Colloidal Silica Particle Synthesis and Future Industrial Manufacturing Pathways: A Review

Colloidal silica is used in many applications including catalysis, pharmaceuticals, and coatings. Although naturally formed silica materials are widely available, they are often in forms that are difficult to process or are even harmful to health. Therefore, uniform colloidal silicas are generally manufactured using synthetic chemical processes. While established high temperature gaseous synthesis methods fall out of favor in our energy conscious society, liquid synthesis methods are current industrial leaders. The precipitated silica method provides the majority share of commercially produced specialty silicas with its economic advantages predicted to continue to grow in the future. The biomimetic method and microemulsion methods of synthesis provide a superior level of surface chemistry and morphological control than current industrial processes and are the major focus of current silica synthesis research. Movement toward more tailor-made products and ecologically friendly production methods will likely provide incentive for biomimetic methods, in particular, to take more of a market share. However, the lack of procedures to viably scale up the biomimetic and microemulsion methods still forms significant gaps in the literature. In this review, the current methods of colloidal silica synthesis are discussed alongside significant models and mechanisms of silica formation.