Summary: A novel laboratory scale continuous hydrothermal flow synthesis (CHFS) system has been developed for the controlled synthesis of inorganic nano-materials (particles <100nm) with potential commercial applications from sunscreens and battery materials to fuel cell components and photocatalysts. The CHFS system has many advantages; it is a green technology (using supercritical water as the reagent), which utilises inexpensive precursors (metal nitrate salts) and can controllably produce high quality, technologically important functional nano-materials in an efficient single step (or fewer steps than conventionally). This project seeks to move the existing laboratory scale CHFS system (developed over the past few years at QMUL) towards a x10 pilot scale-up (nano-powder production of up to 500g per 12h depending on variables). The proposed research will initially compare the ability to control particle characteristics of the CHFS system at the laboratory scale over a large range of process variables (flow rates, temperatures, pressures, etc), building full operational envelopes that will describe reactor variables versus particle properties for each material. In particular, we will utilise process analytical technology (PAT)and the data will help develop univariate and multivariate understanding of the temporal operational spaces and interactions between process variables and product quality. PATand chemometrics incorporated with combined computational fluid dynamics modelling of hydrodynamics/mixing and population balance modelling of particle size evolution via nano-precipitation will be used to study alternative nozzles designs and other potential bottleneck factors. This will lead to a generic strategy for scaling up and controlled manufacture of nanomaterials with consistent, reproducible and predictable quality. The scale up quantities of nano-powders from the pilot plant will allow industrial partners to perform prototyping or comprehensive commercial evaluation of nano-powders in a range of applications which they have hitherto not been able to conduct due to lack of sufficient high quality material. Importantly, the know-how acquired on the project and the proposed feasibility studies will reduce the risk and commercial barriers for industry that might consider building a larger industrial scale CHFS plant in the future.

CREATe-Net is composed of 3 academic institutions in Europe (Saarland Univ., DE; Technical Univ. of Catalonia, ES; and INM - Leibniz Institute for New Materials, DE), 3 non-academic institutions in Europe (AB Sandvik Coromant, SE; Steinbeis Research and Innovation Centers, DE; and Nanoforce Ltd., UK), as well as 6 academic partners outside Europe (CSIR - Council for Scientific and Industrial Research, ZA; Univ. Católica de Uruguay, UY; Instituto de Investigaciones en Ciencia e Ingeniería de Materiales, AR; Univ. de Concepción, CL; Univ. de Sao Paulo, BR; and Georgia Institute of Technology, US). The network will cooperate in the field of design, processing and characterization of novel composite materials for resource-efficient applications and environmentally friendly technologies, in particular energy storage, bearings, electrical contacts, and cutting tools. The purpose of the network is to combine different thematic expertises of the academic and industrial network members in the multidisciplinary field of materials science and engineering in order to design new composite materials with superior properties and performance. The expertise of the network includes: a) design by modelling at different scales (e. g. atomistic modelling, thermodynamic and kinetic modelling, finite element modelling); b) novel processing methods (e . g. atomic layer deposition, severe plastic deformation and rapid solidification); c) advanced characterization methods (e. g. serial sectioning and atom probe tomography, high resolution transmission electron microscopy); d) processing/characterization of carbon materials, metal and ceramic matrix composites as well as functionally graded materials; and e) performance testing for targeted applications (available through special designed testing facilities at the research centres and industrial partners). Two workshops and one final conference will contribute to the exchange of knowledge beside the exchange of researchers.

Summary: A novel laboratory scale continuous hydrothermal flow synthesis (CHFS) system has been developed for the controlled synthesis of inorganic nano-materials (particles <100nm) with potential commercial applications from sunscreens and battery materials to fuel cell components and photocatalysts. The CHFS system has many advantages; it is a green technology (using supercritical water as the reagent), which utilises inexpensive precursors (metal nitrate salts) and can controllably produce high quality, technologically important functional nano-materials in an efficient single step (or fewer steps than conventionally). This project seeks to move the existing laboratory scale CHFS system (developed over the past few years at QMUL) towards a x10 pilot scale-up (nano-powder production of up to 500g per 12h depending on variables). The proposed research will initially compare the ability to control particle characteristics of the CHFS system at the laboratory scale over a large range of process variables (flow rates, temperatures, pressures, etc), building full operational envelopes that will describe reactor variables versus particle properties for each material. In particular, we will utilise on-line measurement of dynamic laser light scattering particle sizing, and at-line analytical methods. This data will help develop univariate and multivariate understanding of the temporal operational spaces and interactions between process variables and product quality. On-line sensing and chemometrics incorporated with combined computational fluid dynamics modelling of hydrodynamics/mixing and population balance modelling of particle size evolution via nano-precipitation will be used to study alternative nozzles designs and other potential bottleneck factors. This will lead to a generic strategy for scaling up and controlled manufacture of nanomaterials with consistent, reproducible and predictable quality. The scale up quantities of nano-powders from the pilot plant will allow industrial partners to perform prototyping or comprehensive commercial evaluation of nano-powders in a range of applications which they have hitherto not been able to conduct due to lack of sufficient high quality material. Importantly, the know-how acquired on the project and the proposed feasibility studies will reduce the risk and commercial barriers for industry that might consider building a larger industrial scale CHFS plant in the future.

Plastic Electronics embodies an approach to future electronics in their broadest sense (including electronic, optoelectronic and photonic structures, devices and systems) that combines the low temperature, versatile manufacturing attributes of plastics with the functional properties of semiconductors and metals. At its heart is the development, processing and application of advanced materials encompassing molecular electronic materials, low temperature processed metals, metal oxides and novel hybrids. As such it constitutes a challenging and far-ranging training ground in tune with the needs of a wide spectrum of industry and academia alike. The general area is widely recognised as a rapidly developing platform technology with the potential to impact on multiple application sectors, including displays, signage and lighting, large area electronics, energy generation and storage, logistics, advertising and brand security, distributed sensing and medical devices. The field is a growth area, nationally and globally and the booming organic (AMOLED) display and printed electronics industries have been leading the way, with the emerging opportunities in the photonics area - i.e. innovative solid-state lighting, solar (photovoltaics), energy storage and management now following. The world-leading, agenda-setting UK academic PE research, much of it sponsored by EPSRC, offers enormous potential that is critical for the development and growth of this UK technology sector. PE scientists are greatly in demand: both upstream for materials, process and equipment development; and downstream for device fabrication and wide-ranging applications innovation. Although this potential is recognised by UK government and industry, PE makes a major contribution to the Advanced Materials theme identified in Science Minister David Willet's 'eight great technologies', growth is severely limited by the shortage of trained scientists and engineers capable of carrying ideas forward to application. This is confirmed by industry experts who argue that a comprehensive training programme is essential to deliver the workforce of scientists and engineers needed to create a sustainable UK PE Industry. The aim of the PE-CDT is to provide necessary training to develop highly skilled scientists and engineers, capable both of leading development and of contributing growth in a variety of aspects; materials-focused innovation, translation and manufacturing. The CDT brings together three leading academic teams in the PE area: the Imperial groups, with expertise in the synthesis, materials processing, characterisation, photonics and device physics, the Oxford team with expertise in ultrafast spectroscopes probes, meso and nano-structured composites, vacuum processing and up scaling as well as the material scientists and polymer technologists at QMUL. This compact consortium encompasses all the disciplines relevant to PE, including materials physics, optoelectronics, physical chemistry, device engineering and modelling, design, synthesis and processing as well as relevant industrial experience. The programme captures the essentially multidisciplinary nature of PE combining the low temperature, versatile manufacturing attributes of plastics with the functional properties of semiconductors and metals. Yet, to meet the needs of the PE industry, it also puts in place a deep understanding of basic science along with a strong emphasis on professional skills and promoting interdisciplinary learning of high quality, ranging across all areas of plastic electronics.