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Peng C, Zhu X, Zhang J, Zhao W, Jia J, Wu Z, Yu Z, Dong Z. Antisolvent fabrication of monodisperse liposomes using novel ultrasonic microreactors: Process optimization, performance comparison and intensification effect. ULTRASONICS SONOCHEMISTRY 2024; 103:106769. [PMID: 38266590 PMCID: PMC10818068 DOI: 10.1016/j.ultsonch.2024.106769] [Citation(s) in RCA: 3] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Subscribe] [Scholar Register] [Received: 09/25/2023] [Revised: 01/07/2024] [Accepted: 01/14/2024] [Indexed: 01/26/2024]
Abstract
Liposomes as drug carriers for the delivery of therapeutic agents have triggered extensive research but it remains a grand challenge to develop a novel technology for enabling rapid and mass fabrication of monodisperse liposomes. In this work, we constructed a novel ultrasonic microfluidic technology, namely ultrasonic microreactor (USMR) with two different conjunction structure (co-flow and impinge flow, corresponding to USMR-CF and USMR-IF, respectively), to prepare uniform liposomes by antisolvent precipitation method. In this process, the monodisperse liposomes with tunable droplet sizes (DS) in 60-100 nm and a polydispersity index (PDI) less than 0.1 can easily be achieved by tuning the total flow rate, flow rate ratio, ultrasonic power, and lipid concentration within the two USMRs. Impressively, the USMR-IF is superior for reducing the PDI and tuning DS of the liposomes over the USMR-CF. More importantly, the ultrasonic can effectively reduce DS and PDI at the low TFR and support the IF-micromixer in reducing the PDI even at a high TFR. These remarkable performances are mainly due to the rapid active mixing, fouling-free property and high operation stability for USMR-IF. In addition, diverse lipid formulations can also be uniformly assembled into small liposomes with narrow distribution, such as the prepared HSPC-based liposome with DS of 59.6 nm and PDI of 0.08. The liposomes show a high stability and the yield can reach a high throughput with 108 g/h by using the USMR-IF at an initial lipid concentration of 60 mM. The results in the present work highlight a novel ultrasonic microfluidic technology in the preparation of liposomes and may pave an avenue for the rapid, fouling-free, and high throughput fabrication of different and monodisperse nanomedicines with controllable sizes and narrow distribution.
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Affiliation(s)
- Caihe Peng
- School of Pharmacy, Changchun University of Chinese Medicine, 130117 Changchun, China
| | - Xiaojing Zhu
- Chemistry and Chemical Engineering Guangdong Laboratory, 515031 Shantou, China.
| | - Jie Zhang
- Chemistry and Chemical Engineering Guangdong Laboratory, 515031 Shantou, China
| | | | - Jingfu Jia
- Chemistry and Chemical Engineering Guangdong Laboratory, 515031 Shantou, China
| | - Zhilin Wu
- Chemistry and Chemical Engineering Guangdong Laboratory, 515031 Shantou, China; College of Chemistry and Chemical Engineering, Key Laboratory for Preparation and Application of Ordered Structural Materials of Guangdong Province, Shantou University, 515063 Shantou, China
| | - Zhixin Yu
- School of Pharmacy, Changchun University of Chinese Medicine, 130117 Changchun, China.
| | - Zhengya Dong
- Chemistry and Chemical Engineering Guangdong Laboratory, 515031 Shantou, China; College of Chemistry and Chemical Engineering, Key Laboratory for Preparation and Application of Ordered Structural Materials of Guangdong Province, Shantou University, 515063 Shantou, China; MoGe um-Flow Technology Co., Ltd., 515031 Shantou, China.
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Ma C, Duan XN, Yin JB, Sang L, Zhang JS. Preparation of Pd/Al 2O 3/Nickel Microfoam Catalysts by Electrodeposition for Hydrogenation in a Micropacked Bed Reactor. Ind Eng Chem Res 2021. [DOI: 10.1021/acs.iecr.1c02985] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/30/2022]
Affiliation(s)
- Chi Ma
- State Key Laboratory of Chemical Engineering, Department of Chemical Engineering, Tsinghua University, Beijing 100084, China
| | - Xiao-Nan Duan
- State Key Laboratory of Chemical Engineering, Department of Chemical Engineering, Tsinghua University, Beijing 100084, China
| | - Jia-Bin Yin
- State Key Laboratory of Chemical Engineering, Department of Chemical Engineering, Tsinghua University, Beijing 100084, China
| | - Le Sang
- State Key Laboratory of Chemical Engineering, Department of Chemical Engineering, Tsinghua University, Beijing 100084, China
| | - Ji-Song Zhang
- State Key Laboratory of Chemical Engineering, Department of Chemical Engineering, Tsinghua University, Beijing 100084, China
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Ma C, Sang L, Duan X, Yin J, Zhang J. An efficient method for enhancing adhesion and uniformity of Al2O3 coatings on nickel micro-foam used in micropacked beds. Chin J Chem Eng 2021. [DOI: 10.1016/j.cjche.2021.05.022] [Citation(s) in RCA: 3] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
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Mc Carogher K, Dong Z, Stephens DS, Leblebici ME, Mettin R, Kuhn S. Acoustic resonance and atomization for gas-liquid systems in microreactors. ULTRASONICS SONOCHEMISTRY 2021; 75:105611. [PMID: 34119738 PMCID: PMC8207318 DOI: 10.1016/j.ultsonch.2021.105611] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 03/20/2021] [Accepted: 05/27/2021] [Indexed: 06/12/2023]
Abstract
It is shown that a liquid slug in gas-liquid segmented flow in microchannels can act as an acoustic resonator to disperse large amounts of small liquid droplets, commonly referred to as atomization, into the gas phase. We investigate the principles of acoustic resonance within a liquid slug through experimental analysis and numerical simulation. A mechanism of atomization in the confined channels and a hypothesis based on high-speed image analysis that links acoustic resonance within a liquid slug with the observed atomization is proposed. The observed phenomenon provides a novel source of confined micro sprays and could be an avenue, amongst others, to overcome mass transfer limitations for gas-liquid processes in flow.
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Affiliation(s)
- Keiran Mc Carogher
- KU Leuven, Department of Chemical Engineering, Celestijnenlaan 200F, 3001 Leuven, Belgium
| | - Zhengya Dong
- KU Leuven, Department of Chemical Engineering, Celestijnenlaan 200F, 3001 Leuven, Belgium
| | - Dwayne S Stephens
- Drittes Physikalisches Institut, Georg-August-Universität Göttingen, Friedrich-Hund-Platz 1, 37077 Göttingen, Germany
| | - M Enis Leblebici
- Center for Industrial Process Technology, Department of Chemical Engineering, KU Leuven, Agoralaan Building B, 3590 Diepenbeek, Belgium
| | - Robert Mettin
- Drittes Physikalisches Institut, Georg-August-Universität Göttingen, Friedrich-Hund-Platz 1, 37077 Göttingen, Germany
| | - Simon Kuhn
- KU Leuven, Department of Chemical Engineering, Celestijnenlaan 200F, 3001 Leuven, Belgium.
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Khasi S, Fayazi A, Kantzas A. A Pore-Scale Model for Dispersion and Mass Transfer during Acoustically Assisted Miscible Displacements in Porous Media. Ind Eng Chem Res 2021. [DOI: 10.1021/acs.iecr.0c05141] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Saeid Khasi
- Department of Chemical and Petroleum Engineering, University of Calgary, Calgary, AB T2N 1N4, Canada
| | - Amir Fayazi
- Department of Chemical and Petroleum Engineering, University of Calgary, Calgary, AB T2N 1N4, Canada
| | - Apostolos Kantzas
- Department of Chemical and Petroleum Engineering, University of Calgary, Calgary, AB T2N 1N4, Canada
- PERM Inc., Calgary, AB T2E 6P2, Canada
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Dong Z, Delacour C, Mc Carogher K, Udepurkar AP, Kuhn S. Continuous Ultrasonic Reactors: Design, Mechanism and Application. MATERIALS 2020; 13:ma13020344. [PMID: 31940863 PMCID: PMC7014228 DOI: 10.3390/ma13020344] [Citation(s) in RCA: 58] [Impact Index Per Article: 11.6] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 12/16/2019] [Revised: 01/06/2020] [Accepted: 01/08/2020] [Indexed: 01/01/2023]
Abstract
Ultrasonic small scale flow reactors have found increasing popularity among researchers as they serve as a very useful platform for studying and controlling ultrasound mechanisms and effects. This has led to the use of these reactors for not only research purposes, but also various applications in biological, pharmaceutical and chemical processes mostly on laboratory and, in some cases, pilot scale. This review summarizes the state of the art of ultrasonic flow reactors and provides a guideline towards their design, characterization and application. Particular examples for ultrasound enhanced multiphase processes, spanning from immiscible fluid-fluid to fluid-solid systems, are provided. To conclude, challenges such as reactor efficiency and scalability are addressed.
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Du C, Wang P, Hu Y, Zhang J, Luo G. Liquid–Liquid Mass Transfer Enhancement in Milliscale Packed Beds. Ind Eng Chem Res 2019. [DOI: 10.1021/acs.iecr.9b04225] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
Affiliation(s)
- Chencan Du
- The State Key Laboratory of Chemical Engineering, Department of Chemical Engineering, Tsinghua University, Beijing 100084, China
| | - Peicheng Wang
- The State Key Laboratory of Chemical Engineering, Department of Chemical Engineering, Tsinghua University, Beijing 100084, China
| | - Yunpeng Hu
- The State Key Laboratory of Chemical Engineering, Department of Chemical Engineering, Tsinghua University, Beijing 100084, China
| | - Jisong Zhang
- The State Key Laboratory of Chemical Engineering, Department of Chemical Engineering, Tsinghua University, Beijing 100084, China
| | - Guangsheng Luo
- The State Key Laboratory of Chemical Engineering, Department of Chemical Engineering, Tsinghua University, Beijing 100084, China
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Navarro-Brull FJ, Teixeira AR, Giri G, Gómez R. Enabling low power acoustics for capillary sonoreactors. ULTRASONICS SONOCHEMISTRY 2019; 56:105-113. [PMID: 31101244 DOI: 10.1016/j.ultsonch.2019.03.013] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.2] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 12/07/2018] [Revised: 03/08/2019] [Accepted: 03/12/2019] [Indexed: 06/09/2023]
Abstract
Capillary reactors demonstrate outstanding potential for on-demand flow chemistry applications. However, non-uniform distribution of multiphase flows, poor solid handling, and the risk of clogging limit their usability for continuous manufacturing. While ultrasonic irradiation has been traditionally applied to address some of these limitations, their acoustic efficiency, uniformity and scalability to larger reactor systems are often disregarded. In this work, high-speed microscopic imaging reveals how cavitation-free ultrasound can unclog and prevent the blockage of capillary reactors. Modeling techniques are then adapted from traditional acoustic designs and applied to simulate and prototype sonoreactors with wider and more uniform sonication areas. Blade-, block- and cylindrical shape sonotrodes are optimized to accommodate longer capillary lengths in sonoreactors resonating at 28 kHz. Finally, a novel helicoidal capillary sonoreactor is proposed to potentially deal with a high concentration of solid particles in miniaturized flow chemistry. The acoustic designs and first principle rationalization presented here offer a transformative step forward in the scale-up of efficient capillary sonoreactors.
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Affiliation(s)
- Francisco J Navarro-Brull
- Institut Universitari d'Electroquímica i Departament de Química Física, Universitat d'Alacant, Apartat 99, E-03080 Alicante, Spain
| | - Andrew R Teixeira
- Department of Chemical Engineering, Worcester Polytechnic Institute, Worcester, MA 01609, United States
| | - Gaurav Giri
- Department of Chemical Engineering, University of Virginia, Charlottesville, VA 22904, United States
| | - Roberto Gómez
- Institut Universitari d'Electroquímica i Departament de Química Física, Universitat d'Alacant, Apartat 99, E-03080 Alicante, Spain.
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