutical industry, face challenges such as limited control over particle size, toxicity, high energy requirements, and difficulties in scaling up production, with existing techniques often resulting in particle growth due to Ostwald ripening and requiring surface modifiers.
Innovation Solution
A device comprising a microjet reactor and a spray dryer unit where jets of solvent and nonsolvent collide at controlled angles and pressures, followed by a spray dryer unit with temperature and volume flow regulation to prevent Ostwald ripening, producing nanoparticles with controlled size and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional nanoparticle production methods are used, then particles can be produced, but particle size control is limited and Ostwald ripening occurs causing particle growth
Solution Approach 1:
The invention controls particle size by precisely adjusting process parameters including jet collision angle (90-180°), pressure (5-50 bar), flow rates, temperature, and solvent/nonsolvent ratios. These parameter changes enable controlled precipitation that prevents Ostwald ripening while achieving desired particle sizes below 1 µm
Solution Approach 2:
The invention utilizes phase transition from dissolved state to precipitated solid phase through controlled solvent-nonsolvent mixing. The rapid phase separation upon jet collision creates uniform nucleation conditions that prevent subsequent particle growth via Ostwald ripening
2Quantity of substance
If high energy input methods are used for nanoparticle production, then particles can be formed, but energy consumption is high and scaling up is difficult
Solution Approach 1:
The invention replaces high-energy mechanical methods (ball milling, sonication) with a low-energy jet mixing approach. The kinetic energy from simple liquid jets colliding at controlled angles provides sufficient mixing and nucleation energy without the high power consumption and scaling difficulties of mechanical systems
Solution Approach 2:
The invention uses hydraulic jet systems to deliver solvent and nonsolvent through controlled pressure and flow rates. This pneumatic-hydraulic approach enables scalable production from laboratory to industrial levels without proportionally increasing energy input, as the jet collision process remains inherently efficient
3Stability of the object's composition
If surface modifiers are used to prevent particle aggregation, then particle stability improves, but the need for additional chemicals increases
Solution Approach 1:
The invention achieves particle stability through self-organization during the precipitation process itself. The controlled jet mixing creates conditions where particles form with inherent stability, eliminating or reducing the need for external surface modifiers and simplifying the overall process
4Productivity
If jet collision angle is increased to improve mixing, then precipitation efficiency increases, but particle size control becomes more difficult
Solution Approach 1:
The invention optimizes the collision angle parameter within the specific range of 90-180° to achieve the desired balance. This parameter optimization, combined with controlled pressure and flow rate adjustments, enables both rapid precipitation and uniform particle size distribution below 1 µm
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of nanoparticles with sizes mostly below 1 µm, largely preventing Ostwald ripening and maintaining particle stability, while minimizing the need for surface modifiers and ensuring efficient scaling from laboratory to industrial production.
Implementation Method 1
a jet of a solvent containing at least one target molecule and a jet of a nonsolvent, which are conveyed via high-pressure pumps, emerge from nozzles and meet at a collision point... This results in a very rapid precipitation... in the course of which micro- or nanoparticles are formed
Implementation Method 2
producing dispersions and solids by controlled precipitation, co-precipitation and self-organization processes
Implementation Method 3
the spray dryer unit, which is designed as a pipe section directly connected to the product outlet of the microjet reactor with lateral feeding of one or more streams of air or inert gas... producing nanoparticles with controlled size and stability... largely preventing Ostwald ripening
Data Source
Figure 1
AI summary
The invention relates to an apparatus and a method for producing dispersions and solids by controlled precipitation, coprecipitation and self-organising processes in a microjet reactor, wherein a jet of a solvent (2) containing at least one target molecule collides with a jet of a non-solvent (3) at defined pressures and flow rates at a collision point (K) in the reactor chamber of the microjet reactor, and wherein the microjet reactor has a gas inlet (5) for admitting gas to the reactor chamber (1) and a reactant outlet (6) for discharging the reactants in a gas stream. This results in very rapid precipitation, coprecipitation or a chemical reaction in which microparticles or nanonparticles are produced. In order to provide an apparatus that can perform solvent/non-solvent precipitation in such a way as to produce particles that are as small as possible and are largely unaffected by Ostwald ripening in the resulting dispersion, the invention proposes connecting a spray-drying unit (7) to the reactant outlet and providing a control circuit (11) to optimise and maintain the operating parameters of the spray-drying unit (7).