A new method for the large-scale hydrothermal production and activation of ZIF-8 is presented in this communication. Activated ZIF-8 has been produced, at lab-scale and pilot-scale, at a rate of 27 g h⁻¹ and 810 g h⁻¹ respectively with the activated material showing a surface area of 1800 m² g⁻¹.

Here we report a new low temperature dry ice carbonation approach for the synthesis of carbonate-based nano- and micro-particulate materials, which enables the preparation of monodispersed calcium carbonate nanoparticles and microspheres with very high purity phases.

As nanotechnology becomes increasingly important and ubiquitous, new and scalable synthetic approaches are needed to meet the growing demand for industrially viable routes to nanomaterial production. Continuous-flow hydrothermal synthesis or supercritical water hydrothermal synthesis (scWHS) is emerging as a versatile solution to this problem. The process was initially developed to take advantage of the tunable chemical and physical properties of superheated water to produce metal oxide nanoparticles by rapid nucleation and precipitation. The development of new mixing regimes and reactor designs has been facilitated by the modelling of reactor systems. These new reactor designs further exploit the properties of supercritical water to promote faster and more uniform mixing of reagent streams. The synthetic approach has been expanded beyond the metal oxide systems for which it was conceived, and now encompasses metal sulfides, metal phosphates, metal nanoparticles and metal–organic frameworks. In many of these cases, some degree of size and shape control can be achieved through careful consideration of both chemistry and reactor design. This review briefly considers the development of scWHS reactor technology, before highlighting some of our recent work in expanding the scope of this synthetic method to include a wide range of materials.

Continuous flow synthesis offers potential for large-scale production of metal–organic frameworks with control of composition and microstructure for practical applications.

Continuous-flow hydrothermal and solvothermal syntheses offer substantial advantages over conventional processes, producing high quality materials from a wide range of precursors. In this study, we evaluate the “cradle-to-gate” life cycle environmental impacts of alternative titanium dioxide (TiO₂) nanoparticle production parameters, considering a range of operational conditions, precursors, material properties and production capacities. A detailed characterisation of the nano-TiO₂ products allows us, for the first time, to link key nanoparticle characteristics to production parameters and environmental impacts, providing a useful foundation for future studies evaluating nano-TiO₂ applications. Five different titanium precursors are considered, ranging from simple inorganic precursors, like titanium oxysulphate (TiOS), to complex organic precursors such as titanium bis(ammonium-lactato)dihydroxide (TiBALD). Synthesis at the laboratory scale is used to determine the yield, size distribution, crystallinity and phase of the nanoparticles. The specifications and operating experience of a full scale plant (>1000 t per year) are used to estimate the mass and energy inputs of industrial scale production for the life cycle assessment. Overall, higher process temperatures are linked to larger, more crystalline nanoparticles and higher conversion rates. Precursor selection also influences nano-TiO₂ properties: production from TiOS results in the largest particle sizes, while TiBALD achieves the smallest particles and narrowest size distribution. Precursor selection is the main factor in determining cradle-to-gate environmental impacts (>80% in some cases), due to the production impact of complex organic precursors. Nano-TiO₂ production from TiOS shows the lowest global warming potential (GWP) (<12 kg CO₂-eq. per kg TiO₂) and cumulative energy demand (CED) (<149 MJ kg⁻¹ TiO₂) due to the low environmental impact of the precursor, the use of water as a solvent and its high yield even at lower temperatures. Conversely, the TiBALD precursor shows the highest impact (86 kg CO₂-eq. per kg TiO₂ and 1952 MJ kg⁻¹ TiO₂) due to the need for additional post-synthesis steps and complexity of precursor manufacturing. The main purpose of this study is not a direct comparison of the environmental impacts of TiO₂ nanoparticles manufactured utilizing various precursors under different conditions, but to provide an essential foundation for future work evaluating potential applications of nano-TiO₂ and their life cycle environmental impacts.

Continuous flow hydrothermal synthesis offers a cheap, green and highly scalable route for the preparation of inorganic nanomaterials which has predominantly been applied to metal oxide based materials. In this work we report the first continuous flow hydrothermal synthesis of metal sulphide nanomaterials. A wide range of binary metal sulphides, ZnS, CdS, PbS, CuS, Fe_(1−x)S and Bi₂S₃, have been synthesised. By varying the reaction conditions two different mechanisms may be invoked; a growth dominated route which permits the formation of nanostructured sulphide materials, and a nucleation driven process which produces nanoparticles with temperature dependent size control. This offers a new and industrially viable route to a wide range of metal sulphide nanoparticles with facile size and shape control.