A continuous flow mode with a scalable tubular reactor for the green preparation of stable alkali lignin nanoparticles assisted by ultrasound

Lignin nanoparticles (LNPs) have become a hot topic recently because of their improved physicochemical properties and the excellent integration into various industrial sectors compared to lignin. However, the green large-scale production of stable LNPs severely restricts the high-value applications of LNPs. In this work, a simple and potentially scalable continuous-flow mode setup with a tubular flow reactor was designed for the green preparation of stable alkali LNPs assisted by ultrasound. When the flow rates of lignin solution and nitric acid solution were 8.00 mL/min and 2.67 mL/min respectively, and the length of the tube was 5.5 m, the average residence time of mixed solution was 62.2 s in the tubular reactor. Spheroid nanoparticles with an average size of 97.2 nm were obtained under this optimized condition. Furthermore, the results showed a better control of the mixing compared to the batch process, resulting in a homogeneous distribution of smaller particle sizes thus improving stability and UV-blocking properties. This is attributed to the better mixing and excellent mass transfer characteristics in the tube, which provides favorable conditions for the full contact and uniform dispersion of the mixed solution. More importantly, continuous flow mode makes it possible to prepare LNPs with excellent physicochemical properties on a large scale, which will bring great opportunities for the industrial production and application of LNPs.