| Summary: | This study introduces the Double-Diamond Reactor (DDR), a novel planar passive microreactor designed to overcome the following conventional limitations: inefficient mass transfer, high flow resistance, and clogging. The DDR integrates splitting–turning–impinging (STI) hydrodynamic principles via CFD-guided optimization, generating chaotic advection to enhance mixing. Experimental evaluations using Villermaux–Dushman tests showed a segregation index (<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><msub><mrow><mi>X</mi></mrow><mrow><mi>s</mi></mrow></msub></mrow></semantics></math></inline-formula>) as low as 0.027 at 100 mL·min<sup>−1</sup>, indicating near-perfect mixing. In BaSO<sub>4</sub> nanoparticle synthesis, the DDR achieved a 46% smaller average particle size (95 nm) and narrower distribution (<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><msub><mrow><mi>σ</mi></mrow><mrow><mi>g</mi></mrow></msub><mo>=</mo><mn>1.27</mn></mrow></semantics></math></inline-formula>) compared to reference designs (AFR-1), while maintaining low pressure drops (<20 kPa at 60 mL·min<sup>−1</sup>). The DDR’s superior performance stems from its hierarchical flow division and concave-induced vortices, which eliminate stagnant zones. This work demonstrates the DDR’s potential for high-throughput nanomaterial synthesis with precise control over particle characteristics, offering a scalable and energy-efficient solution for advanced chemical processes.
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