Nanoparticle synthesis at high production rates by flame spray pyrolysis

Scaling-up of nanoparticle synthesis by the versatile flame spray pyrolysis process at production rates up to is investigated. Product silica powder is collected continuously in a baghouse filter unit which is cleaned periodically by air-pressure shocks. The effect of powder production rate, dispersion gas flow rate and precursor (hexamethyldisiloxane, HMDSO) concentration on product particle size, morphology and carbon content is investigated. Droplet size distributions of the cold spray are measured by laser diffraction, while N₂ adsorption (BET), transmission electron microscopy and thermogravimetric analysis coupled with a mass spectrometer are employed to characterize the product powder. The product primary particle size was precisely controlled from 10 to and compared to a well-established vapor-fed flame aerosol reactor.     

Structural and luminescence properties of undoped,Nd3+ and Er3+ doped TiO2 nanoparticles synthesized by flame spray pyrolysis method

Bulk and thin film forms of titanium dioxide (TiO₂) have been studied many times due to its very promising optical properties. In this study, low-cost flame spray pyrolysis (FSP) synthesis of Nd³⁺/Er³⁺doped TiO₂ nanoparticles has been reported for the first time. The produced particles were post-annealed after FSP process at 550 °C in order to obtain crystalline structure. The phase and elemental analysis of the produced materials were performed by X-Ray Diffraction (XRD) and X-Ray Photoelectron Spectroscopy (XPS), respectively. The surface morphology, accurate size and specific surface area of the primary particles were identified using scanning electron microscopy (SEM) and particle size analyser. Luminescent properties of the produced nanoparticles were investigated by steady state and time resolved fluorescence spectra. Doping of TiO₂ nanoparticles with the rare earths of Nd³⁺and Er³⁺resulted in visible and near-infrared light emission when excited at 364 nm. The utilized nanoparticles yielded bi-and tri-exponential decay curves. Additionally, they exhibited typical upconversion luminescence when radiated by 810 nm.     

Synthesis of ZnO nanoparticles by an aerosol process

Spherical nano-sized zinc oxide (ZnO) particles were produced by a spray pyrolysis method using the aerosol technique described in this study. The effects of reaction temperatures of 600, 800 and 1000 °C and collection locations of the particles, such as the flask collector and the tube exit, on the morphology and crystal structure of the ZnO particles were investigated. X-ray diffraction (XRD) studies showed that the crystallinity of the particles was increased by increasing the reaction temperature from 600 °C to 1000 °C. Fourier transform infrared spectroscopy (FTIR) measurements revealed that the particles were pure and similar to each other. Scanning electron microscopy (SEM) revealed that the synthesized nanoparticles had sizes between 200 nm and 400 nm, with uniform morphologies. A computational fluid dynamics (CFD) model of the horizontally positioned tube reactor was developed. Simulation results provided information about the residence time and the temperature distribution along the tube, which were found to be correlated to the particle morphology.     

Synthesis of TiO2 microspheres by ultrasonic spray pyrolysis and photocatalytic activity evaluation

This work presents and discusses TiO₂ microspheres synthesized by ultrasonic spray pyrolysis. A simple setup allowed for the continuous production of TiO₂ nanocrystals. During the process, the particles experienced a short residence time (ca. 40 s) at the set temperature (700 °C), promoting phase stability and limited particle coarsening. As a result, porous anatase TiO₂ microspheres with crystallite size ～8 nm and specific surface area ～27 m² g^-1 were produced as soft spherical agglomerates of ～0.6 μm. Samples were analyzed using X-ray diffraction, BET specific surface area, SEM, TEM, XPS, and UV/Vis diffuse reflectance spectra, as well as in their photocatalytic activities. Photoactivity was evaluated through the degradation of the model contaminant acetaminophen under UV irradiation, and the results confirmed the superior performance of the synthesized TiO₂ microspheres, exceeding the commercial standard TiO₂ P25 by ca. 60% in terms of reactivity.     

Effects of Co dopants and flame conditions on the formation of Co/ZrO2 nanoparticles by flame spray pyrolysis and their catalytic properties in CO hydrogenation

The Co/ZrO₂ catalysts with various Co loadings (5–10 wt.%) were prepared by one-step flame spray pyrolysis (FSP) under different flame conditions. As revealed by XRD and TEM, all the resulting Co/ZrO₂ nanoparticles were composed of single-crystalline particles exhibiting the characteristic tetragonal structure of ZrO₂. Varying the amount of Co dopants during FSP synthesis did not alter the primary particle size of ZrO₂ which was determined to be ca. 14 nm. On the other hand, increasing precursor feed rate from 3 to 8 ml/min resulted in an increase of ZrO₂ crystallite size from 10 to 19 nm. The higher precursor feed rate produced higher enthalpy of flame and longer residence times, which increased coalescence and sintering of the particles. Compared to the Co/ZrO₂ prepared by conventional impregnation method, the catalytic activities of the FSP-made catalysts were much higher. Moreover, the hydrogenation rates of the FSP-made Co/ZrO₂ catalysts were increased with increasing Co loading and precursor feed rate. According to H₂ chemisorption and H₂ temperature program reduction results, the improvement of catalytic activity and C₂–C₆ selectivities of the FSP-made catalysts in the CO hydrogenation was attributed to the higher number of Co metal active sites and lower interaction between Co/CoO and ZrO₂ support obtained via the FSP synthesis.     

Solvent nature effect in preparation of perovskites by flame pyrolysis: 2. Alcohols and alcohols + propionic acid mixtures

The effect of either pure alcohols or alcohols + propionic acid mixtures as solvents for the preparation by flame pyrolysis of a standard LaCoO₃ catalyst, to be employed for the catalytic flameless combustion of methane, has been investigated. All the catalysts proved very active for the mentioned reaction. Low-MW pure alcohols showed however less suitable than alcohols-propionic acid mixtures, leading to lower perovskite phase purity, less particle size homogeneity and lower specific surface area. The high volatility of the solvent seems to be the major cause, together with the improper behaviour of nitrates (forced by solubility reasons) as perovskite metals precursors. However, the addition of propionic acid to the alcohols allowed to use the acetates as precursors and hence to obtain high perovskitic phase purity, high SSA and uniform particle size. Moreover, the increase of combustion enthalpy of the solvent, through the addition of higher-MW alcohols, leading to progressively higher flame temperature, strongly improved the thermal resistance of the catalyst, without lowering catalytic performance.     

Synthesis of nanosized vanadium pentoxide/carbon composites by spray pyrolysis for electrochemical capacitor application

Nanostructured vanadium pentoxide/carbon (V₂O₅/carbon) composite powders with enhanced specific capacitance were synthesized by the spray pyrolysis technique. Electrochemical properties were examined by the cyclic voltammetry technique. Following analysis of powders sprayed at different temperatures, composite powders obtained at an optimum temperature of 450 °C yielded a maximum specific capacitance of 295 F g⁻¹ in 2 M KCl electrolyte at a 5-mV s⁻¹ scan rate. The weight percentage of carbon-related species was 2.7 wt% in this V₂O₅/carbon composite, as detected by thermogravimetric analysis (TGA) and confirmed by transmission electron microscope energy dispersive spectroscopy (TEM-EDS) analysis. Following initial X-ray diffraction (XRD) characterization, scanning electron microscope (SEM), TEM and high-resolution TEM (HRTEM) imaging revealed a specific morphology of spherical shell agglomerates of V₂O₅ nanorods and nanoribbons, with each shell comprising a network of these one- and two-dimensional nanoparticles in an amorphous carbon matrix. The V₂O₅ network was not fully dense, and the majority of the nanorod sizes were in the range of 50-150 nm, with additional long nanoribbons extending from the outsides of the spherical shells. The specific surface area was 18 m² g⁻¹ for the composite powders, and the pore size distribution revealed that the majority of pores had diameters in the range of 40-50 Å, which was relatively larger than the pore diameters obtained at 500 °C and would be beneficial for electrochemical performance. The enhancement of the specific capacitance in V₂O₅/carbon composites was attributed to the distribution of amorphous carbon throughout the V₂O₅ and the particular open nanostructure.     

Preparation and characterization of CeO2/TiO2 nanoparticles by flame spray pyrolysis

Nanocrystalline TiO₂, CeO₂ and CeO₂-doped TiO₂ have been successfully prepared by one-step flame spray pyrolysis (FSP). Resulting powders were characterized with X-ray diffraction (XRD), N₂-physisorption, Transmission Electron Microscopy (TEM) and UV-Vis spectrophotometry. The TiO₂ and CeO₂-doped TiO₂ nanopowders were composed of single-crystalline spherical particles with as-prepared primary particle size of 10-13 nm for Ce doping concentrations of 5-50 at%, while square-shape particles with average size around 9 nm were only observed from flame-made CeO₂. The adsorption edge of resulting powder was shifted from 388 to 467 nm as the Ce content increased from 0 to 30 at% and there was an optimal Ce content in association with the maximum absorbance. This effect is due to the insertion of Ce^3+/4+ in the TiO₂ matrix, which generated an n-type impurity band.     

Influence of flame conditions on the dispersion of Pd on the flame spray-derived Pd/TiO2 nanoparticles

The Pd/TiO₂ nanoparticles containing 5 wt.% Pd were synthesized by one-step flame spray pyrolysis (FSP) under different flame conditions. As revealed by both X-ray diffraction (XRD) and transmission electron microscopy (TEM) results, the average particle sizes of Pd/TiO₂ were increased from 9.7 to 24.6 nm with increasing the precursor concentration and the feed flow rate as well as reduction of the O₂ dispersing gas during FSP synthesis. Although the BET surface area and %anatase phase content were decreased with increasing Pd/TiO₂ particle size, %Pd dispersion as determined from the amounts of CO chemisorption were higher on the larger size FSP-made Pd/TiO₂ nanoparticles. It is suggested that the shorter residence time in flame and/or the lower combustion energy (enthalpy density) resulted in more coverage of Pd surface by the formation of Ti-O groups, rendering lower CO chemisorption ability of the smaller size Pd/TiO₂.     

Characteristics of samaria-doped ceria nanoparticles prepared by spray pyrolysis

Samaria-doped ceria (SDC) nanoparticles were prepared by spray pyrolysis. The means sizes of the samaria-doped ceria nanoparticles were controlled from 21 to 150 nm by changing the calcination temperatures between 700 and 1200 °C. The pellets formed from the SDC particles calcined at temperatures between 700 and 1000 °C had similar grain sizes between 0.75 and 0.82 μm. However, pellet formed from the SDC particles calcined at a temperature of 1200 °C had large grain size of 1.22 μm. The pellet formed from the SDC particles calcined at a temperature of 1000 °C had slightly smaller resistance of grain-boundary than those of the pellets formed from the SDC particles calcined at temperatures between 700 and 900 °C. However, the pellet formed from the SDC particles calcined at a temperature of 1200 °C had low resistance of grain-boundary. The pellet formed from the SDC particles calcined at a temperature of 1200 °C had conductivity of 44.65 × 10^?3 S cm^?1 at a measuring temperature of 700 °C that more twice than those of the pellets formed from the SDC calcined below 1000 °C.     

Photocatalytic plate-like La2Ti2O7 nanoparticles synthesized via liquid-feed flame spray pyrolysis (LF-FSP) of metallo-organic precursors

Nanoparticles (NPs) of a perovskite-slab-type oxide, La₂Ti₂O₇, were synthesized using LF-FSP coupled with subsequent heat treatments, and their photocatalytic activity was evaluated using decolorization of methyl orange solution under Uv irradiation. The LF-FSP process used metallo-organic precursors to produce NPs with very low agglomeration with average particle sizes (APSs) of 26 nm (LF-FSP NP). Optimized heat treatment of these NPs at 1000°C/3 h/air gave small, plate-like NPs with high crystallinity, and BET specific surface areas (SSAs) of 14 m²/g, that exhibited the best observed photocatalytic activity. High-angle annular dark-field scanning TEM showed that heat-treating eliminates microstructural defects in these NPs, improving photocatalytic activity by ≈30%. The current approach to perovskite-slab-type NPs using LF-FSP provides a simple route to materials with superior photocatalytic activity and offers the advantage of good productivity, 30 g/h.     

Synthesis of NiO-YSZ composite particles for an electrode of solid oxide fuel cells by spray pyrolysis

NiO-YSZ (YSZ: Y₂O₃-stabilized ZrO₂) composite particles for a Ni-YSZ cermet anode in solid oxide fuel cells (SOFCs) were synthesized via spray pyrolysis (SP). The formation mechanism of the composite particles by this process was analyzed. The internal microstructure of the particles synthesized during SP processing was observed at each heating temperature of 200, 300, 400 and 1000 °C, and then the formation mechanism of the composite structure was discussed. As a result, it was found that NiO-YSZ composite particles were formed through the following steps. Firstly, during the evaporation stage up to 200 °C, a filled particle with Ni(CH₃COO)₂ and YSZ fine grains were formed from the atomized droplet containing Ni ion and dispersed YSZ sol by volume precipitation. Secondly, during the continuous thermolysis stage up to 400 °C, YSZ grains were formed and moved to the surface of the composite particle by the outgas and the oxidation of Ni(CH₃COO)₂. Finally, the NiO-YSZ composite particle that has NiO grains uniformly covered with fine YSZ grains was formed after the final sintering stage up to 1000 °C.     

Firing characteristics of size-controlled silver-glass composite powders prepared by spray pyrolysis

Size-controlled spherical silver-glass composite powders were directly prepared by using spray pyrolysis. The mean sizes of the composite powders changed from 0.34 to 0.78 μm when the concentration of the spray solution was changed from 0.05 to 2 M. The firing characteristics of composite powders formed from the spray solutions with a glass content equal to 3 wt.% of the silver component were affected by the mean sizes of the powders. Silver-conducting films formed from large-sized composite powders had a denser structure than those formed from small-sized composite powders. Further, silver-conducting films formed from composite powders with a mean size of 0.78 μm had specific resistances of 3 and 2 μΩ cm at firing temperatures of 450 and 500 °C. However, silver-conducting films formed from composite powders with a mean size of 0.34 μm had specific resistances of 8.2 and 6.9 μΩ cm at firing temperatures of 450 and 500 °C.     

Synthesis of nanocrystalline TaC powders via single-step high temperature spray pyrolysis from solution precursors

Nanocrystalline powders for high temperature ceramics (HTC) and ultrahigh temperature ceramics (UHTC) are important materials for aerospace and other important industrial applications. In this study, a low cost, single-step synthesis method for nanocrystalline HTC and UHTC powders is reported, which is based on high temperature spray pyrolysis (HTSP) process. The synthesis starts with solution of oxide and carbon precursors dissolved in common organic solvents, which are broken into fine droplets (e.g., via nebulizer). The droplets then go through processes of solvent removal, thermolysis, and rapid in situ carbothermal reduction (CTR), all in one single pass in a tube furnace operated at high temperature. The synthesis method was demonstrated successfully using the example of tantalum carbide (TaC) from precursors of tantalum chloride (TaCl₅) and phenolic resin in a single-step HTSP process with maximum temperature of 1650 °C in one pass that finished within minutes, yielding agglomerated nanocrystalline TaC UHTC powders.     

Characterization of surface-modified ceria oxide nanoparticles synthesized continuously in supercritical methanol

Surface-modified ceria oxide (CeO₂) nanoparticles were synthesized continuously in supercritical methanol at 400 °C, 30 MPa and a residence time of 40 s using a flow type reactor system. Oleic acid and decanoic acid were used as the surface modifiers. Transmission electron microscopy (TEM) showed that the surface modifiers changed drastically the shape and size of the nanoparticles. When 0.3 M of the surface modifiers were used, primary particles with diameter of 2–3 nm loosely aggregated and formed secondary particles with size of 30–50 nm. Wide angle X-ray diffraction (WAXD) analysis revealed that the surface-modified nanoparticles retained CeO₂ crystalline structure. The surface-modified CeO₂ nanoparticles had a very high surface area (140–193 m²/g) compared to the unmodified CeO₂ particles synthesized in supercritical water (8.5 m²/g). Fourier transform infrared (FT-IR) and thermogravimetric analysis (TGA) indicated that aliphatic, carboxylate and hydroxyl groups were chemically bounded on the surface of CeO₂ nanoparticles. Dispersability test using ultraviolet transmittance showed that most of the surface-modified CeO₂ nanoparticles were dispersed in ethylene glycol for 30 days while the unmodified CeO₂ particles synthesized in supercritical water or in supercritical methanol were precipitated after 7–15 days.     

Highly-dispersible boron nitride nanoparticles by spray drying and pyrolysis

A spray drying and pyrolysis synthesis route was developed and it successfully prepared boron nitride (BN) nanoparticles with high dispersivity. During the experiment, the extremely rapid drying of the boric acid/urea solution during the spray-drying process resulted in the formation of homogeneous precursors, which was the key for the final pyrolysis synthesis of BN nanoparticles with high dispersibility and uniform diameters (~20 nm). Compared with boron nitride synthesized without using spray drying, the as-prepared BN nanoparticles possess higher specific surface area (145.01 m² g⁻¹) and larger pore volume (0.41 cm³ g⁻¹). Especially, we used the BN nanoparticles as lubricant and incorporated it into the liquid paraffin (LP). The experiment results show that the LP presents outstanding antifriction properties for a BN content of 1.5 wt%. These results suggest that the h-BN nanoparticles have significant potential applications in the field of tribology.     

Characterization of luminescent SrAl2O4 films doped with terbium and europium ions deposited by ultrasonic spray pyrolysis technique

SrAl₂O₄, SrAl₂O₄:Tb³⁺ and SrAl₂O₄:Eu³⁺:Eu²⁺ films were synthesized by means of the ultrasonic spray pyrolysis technique. These samples, characterized by X-Ray Diffraction, showed the monoclinic phase of the strontium aluminate. Images of the surface morphology of these films were obtained by SEM and the chemical composition was measured by EDS and XPS. The photoluminescence and cathodoluminescence characteristics of the films were studied as a function of the terbium and europium concentrations. The optimal PL emission intensities were reached at 8?at% for terbium doped films and 6?at% for europium doped samples. The CL emission spectra for europium doped films showed the typical bands of Eu³⁺ ions and also a broadband centered at 525?nm which is attributed to Eu²⁺ ions. XPS measurements confirm the presence of Eu³⁺ and Eu²⁺ in europium doped SrAl₂O₄ films, without having been subjected to a reducing atmosphere. Chromatic diagrams exhibited green color for SrAl₂O₄:Tb³⁺ films, red and yellow colors for SrAl₂O₄:Eu³⁺:Eu²⁺ films. The PL decay curves were also obtained: the averaged decay time was 2.7?ms for SrAl₂O₄:Tb³⁺ films and 1.9?ms for SrAl₂O₄:Eu³⁺ films. Similar results were obtained by the stretched exponential model.     

Morphological and electrochemical properties of LiV3O8 cathode powders prepared by spray pyrolysis

Lithium trivanadate (LiV₃O₈) powders are prepared by spray pyrolysis. The precursor powders of LiV₃O₈ obtained by spray pyrolysis have spherical and rod-like morphologies. The LiV₃O₈ powders post-treated at 300 °C and 400 °C also have spherical and rod-like morphologies. However, the LiV₃O₈ cathode powders post-treated at 500 °C consist of only rod-like crystals. The crystalline structure of the precursor powders that were directly prepared by spray pyrolysis comprised of LiV₃O₈ layers along with a small amount of β-Li_0.33V₂O₅ impurity. The peak due to β-Li_0.33V₂O₅ persisted in the XRD spectrum even after post-treatment at 300 °C. On the other hand, crystalline structures of the powders post-treated at 400 °C and 500 °C comprised pure LiV₃O₈ layers. The initial discharge capacities of the LiV₃O₈ cathode powders decrease from 344 mAh g⁻¹ to 261 mAh g⁻¹ when the post-treatment temperatures increase from 300 °C to 500 °C. The discharge capacities of the LiV₃O₈ cathode powders obtained after post-treatment at 400 °C and 500 °C are approximately 255 mAh g⁻¹ and 236 mAh g⁻¹, respectively, after 40 cycles.     

火焰喷雾热解法制备纳米晶镁铝尖晶石粉

以硝酸镁和硝酸铝(均为分析纯)混合物(其中Mg与Al的摩尔比为1∶2)为溶质,不同体积比的蒸馏水和乙醇为溶剂(其体积比分别为3∶2,1∶1,2∶3),制备成Mg2 浓度分别为0.1 mol.L-1、0.3 mol.L-1和0.5 mol.L-1的前驱物溶液,置于密闭容器内,分别在不同的容器压力(0.1 MPa,0.2 MPa,0.3 MPa,0.4 MPa)下用火焰喷雾热解法合成纳米晶镁铝尖晶石,借助XRD、SEM和激光粒度分析仪研究了乙醇和水的体积比、溶液浓度和容器压力对合成镁铝尖晶石粉的产量和形貌的影响。研究结果表明:合成粉末的颗粒尺寸和晶粒尺寸都随乙醇和水比值的减小而增加,其晶粒尺寸随前驱物溶液浓度的增加先减小后增大,随容器压力的变化很小,但随着压力的增加,合成粉末的团聚体增多、增大,产量明显增大。综合考虑认为,本试验的最佳合成条件是前驱物溶液中Mg2 浓度0.3 mol.L-1,乙醇和水的体积比3∶2,容器压力0.3 MPa,此时得到的合成尖晶石粉末几乎都为球形,但粒度分布范围较宽。     

Realization of Eu-doped p-SnO2 thin film by spray pyrolysis deposition

We report the fabrication of p-SnO₂ thin films by spray pyrolysis deposition using europium (Eu) as an acceptor. Structural and chemical investigations verified that Eu³⁺ ions were successfully incorporated into the SnO₂ crystal by substituting the Sn⁴⁺ sites in the lattice. Even though the undoped SnO₂ thin film showed n-type properties with a charge carrier concentration of −2.343 × 10¹⁸ cm⁻³, SnO₂ showed p-type properties as the Eu was incorporated. In addition, the charge carrier concentration of the Eu-doped SnO₂ increased to 9.121 × 10¹⁹ cm⁻³ as the molar content of the Eu source was increased to 0.2 mM. The optical transmittance was not degraded by the Eu doping and was maintained between 70 and 80% in the visible wavelength spectral range, while the optical band gap of the Eu-doped SnO₂ increased due to the Burstein-Moss effect. The thin film field-effect transistor fabricated by using the Eu-doped SnO₂ showed the typical gate-modulated drain current characteristic of a p-channel transistor with depletion mode. These results demonstrated the effectiveness of Eu as a dopant for p-SnO₂.