SpraySyn-A standardized burner configuration for nanoparticle synthesis in spray flames

Spray-Flame Synthesis of NASICON-Type Rhombohedral (α) Li1+xYxZr2-x(PO4)3 [x = 0-0.2] Solid Electrolytes

Since solid electrolytes have a broad electrochemical stability window, are exceptionally electrochemically stable against Li metal, and function as a physical separator to prevent dendrite growth, they are at the forefront of alternate possibilities, further increasing the stability and energy density of Li-ion batteries. NASICON-type electrolytes are a promising candidate due to their negligible moisture sensitivity, which results in outstanding stability and a lower probability of Li2CO3 passivity under the ambient atmosphere. However, one of the most promising representatives, Li1+xYxZr2-x(PO4)3 (LYZP), has multiple stable phases with significant variation in their corresponding Li-ion conductivity. In this paper, we have successfully synthesized the highly ionically conductive rhombohedral phase of LYZP via spray-flame synthesis. Two different solvent mixtures (e.g., 2-ethyl hexanoic acid/ethanol, propanol/propanoic acid) were chosen to explore the effect of precursor composition and combustion enthalpy on the phase composition of the nanoparticle. The as-synthesized nanoparticles from spray-flame synthesis consisted of the crystalline tetragonal zirconia (t-ZrO2) phase, while lithium, yttrium, and phosphate were present on the nanoparticles' surface as amorphous phases. However, a short annealing step (1 h) was sufficient to obtain the NASICON phase. Moreover, we have shown the gradual phase conversion from orthorhombic β phase to rhombohedral α phase as the annealing temperature increased from 700 °C to 1300 °C (complete removal of β phase). In this context, Y3+ doping was also crucial, along with the appropriate solvent mixture and annealing temperature, for obtaining the much-desired rhombohedral α phase. Further, 0.2 at% Y3+ doping was added to the solvent mixture of 2-ethyl hexanoic acid/ethanol, and annealing at 1300 °C for 1 h resulted in a high ionic conductivity of 1.14∙10-5 S cm-1.

Titania/graphene nanocomposites from scalable gas-phase synthesis for high-capacity and high-stability sodium-ion battery anodes

In sodium-ion batteries (SIBs), TiO2or sodium titanates are discussed as cost-effective anode material. The use of ultrafine TiO2particles overcomes the effect of intrinsically low electronic and ionic conductivity that otherwise limits the electrochemical performance and thus its Na-ion storage capacity. Especially, TiO2nanoparticles integrated in a highly conductive, large surface-area, and stable graphene matrix can achieve an exceptional electrochemical rate performance, durability, and increase in capacity. We report the direct and scalable gas-phase synthesis of TiO2and graphene and their subsequent self-assembly to produce TiO2/graphene nanocomposites (TiO2/Gr). Transmission electron microscopy shows that the TiO2nanoparticles are uniformly distributed on the surface of the graphene nanosheets. TiO2/Gr nanocomposites with graphene loadings of 20 and 30 wt% were tested as anode in SIBs. With the outstanding electronic conductivity enhancement and a synergistic Na-ion storage effect at the interface of TiO2nanoparticles and graphene, nanocomposites with 30 wt% graphene exhibited particularly good electrochemical performance with a reversible capacity of 281 mAh g-1at 0.1 C, compared to pristine TiO2nanoparticles (155 mAh g-1). Moreover, the composite showed excellent high-rate performance of 158 mAh g-1at 20 C and a reversible capacity of 154 mAh g-1after 500 cycles at 10 C. Cyclic voltammetry showed that the Na-ion storage is dominated by surface and TiO2/Gr interface processes rather than slow, diffusion-controlled intercalation, explaining its outstanding rate performance. The synthesis route of these high-performing nanocomposites provides a highly promising strategy for the scalable production of advanced nanomaterials for SIBs.

Prediction of future breakthroughs in materials synthesis and manufacturing techniques: a new perspective of synthesis dynamics theory

The continuous development of different kinds of materials plays a significant role in social productivity. However, the lack of a complete synthesis kinetic theory has resulted in the absence of scientific guidance for the emergence of advanced manufacturing technologies, limiting the research and production of new types of materials. The present work aims at obtaining the basic form of the diffusion flux-driving force equation through the concept of ion diffusion so as to establish a synthesis kinetic theory. Using this theory, the scientific principles of existing synthesis technologies are summarized, and the key directions that future manufacturing technologies need to break through are proposed as well. Based on a comprehensive analysis of this theory, the feasible directions are discussed, providing strong support for the early realization of targeted design and manufacturing of new materials with specific functions.

Advanced Flame Spray Pyrolysis (FSP) Technologies for Engineering Multifunctional Nanostructures and Nanodevices

Flame spray pyrolysis (FSP) is an industrially scalable technology that enables the engineering of a wide range of metal-based nanomaterials with tailored properties nanoparticles. In the present review, we discuss the recent state-of-the-art advances in FSP technology with regard to nanostructure engineering as well as the FSP reactor setup designs. The challenges of in situ incorporation of nanoparticles into complex functional arrays are reviewed, underscoring FSP's transformative potential in next-generation nanodevice fabrication. Key areas of focus include the integration of FSP into the technology readiness level (TRL) for nanomaterials production, the FSP process design, and recent advancements in nanodevice development. With a comprehensive overview of engineering methodologies such as the oxygen-deficient process, double-nozzle configuration, and in situ coatings deposition, this review charts the trajectory of FSP from its foundational roots to its contemporary applications in intricate nanostructure and nanodevice synthesis.

Spray Flame Synthesis and Multiscale Characterization of Carbon Black-Silica Hetero-Aggregates

The increasing demand for lithium-ion batteries requires constant improvements in the areas of production and recycling to reduce their environmental impact. In this context, this work presents a method for structuring carbon black aggregates by adding colloidal silica via a spray flame with the goal of opening up more choices for polymeric binders. The main focus of this research lies in the multiscale characterization of the aggregate properties via small-angle X-ray scattering, analytical disc centrifugation and electron microscopy. The results show successful formation of sinter-bridges between silica and carbon black leading to an increase in hydrodynamic aggregate diameter from 201 nm to up to 357 nm, with no significant changes in primary particle properties. However, segregation and coalescence of silica particles was identified for higher mass ratios of silica to carbon black, resulting in a reduction in the homogeneity of the hetero-aggregates. This effect was particularly evident for silica particles with larger diameters of 60 nm. Consequently, optimal conditions for hetero-aggregation were identified at mass ratios below 1 and particle sizes around 10 nm, at which homogenous distributions of silica within the carbon black structure were achieved. The results emphasise the general applicability of hetero-aggregation via spray flames with possible applications as battery materials.

Ultrafast materials synthesis and manufacturing techniques for emerging energy and environmental applications

Energy and environmental issues have attracted increasing attention globally, where sustainability and low-carbon emissions are seriously considered and widely accepted by government officials. In response to this situation, the development of renewable energy and environmental technologies is urgently needed to complement the usage of traditional fossil fuels. While a big part of advancement in these technologies relies on materials innovations, new materials discovery is limited by sluggish conventional materials synthesis methods, greatly hindering the advancement of related technologies. To address this issue, this review introduces and comprehensively summarizes emerging ultrafast materials synthesis methods that could synthesize materials in times as short as nanoseconds, significantly improving research efficiency. We discuss the unique advantages of these methods, followed by how they benefit individual applications for renewable energy and the environment. We also highlight the scalability of ultrafast manufacturing towards their potential industrial utilization. Finally, we provide our perspectives on challenges and opportunities for the future development of ultrafast synthesis and manufacturing technologies. We anticipate that fertile opportunities exist not only for energy and the environment but also for many other applications.

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.

Liquid-Phase Cyclohexene Oxidation with O2 over Spray-Flame-Synthesized La1-x Srx CoO3 Perovskite Nanoparticles

La_1−xSr_xCoO₃ (x=0, 0.1, 0.2, 0.3, 0.4) nanoparticles were prepared by spray‐flame synthesis and applied in the liquid‐phase oxidation of cyclohexene with molecular O₂ as oxidant under mild conditions. The catalysts were systematically characterized by state‐of‐the‐art techniques. With increasing Sr content, the concentration of surface oxygen vacancy defects increases, which is beneficial for cyclohexene oxidation, but the surface concentration of less active Co²⁺ was also increased. However, Co²⁺ cations have a superior activity towards peroxide decomposition, which also plays an important role in cyclohexene oxidation. A Sr doping of 20 at. % was found to be the optimum in terms of activity and product selectivity. The catalyst also showed excellent reusability over three catalytic runs; this can be attributed to its highly stable particle size and morphology. Kinetic investigations revealed first‐order reaction kinetics for temperatures between 60 and 100 °C and an apparent activation energy of 68 kJ mol⁻¹ for cyclohexene oxidation. Moreover, the reaction was not affected by the applied O₂ pressure in the range from 10 to 20 bar. In situ attenuated total reflection infrared spectroscopy was used to monitor the conversion of cyclohexene and the formation of reaction products including the key intermediate cyclohex‐2‐ene‐1‐hydroperoxide; spin trap electron paramagnetic resonance spectroscopy provided strong evidence for a radical reaction pathway by identifying the cyclohexenyl alkoxyl radical.

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.

Spray Flame Synthesis (SFS) of Lithium Lanthanum Zirconate (LLZO) Solid Electrolyte

A spray-flame reaction step followed by a short 1-h sintering step under O₂ atmosphere was used to synthesize nanocrystalline cubic Al-doped Li₇La₃Zr₂O₁₂ (LLZO). The as-synthesized nanoparticles from spray-flame synthesis consisted of the crystalline La₂Zr₂O₇ (LZO) pyrochlore phase while Li was present on the nanoparticles’ surface as amorphous carbonate. However, a short annealing step was sufficient to obtain phase pure cubic LLZO. To investigate whether the initial mixing of all cations is mandatory for synthesizing nanoparticulate cubic LLZO, we also synthesized Li free LZO and subsequently added different solid Li precursors before the annealing step. The resulting materials were all tetragonal LLZO (I4₁/acd) instead of the intended cubic phase, suggesting that an intimate intermixing of the Li precursor during the spray-flame synthesis is mandatory to form a nanoscale product. Based on these results, we propose a model to describe the spray-flame based synthesis process, considering the precipitation of LZO and the subsequent condensation of lithium carbonate on the particles’ surface.

Characterization of tracers for two-color laser-induced fluorescence thermometry of liquid-phase temperature in ethanol, 2-ethylhexanoic-acid/ethanol mixtures, 1-butanol, and o-xylene

The fluorescence spectra of dye solutions change their spectral signature with temperature. This effect is frequently used for temperature imaging in liquids and sprays based on two-color laser-induced fluorescence (2cLIF) measurements by simultaneously detecting the fluorescence intensity in two separate wavelength channels resulting in a temperature-sensitive ratio. In this work, we recorded temperature-dependent absorption and fluorescence spectra of solutions of five laser dyes (coumarin 152, coumarin 153, rhodamine B, pyrromethene 597, and DCM) dissolved in ethanol, a 35/65 vol.% mixture of ethanol/2-ethylhexanoic acid, ethanol/hexamethylsiloxane, o-xylene, and 1-butanol to investigate their potential as temperature tracers in evaporating and burning sprays. The dissolved tracers were excited at either 266, 355, and 532 nm (depending on the tracer) for temperatures between 296 and 393 K (depending on the solvent) and for concentrations ranging between 0.1 and 10 mg/l. Absorption and fluorescence spectra of the tracers were investigated for their temperature dependence, the magnitude of signal re-absorption, the impact of different solvents, and varying two-component solvent compositions. Based on the measured fluorescence spectra, the tracers were analyzed for their 2cLIF temperature sensitivity in the respective solvents. Coumarin 152 showed for single-component solvents the overall best spectroscopic properties for our specific measurement situation related to temperature imaging measurements in spray-flame synthesis of nanoparticles as demonstrated previously in ethanol spray flames [Exp. Fluids61, 77 (2020)10.1007/s00348-020-2909-9].

Multiscale Simulation of the Formation of Platinum-Particles on Alumina Nanoparticles in a Spray Flame Experiment

Platinum decorated alumina particles have the potential of being a highly (cost-)effective catalyst. The particles are synthesized from platinum(II) acetylacetonate dissolved in a mixture of isopropanol and acetic acid with dispersed alumina carriers. The process is simulated by means of large eddy simulation with reaction kinetics and aerosol dynamics modeling. A two mixture fraction approach for tabulated chemistry with a thickened flame model is used to consider the complex reaction kinetics of the solvent spray combustion. Diffusion is described followings Ficks law with a unity Lewis number for the gas phase species, whereas the particle diffusion coefficients are calculated according to the kinetic theory. An extended model for aerosol dynamics, capable of predicting deposition rate and surface particle growth, is derived from the classical sectional technique. The simulations are compared and validated with product particle characteristics obtained from the experimental observations. Distributions for different locations within the simulation domain show the evolution of particle sizes deposited on the alumina particle surface, and transmission electron microscopy (TEM) images of the composite particles are shown in comparison to 3D particles ballistically reconstructed from simulation data. The ratio of deposited platinum on the alumina carrier particles and the mean diameters of the deposited particles are in good agreement with the experimental observation. Overall, the new method has demonstrated to be suitable for simulating the particle decoration process.

Europium-Doped Ceria-Gadolinium Mixed Oxides: PARAFAC Analysis and High-Resolution Emission Spectroscopy under Cryogenic Conditions for Structural Analysis

Gadolinium-doped ceria or gadolinium-stabilized ceria (GDC) is an important technical material due to its ability to conduct O^2- ions, e.g., used in solid oxide fuel cells operated at intermediate temperature as an electrolyte, diffusion barrier, and electrode component. We have synthesized Ce_1-xGd_xO_2-y:Eu³⁺ (0 ≤ x ≤ 0.4) nanoparticles (11-15 nm) using a scalable spray pyrolysis method, which allows the continuous large-scale technical production of such materials. Introducing Eu³⁺ ions in small amounts into ceria and GDC as spectroscopic probes can provide detailed information about the atomic structure and local environments and allows us to monitor small structural changes. This study presents a novel approach to structurally elucidate europium-doped Ce_1-xGd_xO_2-y:Eu³⁺ nanoparticles by way of Eu³⁺ spectroscopy, processing the spectroscopic data with the multiway decomposition method parallel factor (PARAFAC) analysis. In order to perform the deconvolution of spectra, data sets of excitation wavelength, emission wavelength, and time are required. Room temperature, time-resolved emission spectra recorded at λ_ex = 464 nm show that Gd³⁺ doping results in significantly altered emission spectra compared to pure ceria. The PARAFAC analysis for the pure ceria samples reveals a high-symmetry species (which can also be probed directly via the CeO₂ charge transfer band) and a low-symmetry species. The GDC samples yield two low-symmetry spectra in the same experiment. High-resolution emission spectra recorded under cryogenic conditions after probing the ⁵D₀-⁷F₀ transition at λ_ex = 575-583 nm revealed additional variation in the low-symmetry Eu³⁺ sites in pure ceria and GDC. The total luminescence spectra of CeO_2-y:Eu³⁺ showed Eu³⁺ ions located in at least three slightly different coordination environments with the same fundamental symmetry, whereas the overall hypsochromic shift and increased broadening of the ⁵D₀-⁷F₀ excitation in the GDC samples, as well as the broadened spectra after deconvolution point to less homogeneous environments. The data of the Gd³⁺-containing samples indicates that the average charge density around the Eu³⁺ ions in the lattice is decreased with increasing Gd³⁺ and oxygen vacancy concentration. For reference, the Judd-Ofelt parameters of all spectra were calculated. PARAFAC proves to be a powerful tool to analyze lanthanide spectra in crystalline solid materials, which are characterized by numerous Stark transitions and where measurements usually yield a superposition of different contributions to any given spectrum.

Selective cyclohexene oxidation with O2, H2O2 and tert-butyl hydroperoxide over spray-flame synthesized LaCo1−xFexO3 nanoparticles

A series of spray-flame made LaCo_1−xFe_xO₃ nanoparticles showed promising activity for liquid-phase cyclohexene oxidation. Various oxidizing agents, i.e., O₂, H₂O₂ and tert-butyl hydroperoxide, led to different product selectivities.