Nanoparticle evolution in flame spray pyrolysis—Process design via experimental and computational analysis

Protein Aggregation on Metal Oxides Governs Catalytic Activity and Cellular Uptake

Engineering of catalytically active inorganic nanomaterials holds promising prospects for biomedicine. Catalytically active metal oxides show applications in enhancing wound healing but have also been employed to induce cell death in photodynamic or radiation therapy. Upon introduction into a biological system, nanomaterials are exposed to complex fluids, causing interaction and adsorption of ions and proteins. While protein corona formation on nanomaterials is acknowledged, its modulation of nanomaterial catalytic efficacy is less understood. In this study, proteomic analyses and nano-analytic methodologies quantify and characterize adsorbed proteins, correlating this protein layer with metal oxide catalytic activity in vitro and in vivo. The protein corona comprises up to 280 different proteins, constituting up to 38% by weight. Enhanced complement factors and other opsonins on nanocatalyst surfaces lead to their uptake into macrophages when applied topically, localizing >99% of the nanomaterials in tissue-resident macrophages. Initially, the formation of the protein corona significantly reduces the nanocatalysts' activity, but this activity can be partially recovered in endosomal conditions due to the proteolytic degradation of the corona. Overall, the research reveals the complex relationship between physisorbed proteins and the catalytic characteristics of specific metal oxide nanoparticles, providing design parameters for optimizing nanocatalysts in complex biological environments.

Prevention of uropathogenic E. coli biofilm formation by hydrophobic nanoparticle coatings on polymeric substrates

Biofilms in infections are a major health-care challenge and strategies to reduce their formation on medical devices are crucial. Fabrication of superhydrophobic coatings based on hydrocarbon adsorption on rare-earth oxides constitutes an attractive strategy, but their capacity to prevent biofilm formation has not been studied. Here, we explore a scalable and reproducible nanofabrication process for the manufacture of such superhydrophobic coatings and study their antibiofilm activity against clinically-relevant uropathogenic E. coli. These coatings reduce bacterial biofilm formation and prevent biofouling with potential applications preventing medical device related infections.

Low-nuclearity CuZn ensembles on ZnZrOx catalyze methanol synthesis from CO2

Metal promotion could unlock high performance in zinc-zirconium catalysts, ZnZrOx, for CO2 hydrogenation to methanol. Still, with most efforts devoted to costly palladium, the optimal metal choice and necessary atomic-level architecture remain unclear. Herein, we investigate the promotion of ZnZrOx catalysts with small amounts (0.5 mol%) of diverse hydrogenation metals (Re, Co, Au, Ni, Rh, Ag, Ir, Ru, Pt, Pd, and Cu) prepared via a standardized flame spray pyrolysis approach. Cu emerges as the most effective promoter, doubling methanol productivity. Operando X-ray absorption, infrared, and electron paramagnetic resonance spectroscopic analyses and density functional theory simulations reveal that Cu0 species form Zn-rich low-nuclearity CuZn clusters on the ZrO2 surface during reaction, which correlates with the generation of oxygen vacancies in their vicinity. Mechanistic studies demonstrate that this catalytic ensemble promotes the rapid hydrogenation of intermediate formate into methanol while effectively suppressing CO production, showcasing the potential of low-nuclearity metal ensembles in CO2-based methanol synthesis.

Size of cerium dioxide support nanocrystals dictates reactivity of highly dispersed palladium catalysts

The catalytic performance of heterogeneous catalysts can be tuned by modulation of the size and structure of supported transition metals, which are typically regarded as the active sites. In single-atom metal catalysts, the support itself can strongly affect the catalytic properties. Here, we demonstrate that the size of cerium dioxide (CeO₂) support governs the reactivity of atomically dispersed palladium (Pd) in carbon monoxide (CO) oxidation. Catalysts with small CeO₂ nanocrystals (~4 nanometers) exhibit unusually high activity in a CO-rich reaction feed, whereas catalysts with medium-size CeO₂ (~8 nanometers) are preferred for lean conditions. Detailed spectroscopic investigations reveal support size-dependent redox properties of the Pd-CeO₂ interface.

Advances in Multifunctional Bioactive Coatings for Metallic Bone Implants

To fix the bone in orthopedics, it is almost always necessary to use implants. Metals provide the needed physical and mechanical properties for load-bearing applications. Although widely used as biomedical materials for the replacement of hard tissue, metallic implants still confront challenges, among which the foremost is their low biocompatibility. Some of them also suffer from excessive wear, low corrosion resistance, infections and shielding stress. To address these issues, various coatings have been applied to enhance their in vitro and in vivo performance. When merged with the beneficial properties of various bio-ceramic or polymer coatings remarkable bioactive, osteogenic, antibacterial, or biodegradable composite implants can be created. In this review, bioactive and high-performance coatings for metallic bone implants are systematically reviewed and their biocompatibility is discussed. Updates in coating materials and formulations for metallic implants, as well as their production routes, have been provided. The ways of improving the bioactive coating performance by incorporating bioactive moieties such as growth factors, osteogenic factors, immunomodulatory factors, antibiotics, or other drugs that are locally released in a controlled manner have also been addressed.

Flame Spray Pyrolysis Synthesis of WO3 Sensing Materials: Effects of Flame Parameters on Particle Size Distribution and NO2 Sensing Performance

In this study, the flame spray pyrolysis (FSP) technique was employed to produce WO₃ nanoparticles, which were subsequently used as sensing materials for NO₂ sensors. To enhance the sensing performance, the effects of flame parameters on the particle properties and sensing performances for 150-1200 ppb NO₂ at 125 °C were investigated. The results indicate that WO₃ particles with an average crystal size of about 10-20 nm and a standard deviation of about 3-7.5 nm were generated by controlling the precursor and dispersion oxygen flow rate of FSP. Based on the evaluation of NO₂ sensing performance, WO₃ sensing materials synthesized under the 3/5 flame condition exhibited better sensitivity than sensors made under other flame conditions. In summary, the FSP method and the optimization of flame synthesis parameters could be an effective strategy to prepare the sensing materials with high sensing performance.

Highly Efficient Near-IR Photothermal Microneedles with Flame-Made Plasmonic Nanoaggregates for Reduced Intradermal Nanoparticle Deposition

Near-infrared (NIR) photothermal therapy by microneedles (MNs) exhibits high potential against skin diseases. However, high costs, photobleaching of organic agents, low long-term stability, and potential nanotoxicity limit the clinical translation of photothermal MNs. Here, photothermal MNs are developed by utilizing Au nanoaggregates made by flame aerosol technology and incorporated in water-insoluble polymer matrix to reduce intradermal nanoparticle (NP) deposition. The individual Au interparticle distance and plasmonic coupling within the nanoaggregates are controlled by the addition of a spacer during their synthesis rendering the Au nanoaggregates highly efficient NIR photothermal agents. In situ aerosol deposition of Au nanoaggregates on MN molds results in the fabrication of photothermal MNs with thin plasmonic layers. The photothermal performance of these MN arrays is compared to ones made by three methods utilizing NP dispersions, and it is found that similar temperatures are reached with 28-fold lower Au mass due to reduced light scattering losses of the thin layers. Finally, all developed photothermal MN arrays here cause clinically relevant hyperthermia at benign laser intensities while reducing intradermal NP deposition 127-fold compared to conventional MNs made with water-soluble polymers. Such rational design of photothermal MNs requiring low laser intensities and minimal NP intradermal accumulation sets the basis for their safe clinical translation.

Flame-made ternary Pd-In2O3-ZrO2 catalyst with enhanced oxygen vacancy generation for CO2 hydrogenation to methanol

Palladium promotion and deposition on monoclinic zirconia are effective strategies to boost the performance of bulk In₂O₃ in CO₂-to-methanol and could unlock superior reactivity if well integrated into a single catalytic system. However, harnessing synergic effects of the individual components is crucial and very challenging as it requires precise control over their assembly. Herein, we present ternary Pd-In₂O₃-ZrO₂ catalysts prepared by flame spray pyrolysis (FSP) with remarkable methanol productivity and improved metal utilization, surpassing their binary counterparts. Unlike established impregnation and co-precipitation methods, FSP produces materials combining low-nuclearity palladium species associated with In₂O₃ monolayers highly dispersed on the ZrO₂ carrier, whose surface partially transforms from a tetragonal into a monoclinic-like structure upon reaction. A pioneering protocol developed to quantify oxygen vacancies using in situ electron paramagnetic resonance spectroscopy reveals their enhanced generation because of this unique catalyst architecture, thereby rationalizing its high and sustained methanol productivity.

Assembling multicomponent catalysts to harness synergic effects is challenging. Now, flame spray pyrolysis permits the synthesis of ternary Pd-In₂O₃-ZrO₂ catalysts with an optimal architecture and an enriched density of oxygen vacancies for maximal performance in CO₂-based methanol synthesis.

Investigating spray flames for nanoparticle synthesis via tomographic imaging using multi-simultaneous measurements (TIMes) of emission

Tomographic imaging using multi-simultaneous measurements (TIMes) of spontaneous light emission was performed on various operating conditions of the SpraySyn burner to analyse the flame morphology and its potential impact on spray flame pyrolysis. Concurrent instantaneous and time-averaged three-dimensional measurements of CH* chemiluminescence (flame front indicator) and atomic Na emission from NaCl dissolved in the injected combustible liquid (related to hot burnt products of the spray flame) were reconstructed employing a 29-camera setup. Overlapping regions of CH* and Na are presented using isosurface visualisation, local correlation coefficient fields and joint probability distributions. The instantaneous results reveal the complex nature of the reacting flow and regions of interaction between the flame front with the hot gases that originate from the spray stream. The averaged reconstructions show that the spray flames tested are slightly asymmetric near the burner exit but develop into symmetric bell-shaped distributions at downstream locations. The changes in the flame structure for different operating conditions are analysed in light of previous studies, helping in the better understanding of the nanoparticle synthesis process. Furthermore, the importance of using measurements from two views for significantly improved alignment of the burner based on the originally proposed procedure are discussed in light of the reconstructions. This is an important aspect since the SpraySyn is intended for use as a well-defined standardised burner for nanoparticle synthesis, which is being investigated numerically and experimentally across different research groups.

Modeling and Parameterization of the Evaporation and Thermal Decomposition of an Iron(III) Nitrate Nonahydrate/Ethanol Droplet for Flame Spray Pyrolysis

Flame spray pyrolysis (FSP) is a promising approach to generate nanoparticles from precursor solutions, where the convective droplet heating and evaporation of the single precursor solution droplet play a key role. Depending on the precursor solution under consideration, reactions inside the liquid may occur. The present numerical study concerns the heating, evaporation, and thermal decomposition of single droplets of iron(III) nitrate nonahydrate (INN) and ethanol at an initial temperature of 293.15 K in hot convective air at atmospheric pressure. If the ambience is below the thermal decomposition temperature (Tth) of the INN, iron nitrate particles are directly formed inside the particle, whereas at ambient temperatures beyond Tth, the iron nitrate thermally decomposes into gaseous Fe2O3 and N2O5. Vaporization and thermal decomposition govern the process, depending on the droplet surface temperature. If the ambient temperature is larger than a specific value T+, thermal decomposition is very fast and vaporization dominates the total process time, whereas at lower ambient temperatures, the vaporization is slower, which causes a lower final droplet surface temperature, leading to considerably longer thermal decomposition, which dominates the total process time under that condition. The ambient temperature at which this reversed behavior occurs depends on initial INN loading of the particle and the relative velocity but is largely independent of the initial droplet size. These new results are very useful in choosing the process temperature, which is recommended to lie beyond the ambient air temperature of T+ to assure that the total process time is kept short. The numerical results are parameterized for use in more complex simulations of FSP.

Characterization of Fractal Structures by Spray Flame Synthesis Using X-ray Scattering

In this work, we take on an in-depth characterization of the complex particle structures made by spray flame synthesis. Because of the resulting hierarchical aggregates, very few measurement techniques are available to analyze their primary particle and fractal properties. Therefore, we use small-angle X-ray scattering (SAXS) and transmission electron microscopy (TEM) to investigate the influence of the precursor concentration on the fractal structures of zirconia nanoparticles. The combination of information gained from these measurement results leads to a detailed description of the particle system, including the polydispersity and size distribution of the primary particles. Based on our findings, unstable process conditions could be identified at low precursor concentrations resulting in the broadest size distribution of primary particles with rough surfaces. Higher precursor concentrations lead to reproducible primary particle sizes almost independent of the initial precursor concentration. Regarding the fractal properties, the typical shape of aggregates for aerosols is present for the investigated range of precursor concentrations. In conclusion, the consistent results for SAXS and TEM show a conclusive characterization of a complex particle system, allowing for the identification of the underlying particle formation mechanism.

Toward the Continuous Production of Multigram Quantities of Highly Uniform Supported Metallic Nanoparticles and Their Application for Synthesis of Superior Intermetallic Pt-Alloy ORR Electrocatalysts

A fast and facile pulse combustion (PC) method that allows for the continuous production of multigram quantities of high-metal-loaded and highly uniform supported metallic nanoparticles (SMNPs) is presented. Namely, various metal on carbon (M/C) composites have been prepared by using only three feedstock components: water, metal-salt, and the supporting material. The present approach can be elegantly utilized also for numerous other applications in electrocatalysis, heterogeneous catalysis, and sensors. In this study, the PC-prepared M/C composites were used as metal precursors for the Pt NPs deposition using double passivation with the galvanic displacement method (DP method). Lastly, by using thin-film rotating disc electrode (TF-RDE) and gas-diffusion electrode (GDE) methodologies, we show that the synergistic effects of combining PC technology with the DP method enable production of superior intermetallic Pt-M electrocatalysts with an improved oxygen reduction reaction (ORR) performance when compared to a commercial Pt-Co electrocatalyst for proton exchange membrane fuel cells (PEMFCs) application.

Using In Situ Measurements to Experimentally Characterize TiO2 Nanoparticle Synthesis in a Turbulent Isopropyl Alcohol Flame

The objective of the present work is to show the potential of in situ measurements for the investigation of nanoparticles production in turbulent spray flames. This is achieved by considering multiple diagnostics to characterize the liquid break-up, the reactive flow and the particles production in a spray burner for TiO2 nanoparticle synthesis. The considered liquid fuel is a solution of isopropyl alcohol and titanium tetraisopropoxide (TTIP) precursor. Measurements show that shadowgraphy can be used to simultaneously localize spray and nanoparticles, light scattering allows to characterize the TiO2 nanoparticles distribution in the flame central plane, and spontaneous CH* and OH* chemiluminescences, as well as global light emission results, can be used to visualize the reactive flow patterns that may differ with and without injection of TTIP. Concerning the liquid, it is observed that it is localized in a small region close to the injector nozzle where it is dispersed by the oxygen flow resulting in droplets. The liquid droplets rapidly evaporate and TTIP is quasi-immediately converted to TiO2 nanoparticles. Finally, results show high interactions between nanoparticles and the turbulent eddies.

In Situ Determination of Droplet and Nanoparticle Size Distributions in Spray Flame Synthesis by Wide-Angle Light Scattering (WALS)

The investigation of droplet and nanoparticle formation in spray flame synthesis requires sophisticated measurement techniques, as often both are present simultaneously. Here, wide-angle light scattering (WALS) was applied to determine droplet and nanoparticle size distributions in spray flames from a standardized liquid-fed burner setup. Solvents of pure ethanol and a mixture of ethanol and titanium isopropoxide, incepting nanoparticle synthesis, were investigated. A novel method for the evaluation of scattering data from droplets between 2 µm and 50 µm was successfully implemented. Applying this, we could reveal the development of a bimodal droplet size distribution for the solvent/precursor system, probably induced by droplet micro-explosions. To determine nanoparticle size distributions, an appropriate filter and the averaging of single-shot data were applied to ensure scattering from a significant amount of nanoparticles homogeneously distributed in the measurement volume. From the multivariate analysis of the scattering data, the presence of spherical particles and fractal aggregates was derived, which was confirmed by analysis of transmission electron microscopy images. Monte Carlo simulations allowed determining the distribution parameters for both morphological fractions in three heights above the burner. The results showed relatively wide size distributions, especially for the spherical fraction, and indicated an ongoing sintering, from fractal to spherical particles.

Ultrafast Bubble Bursting by Superamphiphobic Coatings

Controlling bubble motion or passively bursting bubbles using solid interfaces is advantageous in numerous industrial applications including flotation, catalysis, electrochemical processes, and microfluidics. Current research has explored the formation, dissolution, pinning, and rupturing of bubbles on different surfaces. However, the ability to tune and control the rate of bubble bursting is not yet achieved. Scaling down surface-induced bubble bursting to just a few milliseconds is important for any application. In this work, the hierarchical structure of superamphiphobic surfaces is tuned in order to rapidly rupture contacting bubbles. Surfaces prepared using liquid flame spray show ultrafast bubble bursting (down to 2 ms) and superior durability. The coatings demonstrate excellent mechanical and chemical stability even in the presence of surface-active species. Air from the ruptured bubble is absorbed into the aerophilic Cassie-state. Long-term applicability is demonstrated by preventing the accumulation of air in the plastron via a connection of the plastron to the environment. The times recorded for bubble rupture and complete reorganization of air are reduced by approximately a factor of 3 compared to previously reported values. The concept is utilized to passively control surfactant-rich foam in froth flotation. Material collection efficiency increased by more than 60 times compared to controls.

Ultrafast Synthesis of High Entropy Oxide Nanoparticles by Flame Spray Pyrolysis

The synthesis of high entropy oxide (HEO) nanoparticles (NPs) possesses many challenges in terms of process complexity and cost, scalability, tailoring nanoparticle morphology, and rapid synthesis. Herein, we report the synthesis of novel single-phase solid solution (Mn, Fe, Ni, Cu, Zn)₃(O)₄ quinary HEO NPs produced by a flame spray pyrolysis route. The aberration-corrected scanning transmission electron microscopy (STEM) technique is utilized to investigate the spinel crystal structure of synthesized HEO NPs, and energy-dispersive X-ray spectroscopy analysis confirmed the high entropy configuration of five metal elements in their oxide form within a single HEO nanoparticle. Selected area electron diffraction, X-ray diffraction, and Raman spectroscopy analysis results are in accordance with STEM results, providing the key attributes of a spinel crystal structure of HEO NPs. X-ray photoelectron spectroscopy results provide the insightful understanding of chemical oxidation states of individual elements and their possible cation occupancy sites in the spinel-structured HEO NPs.

Fabrication of aerosol-based nanoparticles and their applications in biomedical fields

BACKGROUND

Traditionally, nanoparticles for biomedical applications have been produced via the classical wet chemistry method, with size control remaining a major problem in drug delivery. In recent years, advances in aerosol-based technologies have led to the development of methods that enable the production of nanosized particles and have opened up new opportunities in the field of nano-drug delivery and biomedicine. Aerosol-based technologies have been constantly used to synthesize multifunctional nanoparticles with different properties, which extends their possible biological and medicinal applications. Moreover, aerosol technologies are often more beneficial than other existing approaches because of the major disadvantages of these other techniques.

AREA COVERED

This review provides a brief discussion of the existing aerosol-based nanotechnologies and applications of nanoparticles in a variety of diseases. Various types of nanoparticles, such as graphene oxide, Prussian blue, black phosphorous, gold, copper, silver, tellurium, iron oxide, titania, magnesium oxide, and zinc oxide nanoparticles, prepared using aerosol technologies are discussed in this review. The different tactics used for surface modifications are also outlined. The biomedical applications of nanoparticles in chemotherapy, bacterial/fungal/viral treatment, disease diagnosis, and biological assays are also presented in this review.

EXPERT OPINION

Aerosol-based technologies can be used to design nanoparticles with the desired functionality. This significantly benefits the nanomedicine field, particularly as product parameters are becoming more encompassing and exacting. One of the biggest issues with conventional methods is their scale-up/scale-down and clinical translation. Aerosol-based nanoparticle synthesis helps enhance control over the product properties and facilitate their use for clinical applications.

Dual-Wavelength Excited Intense Red Upconversion Luminescence from Er3+-Sensitized Y2O3 Nanocrystals Fabricated by Spray Flame Synthesis

Er³⁺-sensitized upconversion nanoparticles (UCNPs) have attracted great attention due to their tunable upconversion (UC) emissions, low cytotoxicity, high resistance to photobleaching and especially multiple effective excitation wavelengths. However, detailed energy conversion between Er³⁺ and Tm³⁺ ions in Y₂O₃ UCNPs is still a problem, especially under multi-wavelength and variable pulse width excitation. In this work, we successfully fabricated a series of Er³⁺-sensitized Y₂O₃ nanocrystals by a spray flame synthesis method with a production rate of 40.5 g h⁻¹. The as-prepared UCNPs are a pure cubic phase with a mean size of 14 nm. Excited by both 980 and 808 nm lasers, the tunable upconversion luminescence (UCL) from Er³⁺ ions was achieved by increasing the Er³⁺ doping concentration, co-doping Tm³⁺ ions and extending excitation pulse-width. The investigations of the lifetimes and the laser power dependence of UC emissions further support the proposed mechanism, which provides guidance for achieving effective color control in anticounterfeiting and multiplexed labeling applications. In addition, the red UC emission at about 5 mm beneath the tissue surface was observed in an ex vivo imaging experiment under the excitation of 808 nm laser, indicating that the Y₂O₃:Er³⁺/Tm³⁺ UCNPs have great prospects in further biological applications.