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This approach integrates aerosol processing with a self-assembly mechanism driven by solvent evaporation, offering distinct advantages over conventional sol\u2013gel and hydrothermal methods. The influence of ethanol content, pH, P123 template amount, and reactor temperature (Tr) on the formation of SBA-15 spheres was systematically investigated using gas physisorption, thermogravimetric analysis (TGA), small-angle X-ray scattering (SAXS), and electron microscopy. In the absence of ethanol, the desired spherical morphology was not obtained; instead, the products consisted of mixed, fiber-like elongated features and bundled aggregates, highlighting ethanol\u2019s pivotal role in directing spherical particle formation. An ethanol\/tetraethyl orthosilicate (TEOS) molar ratio of 1 was sufficient to maintain a spherical morphology during continuous runs up to 12 h. For production extending beyond 12 h, a ratio of 3 was required to ensure precursor stability and to balance surface area with pore volume. Adjusting the pH to 3 enabled pore expansion to \u223c20 nm and a pore volume of 1 cm3\/g, with a moderate surface area of 194 m2\/g. Lower ethanol and acid usage suggest a more sustainable process. A P123\/TEOS molar ratio of 0.015 was sufficient to yield well-ordered mesostructures with minimal reactor fouling. Reducing Tr from 400 to 200 \u00b0C decreased energy consumption without sacrificing quality, however, a further reduction to 120 \u00b0C compromised the morphology. Key parameters affecting continuous AA-EISA production are given, showing potential for a robust, energy-efficient, and environmentally conscious route to produce mesoporous silica particles.<\/jats:p>","DOI":"10.1021\/cbe.6c00038","type":"journal-article","created":{"date-parts":[[2026,6,22]],"date-time":"2026-06-22T12:15:17Z","timestamp":1782130517000},"page":"793-808","source":"Crossref","is-referenced-by-count":0,"title":["Continuous Production\nof Mesoporous Silica with Controlled\nStructure via Aerosol-Assisted Evaporation-Induced Self-Assembly"],"prefix":"10.1021","volume":"3","author":[{"given":"Ibrahim A.","family":"Alnutaifi","sequence":"first","affiliation":[{"name":"University College London , , ,","place":["London, United Kingdom, WC1E 7JE"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Nidhi","family":"Kapil","sequence":"additional","affiliation":[{"name":"University College London , , ,","place":["London, United Kingdom, WC1E 7JE"]}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-1810-2537","authenticated-orcid":true,"given":"Marc-Olivier","family":"Coppens","sequence":"additional","affiliation":[{"name":"University College London , , ,","place":["London, United Kingdom, WC1E 7JE"]}],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"316","published-online":{"date-parts":[[2026,6,22]]},"reference":[{"issue":"2\u20133","key":"2026092407081017000_cit1","doi-asserted-by":"publisher","first-page":"1248","DOI":"10.1016\/j.matchemphys.2010.08.066","article-title":"Synthesis and surface characterization of ordered mesoporous silica\nSBA-15","volume":"124","author":"Kokunesoski","year":"2010","journal-title":"Mater. 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Porous Mater."},{"issue":"20","key":"2026092407081017000_cit4","doi-asserted-by":"publisher","first-page":"2400091","DOI":"10.1002\/adom.202400091","article-title":"Luminescence\nof lanthanide complexes\nin mesoporous silica matrices: A textbook example of tris-dipicolinate\neuropium complex adsorbed in SBA-15","volume":"12","author":"Balogh","year":"2024","journal-title":"Adv. Opt.\nMater."},{"issue":"7","key":"2026092407081017000_cit5","doi-asserted-by":"publisher","first-page":"3724","DOI":"10.1007\/s10562-023-04515-8","article-title":"Hydrogen production\nby hydrogen sulfide\ndecomposition using cobalt catalysts doped in SBA-15 synthetized by\nEISA method","volume":"154","author":"Aguilar-Garci\u0301a","year":"2024","journal-title":"Catal. 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