The challenge of continuous CaCO3 particle synthesis is addressed using microfluidic technology. A custom microfluidic chip was used to synthesize CaCO3 nanoparticles in vaterite form. Our focus revolved around exploring one-phase and two-phase synthesis methods tailored for the crystallization of these nanoparticles. The combination of scanning electron microscopy, X-ray diffraction, dynamic light scattering, and small-angle scattering allowed for an evaluation of the synthesis efficiency, including the particle size distribution, morphology, and polymorph composition. The results demonstrated the superior performance of the two-phase system when precipitation occurred inside emulsion microreactors, providing improved size control compared with the one-phase approach. We also discussed insights into particle size changes during the transition from one-phase to two-phase synthesis. The ability to obtain CaCO3 nanoparticles in the desired polymorph form (∼50 nm in size, 86-99% vaterite phase) with the possibility of scaling up the synthesis will open up opportunities for various industrial applications of the developed two-phase microfluidic method.
Keywords: CaCO3; additive manufacturing; microfluidic synthesis; nanoparticles; one-phase synthesis; two-phase synthesis; vaterite.