Turbulence induced shear controllable synthesis of nano FePO₄ irregularly-shaped particles in a counter impinging jet flow T-junction reactor assisted by ultrasound irradiation

FePO₄ (FP) particles with a mesoporous structure amalgamated by nanoscale primary crystals were controllably prepared using an ultrasound-intensified turbulence T-junction microreactor (UTISR). The use of this type of reaction system can effectively enhance the micro-mixing and remarkably improve the mass transfer and chemical reaction rates. Consequently, the synergistic effects of the impinging streams and ultrasonic irradiation on the formation of mesoporous structure of FP nanoparticles have been systematically investigated through experimental validation and CFD simulation. The results revealed that the FP particles with a mesoporous structure can be well synthesised by precisely controlling the operation parameters by applying ultrasound irradiation with the input power in the range of 0–900 W and the impinging stream volumetric flow rate in the range of 17.15–257.22 mL·min⁻¹. The findings obtained from the experimental observation and CFD modelling has clearly indicated that there exists a strong correlation between the particle size, morphology, and the local turbulence shear. The application of ultrasonic irradiation can effectively intensify the local turbulence shear in the reactor even at low Reynolds number based on the impinging stream diameter (Re < 2000), leading to an effective reduction in the particle size (from 273.48 to 56.1 nm) and an increase in the specific surface area (from 21.97 to 114.97 m²·g⁻¹) of FP samples. The FP irregularly-shaped particles prepared by UTISR exhibited a mesoporous structure with a particle size of 56.10 nm, a specific surface area of 114.97 m²·g⁻¹ and a total pore adsorption volume of 0.570 cm³·g⁻¹ when the volumetric flow rate and ultrasound power are 85.74 mL·min⁻¹ and 600 W, respectively.