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2/11/09

Flame spray pyrolysis for nanomaterial fabrication

Flame pyrolysis has been used for many years in the fabrication of simple materials such as carbon black and fumed silica and is being used in the fabrication of many more compounds. Flame spray pyrolysis is of great potential for mass production of nano-materials, especially oxides and supported metals. Flames offer a unique environment for nano-particle growth since they contain high degrees of super-saturation, extremely high temperatures and rapid quench conditions and locking in kinetic structures. Spray jets flames offer the most versatile and controllable pyrolytic conditions for nano-particle formation. Flame spray pyrolysis processes are quite attractive as they can employ a wide array of precursor compared to conventional vapor-fed flame reactors. Each droplet contains the precursor in the same stoichiometry as desired in the product so a broad spectrum of functional metal and mixed metal oxide nanoparticles can be synthesized for catalysis, sensors and electroceramics. Nanoparticles of ZnO, MgO and NiO can be produced from droplets of aqueous salt solution in the flame spray pyrolysis reactor. Conventional spray pyrolysis in which electrical furnace reactor is used is reported to produce nanoparticles only from acetate precursor. If the reactor pressure is low (at 60torr), nitrate salt precursor is also known to produce nanoparticles. At low flame temperature, nanoparticles are not formed and the particle morphology is similar to the morphology produced by the conventional spray pyrolysis. At high flame temperature, nanoparticles are formed, regardless of the salt type. Nanoparticles are formed at lower flame temperature from acetate salts than from nitrate salts. Few examples reported are cited below.
  • Nanoparticles of iron(lll) oxide can be synthesized by spontaneous combustion of ferrocene in ethanol solution using a simple spirit lamp.
  • Continuous, single-step synthesis of cubic monocrystalline Y2O3:Eu3+ nanophosphor particles (10 -20 nm in grain diameter) can be achieved by flame spray pyrolysis.
  • Two component metal oxide nanoparticles such as lithium cobalt oxides (LiCoO2), indium tin oxides (ITO) can be synthesized from aqueous aerosol precursors by the flame spray pyrolysis.
  • Alloyed Pt-Pd noble particles can be formed upon reduction in hydrogen in materialsprepared by flame spray pyrolysis, a technique that allows the preparation of supported noble metal particles within one step.
  • The flame spray pyrolysis system consists of a spray generator, a coflow burner, quartz reactor, particle collection filter and vacuum pump.
  • Nanoscale Y2O3:Eu phosphor particles can be synthesized by flame spray pyrolysis method. Here the starting solution is usually prepared by dissolving yttrium and europium nitrate in distilled water, ethanol or propanol alcohol.
  • A range of TiO2-based photocatalysts and cobalt-based Fischer-Tropsch catalysts have been developed and synthesised via the one-step Flame Spray Pyrolysis.

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