From Batch to Continuous Small-Scale Production of Particles: Mixer Design Methodology for Robust Operation

Layered double hydroxides (LDHs) are a vital tool in many different areas, such as drug delivery, catalysis, anion exchange (materials), polymer processing, etc. Conventionally, LDHs are synthesized in a batch process that consists of particle generation and ripening, where product properties are manipulated for stability and the optimal uptake of genetic material. Continuous processing and intensive mixing holds high promise for improved particle generation and characteristic control. In this contribution, an iterative method, using the mentioned particle generation as a use case, was applied to quickly generate a continuous process optimization platform for continuous, plugging-free particle generation with the required characteristics. Assisted by rapid prototyping and additive manufacturing, a vortex mixer was produced that delivers satisfactory long-term results.