• scale-up;
  • nanomaterial;
  • magnetic nanowires;
  • computational fluid dynamics

Bimetallic one-dimensional cobalt–nickel magnetic nanowires capped on both sides with conical heads were synthesized using the polyol process. Then, the process was scaled up to produce magnetic nanowires in sample aliquots of approximately 20 g. The scale-up strategy involved improving the mixing reagents using either axial or radial mixing configurations and was experimentally validated by comparing the structural and magnetic properties of the resulting nanowires. The results indicated a connection between the flow patterns and the size and shape of the nanowires. When a Rushton turbine was used, shorter nanowires with unconventional small heads were obtained. Because the demagnetizing field is strongly localized near or inside these heads, the coercive field was enhanced nearly twofold. These results were confirmed by micromagnetic simulations using isolated nanowires. In addition, the development of flow patterns at the small and pilot scales was predicted and compared using three-dimensional turbulent computational fluid dynamics simulations. © 2014 American Institute of Chemical Engineers AIChE J, 61: 304–316, 2015