Modelling and optimisation of bio-inspired synthesis of porous silica particles: estimation of kinetics and application to continuous reactors

The bio-inspired silica (BIS) synthesis is a greener process that operates at ambient and mild pH conditions and produces high-value products with applications in wide areas such as energy, environment, and medicine. In this work, batch and continuous experiments of BIS synthesis were conducted. The experimental data and reaction engineering approach were used to estimate key reaction kinetics relevant to BIS formation over a range of pH. The BIS synthesis was performed in a continuous mode using CSTR and bubble column reactors, resulting in yields comparable to small-scale batch experiments. Using the experimental results and the models, the effects of residence time and feed concentrations were investigated, and optimum conditions were identified. These outcomes will be useful for the scale-up of BIS synthesis, reactor design, and optimization of sustainable manufacturing of high-value silicas.