Template-assisted spray-drying method for the fabrication of porous particles with tunable structures

Design and internal structure analysis of submicron aggregated and porous three-way catalyst particles synthesized via spray drying for enhanced CO conversion

The development of efficient three-way catalysts (TWCs) is crucial for reducing vehicle emissions and addressing environmental concerns. However, the widespread application of TWCs is limited by their reliance on expensive precious metals and challenges in optimizing catalytic performance at low temperatures. To address these limitations, this study presents a novel approach to designing and characterizing submicron spherical aggregated TWC particles and porous structured TWC particles, which were synthesized using a spray drying method. The objectives of this research focus on optimizing the particle size of aggregated TWC particles, analyzing the internal porous architecture of porous TWC particles, and evaluating their catalytic performance in CO conversion. The synthesis process allowed precise control over the particle size of aggregated TWC particles by adjusting the concentration of colloidal TWC nanoparticles, revealing that smaller aggregated particles (520 nm) exhibited superior CO conversion efficiency compared to larger particles (1,180 nm) due to enhanced gas accessibility. Cross-sectional and three-dimensional elemental mapping analyses of porous TWC particles provided insights into the homogeneity of elemental distribution and interconnected pore networks, critical for efficient gas transport. Furthermore, the effect of CO gas flow rate on catalytic performance was systematically investigated, demonstrating that lower gas flow rates enhanced CO conversion efficiency at reduced temperatures due to prolonged gas-catalyst contact time. This work demonstrates a clear correlation between particle size of aggregated TWC particles and their catalytic efficiency, as well as highlights the influence of gas flow rates on the catalytic activity of porous TWC particles.

Particulate platform for pulmonary drug delivery: Recent advances of formulation and fabricating strategies

Pulmonary drug delivery for managing respiratory diseases has attained a significant maturity level and holds substantial potential for applications in treating systemic diseases. Advancements in pulmonary delivery techniques have driven the innovative development of dry powder inhalers (DPIs), specifically engineered to optimize the efficacy of pulmonary drug delivery. This review examines recent progress in formulation and manufacturing strategies of inhalable dry powder, focusing on prescription design and fabrication approaches for advanced particulate systems. These include the integration of cutting-edge excipients into conventional formulations, nano-based delivery system, composite particles, and a blend of traditional and next-generation processing techniques, all contributing to enhanced drug delivery efficiency and bioavailability. Additionally, this review discusses the latest advancements in DPI devices. This review aims to provide a clear perspective on emerging inhalable dry powder formulation and processing trends for pulmonary delivery, highlighting the critical role of novel particulate platform in advancing pulmonary drug delivery systems.

Preparation of Hierarchical Porous Zeolite Particles with Multiscale Pore Architectures through a Template-Assisted Spray Process for Enhanced Toluene Adsorption Rate

Hierarchical porous zeolite particles featuring multiscale pore architectures have gained significant attention due to their enhanced mass transfer properties and superior adsorption capabilities. This study reports the first successful synthesis of hierarchical porous zeolites with integrated micropores, mesopores, and macropores using a template-assisted spray process, addressing the limitations of conventional zeolites in adsorbing large organic molecules such as toluene. By employing poly(methyl methacrylate) (PMMA) particles (about 350 nm in size) as a template, we achieved precise control over macropore formation, providing a new level of flexibility in tailoring zeolite pore architectures. The effect of the PMMA/zeolite mass ratio on the resulting macroporous structures and their toluene adsorption performance was systematically investigated. The results revealed that the hierarchical porous zeolite exhibited a significantly enhanced toluene adsorption rate compared to samples synthesized without the PMMA template. This improvement is attributed to the optimized macroporous structure, which facilitates efficient mass transfer. Importantly, this study addresses a critical gap in the literature by demonstrating the successful integration of macropores into zeolites through an environmentally friendly process, with significant implications for applications in volatile organic compound removal. This advancement in porous zeolite design could enable more efficient and practical solutions for industrial air purification and environmental remediation.

Excipient-free inhalable combination shell-core microparticles with clofazimine as shell for extended pulmonary retention of isoniazid in core

Pulmonary delivery of combination anti-tubercular drugs can prevent emergence of drug resistance and improve therapeutic efficacy. However, several drugs in anti-Tuberculosis combinations possess contrasting physicochemical properties that necessitate precise particle engineering with meticulous design for successful co-delivery. High dose requirements further constrain addition of excipients in the formulation. In this work, a clofazimine shell - isoniazid core combination, excipient-free dry powder inhalable microparticle formulation (CFZ INH DPMs) is designed to extend release and prolong pulmonary retention of the short-half-life INH. Firstly, INH-acetone incompatibility was resolved by employing 3 fluid-nozzle spray drying as conventional spray drying of pure INH yielded large particle sizes (D50-26.64 µm) and poor yield for CFZ, whereas CFZ INH DPMs formulation exhibited desired aerodynamic size (D50-3.04 µm; 3.36 µm for INH and 3.28 µm for CFZ). Shell-core morphology was confirmed using TEM and confocal microscopy. DSC and XRD revealed CFZ and INH existed in their inherent crystalline form in CFZ INH DPMs. Solubility of CFZ from the combination DPMs in simulated lung fluid was improved 2 times compared to pure CFZ, while INH dissolution was retarded (85 % in 4 h). The interfacial behavior of DPPC with CFZ using Langmuir-Blodgett isotherms revealed interactions that explain improved solubility of CFZ in pulmonary lipids. In a RAW macrophage culture study, cellular internalization of prepared formulation within 4 h was observed whereas intratracheal administration to Wistar rats demonstrated retention of INH in lungs upto 4 h compared to clearance of pure INH within 1 h. In summation, CFZ INH DPMs demonstrate promising potential for pulmonary targeting and retention of combination anti-TB drugs.

Enhancing CO oxidation performance by controlling the interconnected pore structure in porous three-way catalyst particles

Highly ordered porous structured particles comprising three-way catalyst (TWC) nanoparticles have attracted attention because of their remarkable catalytic performance. However, the conditions for controlling their pore arrangement to form interconnected pore structures remain unclear. In particular, the correlation between framework thickness (distance between pores) or macroporosity and the diffusion of gaseous reactants to achieve a high catalytic performance has not been extensively discussed. Here, the interconnected pore structure was successfully controlled by adjusting the precursor components (i.e., template particle concentration) via a template-assisted spray process. A cross-sectional image analysis was conducted to comprehensively examine the internal structure and porous properties (framework thickness and macroporosity) of the porous TWC particles. In addition, we propose mathematical equations to predict the framework thickness and macroporosity, as well as determine the critical conditions that caused the formation of interconnected pores and broken structures in the porous TWC particles. The evaluation of CO oxidation performance revealed that porous TWC particles with an interconnected pore structure, thin framework, and high macroporosity exhibited a high catalytic performance owing to the effective diffusion and utilization of their internal parts. The study findings provide valuable insights into the design of porous TWC particles with interconnected pore structures to enhance exhaust gas emission control in real-world applications.

Recent development of metal-organic frameworks and their composites in electromagnetic wave absorption and shielding applications

With the rapid development of information and communication industries, the usage of electromagnetic waves has caused the hazard of human health and misfunction of devices. The adsorption and shielding of electromagnetic waves have been achieved in various materials. The unique adjustable spatial structure makes metal-organic frameworks (MOFs) promising for electromagnetic shielding and adsorbing. As MOFs research advances, various large-scale MOF-based materials have been developed. For instance, MOFs spatial structure has been expanded from 2D to 3D to load more ligands. Progress in synthetic methods for MOFs and their derivatives is advancing, with priority on large-scale preparation and green synthesis. This review summarizes the methods for synthesizing MOFs and their derivatives, and explores the effects of MOFs spatial structure on electromagnetic interference (EMI) shielding and electromagnetic wave absorption capabilities. At the same time, detailed examples are used to focus on the applications of five different MOFs composites in electromagnetic shielding and electromagnetic wave absorption. Finally, the current challenges and prospects of MOFs in the electromagnetic field are introduced, providing a useful reference for the preparation and design of MOFs and their composites for electromagnetic wave processing applications.

Recent microencapsulation trends for enhancing the stability and functionality of anthocyanins: a review

Anthocyanins (ACNs) are water-soluble pigments in various fruits and vegetables known for their high antioxidant activity. They are used as natural food colorants and preservatives and have several medicinal benefits. However, their application in functional foods and nutraceuticals is often compromised by their low stability to heat, oxygen, enzymes, light, pH changes, and solubility issues. Spray drying has emerged as an effective microencapsulation technique to enhance the shelf life, quality, and stability of ACNs. This manuscript reviews the latest scientific developments in spray drying microencapsulation of ACNs-rich fruit extracts. Process optimization and the stability and physicochemical properties of the spray-dried, microencapsulated ACNs-rich powders are discussed. This review also covers functional food and nutraceutical applications and introduces novel encapsulation methods, such as freeze-drying, supercritical carbon dioxide (SC-CO2), coacervation, drum drying, and electrospraying, highlighting their potential in improving the utility of ACNs-rich fruit extracts.

Catalyst Supraparticles: Tuning the Structure of Spray-Dried Pt/SiO2 Supraparticles via Salt-Based Colloidal Manipulation to Control their Catalytic Performance

The structure of supraparticles (SPs) is a key parameter for achieving advanced functionalities arising from the combination of different nanoparticle (NP) types in one hierarchical entity. However, whenever a droplet-assisted forced assembly approach is used, e.g., spray-drying, the achievable structure is limited by the inherent drying phenomena of the method. In particular, mixed NP dispersions of differently sized colloids are heavily affected by segregation during the assembly. Herein, the influence of the colloidal arrangement of Pt and SiO2 NPs within a single supraparticulate entity is investigated. A salt-based electrostatic manipulation approach of the utilized NPs is proposed to customize the structure of spray-dried Pt/SiO2 SPs. By this, size-dependent separation phenomena of NPs during solvent evaporation, that limit the catalytic performance in the reduction of 4-nitrophenol, are overcome by achieving even Pt NP distribution. Additionally, the textural properties (pore size and distribution) of the SiO2 pore framework are altered to improve the mass transfer within the material leading to increased catalytic activity. The suggested strategy demonstrates a powerful, material-independent, and universally applicable approach to deliberately customize the structure and functionality of multi-component SP systems. This opens up new ways of colloidal material combinations and structural designs in droplet-assisted forced assembly approaches like spray-drying.

Tailored Sugar-Mediated Porous Particle Structures for Improved Dispersion of Drug Nanoparticles in Spray-Freeze-Drying

We fabricated porous particles incorporating sugars (mannitol, sucrose, or dextran) and fenofibrate nanoparticles (FNPs) by using spray-freeze-drying (SFD). The type of sugar significantly influenced the pore architecture of the resulting SFD particles. Rapid freezing of droplets containing dextran produced ice encapsulation within a dextran matrix, forming porous dextran particles. In the presence of FNPs, the particle size (approximately 4 μm) and pore volume (0.3 cm3/g) of SFD dextran were barely affected. In contrast, SFD particles derived from mannitol and sucrose exhibited denser structures with a lower pore volume than dextran. SFD mannitol incorporating FNPs produced porous structures. FNPs containing surfactant and polymer, which reduced surface tension and increased viscosity, promoted the formation of small droplets with a polymeric structure and porous particles with a relatively sharp size distribution with a median around 5 μm. FNPs were uniformly distributed in SFD dextran, which featured large pore structures, whereas in SFD mannitol, the Raman signal of FNPs was more broadly distributed across the powder samples. Both morphologies contributed to enhancing the FNP dispersibility within a redispersed suspension of SFD particles. FNPs in SFD mannitol and dextran matrices maintained their particle size distribution from before SFD, showing no aggregation upon redispersion. Dextran formed a highly porous network irrespective of the presence of FNPs, whereas mannitol tended to alter the particle attributes upon FNP inclusion. In conclusion, SFD particles derived from dextran and mannitol might help to increase FNP dispersibility by increasing the formation of porous architectures.

Controllable Synthesis of Porous and Hollow Nanostructured Catalyst Particles and Their Soot Oxidation

The introduction of macroporous structures into three-way catalysts (TWCs) through polymer template-assisted spray drying has attracted attention because of its enhanced gas diffusion and catalytic performance. However, the surface charge effect of polymeric template components has not been investigated to control the structure of the TWC particles during synthesis. Thus, this study investigated the effect of template surface charges on the self-assembly behavior of TWC nanoparticles (NPs) during drying. The self-assembly of TWC NPs and polymer particles with different charges produced a hollow structure, whereas using the same charges generated a porous one. Consequently, the mechanism of particle self-assembly during drying and final structure particle formation is proposed in this study. Here, porous TWC particles demonstrated a faster oxidation of soot particles than that of hollow-structured particles. This occurred as a result of the larger contact area between the catalyst surface and the solid reactant. Our findings propose a fundamental self-assembly mechanism for the formation of different TWC structures, thereby enhancing soot oxidation performance using macroporous structures.

Influence of cation concentration and valence on the structure and texture of spray-dried supraparticles from colloidal silica dispersions

The structure and texture of supraparticles determine their properties and performance, thus playing a critical role in research studies as well as industrial applications. The addition of salts is a well-known strategy to manipulate the colloidal stability of nanoparticles. In this study, this approach is used to tune the structure of spray-dried supraparticles. Three different salts (NaCl, CaCl2, and AlCl3) were added to binary silica (SiO2) nanoparticle dispersions (of 40 and 400 nm in size) to change their colloidal stability by lowering the electrostatic repulsion or enhancing the cation bridging. Dependent on the cation valence of the added salt and the nanoparticle size, the critical salt concentration, which yields nanoparticle agglomeration, is reached at different salt amounts. This phenomenon is exploited to tune the final structure of supraparticles - obtained by spray-drying binary dispersions - from core-shell to Janus-like to well-mixed structures. This consequently also tunes textural properties, like surface roughness and the pore system of the obtained supraparticles. Our results provide insights for controlling the structure of spray-dried supraparticles by manipulating the stability of binary nanoparticle dispersions, and they establish a framework for composite particle design.

Microparticles and multi-unit systems for advanced drug delivery

Microparticles have unique benefits in the formulation of multiparticulate and multi-unit type pharmaceutical dosage forms allowing improved drug safety and efficacy with favorable pharmacokinetics and patient centricity. On the other hand, the above advantages are served by high and well reproducible quality attributes of the medicinal product where even flexible design and controlled processability offer success as well as possible longer product life-cycle for the manufacturers. Moreover, the specific demands of patients can be taken into account, including simplified dosing regimens, flexible dosage, drug combinations, palatability, and ease of swallowing. In the more than 70 years since the first modified-release formulation appeared on the market, many new formulations have been marketed and many publications have appeared in the literature. More unique and newer pharmaceutical technologies and excipients have become available for producing tailor-made particles with micrometer dimensions and beyond. All these have contributed to the fact that the sub-units (e.g. minitablets, pellets, microspheres) that make up a multiparticulate system can vary widely in composition and properties. Some units have mucoadhesive properties and others can float to contribute to a suitable release profile that can be designed for the multiparticulate formula as a whole. Nowadays, there are some available formulations on the market, which are able to release the active substance even for several months (3 or 6 months depending on the type of treatment). In this review, the latest developments in technologies that have been used for a long time are presented, as well as innovative solutions such as the applicability of 3D printing to produce subunits of multiparticulate systems. Furthermore, the diversity of multiparticulate systems, different routes of administration are also presented, touching the ones which are capable of carrying the active substance as well as the relevant, commercially available multiparticle-based medical devices. The versatility in size from 1 µm and multiplicity of formulation technologies promise a solid foundation for the future applications of dosage form design and development.

Multifunctional, Hybrid Materials Design via Spray-Drying: Much more than Just Drying

Spray-drying is a popular and well-known "drying tool" for engineers. This perspective highlights that, beyond this application, spray-drying is a very interesting and powerful tool for materials chemists to enable the design of multifunctional and hybrid materials. Upon spray-drying, the confined space of a liquid droplet is narrowed down, and its ingredients are forced together upon "falling dry." As  detailed in this article, this enables the following material formation strategies either individually or even in combination: nanoparticles and/or molecules can be assembled; precipitation reactions as well as chemical syntheses can be performed; and templated materials can be designed. Beyond this, fragile moieties can be processed, or "precursor materials" be prepared. Post-treatment of spray-dried objects eventually enables the next level in the design of complex materials. Using spray-drying to design (particulate) materials comes with many advantages-but also with many challenges-all of which are outlined here. It is believed that multifunctional, hybrid materials, made via spray-drying, enable very unique property combinations that are particularly highly promising in myriad applications-of which catalysis, diagnostics, purification, storage, and information are highlighted.

Communicating Supraparticles to Enable Perceptual, Information-Providing Matter

Materials are the fundament of the physical world, whereas information and its exchange are the centerpieces of the digital world. Their fruitful synergy offers countless opportunities for realizing desired digital transformation processes in the physical world of materials. Yet, to date, a perfect connection between these worlds is missing. From the perspective, this can be achieved by overcoming the paradigm of considering materials as passive objects and turning them into perceptual, information-providing matter. This matter is capable of communicating associated digitally stored information, for example, its origin, fate, and material type as well as its intactness on demand. Herein, the concept of realizing perceptual, information-providing matter by integrating customizable (sub-)micrometer-sized communicating supraparticles (CSPs) is presented. They are assembled from individual nanoparticulate and/or (macro)molecular building blocks with spectrally differentiable signals that are either robust or stimuli-susceptible. Their combination yields functional signal characteristics that provide an identification signature and one or multiple stimuli-recorder features. This enables CSPs to communicate associated digital information on the tagged material and its encountered stimuli histories upon signal readout anywhere across its life cycle. Ultimately, CSPs link the materials and digital worlds with numerous use cases thereof, in particular fostering the transition into an age of sustainability.

Comparative Analysis of Concurrent (CC), Mixed Flow (MX), and Combined Spray Drying Configurations on the Physicochemical Characteristics of Satsuma Mandarin (Citrus unshiu) Juice Powders

Satsuma mandarins are good sources of vitamin C and can be used as raw materials to produce novel plant-based food ingredients including satsuma mandarin juice powders (SJP). Food powders produced via spray drying often show thermal degradation due to the drying conditions and high drying air temperatures. The aim of this study was to evaluate the effect of using different spray drying configurations, including concurrent (CC), mixed flow (MX), and combined (CC + MX), at two inlet air temperatures (160 and 180 °C) on the physicochemical properties of SJP. Remarkably, SJP produced using the CC spray drying configuration exhibited a higher vitamin C content (3.56-4.01 mg/g) and lower moisture levels (15.18-16.35 g/100 g) than powders produced via MX or CC + MX. The vitamin C content of MX and CC + MX powders ranged from 2.88 to 3.33 mg/g. Meanwhile, all SJP had water activity values below 0.19. Furthermore, MX powders displayed the largest mean particle sizes (D50) (8.69-8.83 µm), higher agglomeration, and a rapid dissolution. Despite these differences, all SJP variants exhibited consistent color, surface area, and pore volumes. Notably, powders dried at higher inlet air temperatures (180 °C) showed less vitamin C content and increased thermal damage when compared with powders dried at 160 °C inlet air temperature. This study demonstrated the feasibility of producing high-quality SJP with an extended shelf life. SJP can be used as a novel plant-based ingredient in different food applications.

Supraparticles for naked-eye H2 indication and monitoring: Improving performance by variation of the catalyst nanoparticles

The recent transition to H₂-based energy storage demands reliable H₂ sensors that allow for easy, fast, and reliable detection of leaks. Conventional H₂ detectors are based on the changes of physical properties of H₂ probes induced by subsurface H-atoms to a material such as electrical conductivity. Herein, we report on highly reactive gasochromic H₂ detectors based on the adsorption of H₂ on the material surface. We prepared supraparticles (SPs) containing different types of noble metal nanoparticles (NPs), silica NPs, and the dye resazurin by spray-drying and tested their performance for H₂ detection. The material undergoes a distinct color change due to the hydrogenation of the purple resazurin to pink resorufin and, finally, colorless hydroresorufin. The stepwise transition is fast and visible to the naked eye. To further improve the performance of the sensor, we tested the reactivity of SPs with different catalytically active NPs by means of in situ diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS). We show that the choice of the NP catalyst has a pronounced effect on the response of the H₂ indicator. In addition, we demonstrate that the performance depends on the size of the NPs. These effects are attributed to the availability of reactive H-atoms on the NP surface. Among the materials studied, Pt-containing SPs gave the best results for H₂ detection.

From Meso to Macro: Controlling Hierarchical Porosity in Supraparticle Powders

A drying droplet containing colloidal particles can consolidate into a spherical assembly called a supraparticle. Such supraparticles are inherently porous due to the spaces between the constituent primary particles. Here, the emergent, hierarchical porosity in spray-dried supraparticles is tailored via three distinct strategies acting at different length scales. First, mesopores (<10 nm) are introduced via the primary particles. Second, the interstitial pores are tuned from the meso- (35 nm) to the macro scale (250 nm) by controlling the primary particle size. Third, defined macropores (>100 nm) are introduced via templating polymer particles, which can be selectively removed by calcination. Combining all three strategies creates hierarchical supraparticles with fully tailored pore size distributions. Moreover, another level of the hierarchy is added by fabricating supra-supraparticles, using the supraparticles themselves as building blocks, which provide additional pores with micrometer dimensions. The interconnectivity of the pore networks within all supraparticle types is investigated via detailed textural and tomographic analysis. This work provides a versatile toolbox for designing porous materials with precisely tunable, hierarchical porosity from the meso- (3 nm) to the macroscale (≈10 µm) that can be utilized for applications in catalysis, chromatography, or adsorption.

Rice husk-derived silicon nanostructured anode to enhance power generation in microbial fuel cell treating distillery wastewater

The present study aims to utilize rice husk as a source of silica to prepare rice husk derived silicon nanoparticles (RH-Si) and demonstrate its ability as an anode modifier in a two-chambered H-shaped microbial fuel cell (MFC). The silicon nanoparticles synthesized by magnesiothermal reduction process were spherical in shape and ranged in size from 15 to 60 nm. The anode modified with silicon nanoparticles of 0.50 mg cm^-2 recorded the maximum power and current density of 190.5 mW m^-2 and 1.5 A m^-2 corresponding to 7.6-fold and 3-fold increase as compared to the control . The modified anode also recorded a COD removal and coulombic efficiency of 74% and 49%, respectively in MFC operated with combined distillery and domestic wastewater at a HRT and OLR of 72 h and 59.2 gCOD L^-1 d^-1, respectively. The results evidence that RH derived silicon NPs are good anode modifiers and effective in enhancing bioelectricity generation and COD removal in MFCs.

Aerosol-assisted synthesis of titania-based spherical and fibrous materials with a rational design of mesopores using PS-b-PEO

Surfactant-assisted synthesis is a promising technique for the tailor-made design of highly porous metal oxide based nanomaterials. There has been a demand for the comprehensive design of their morphology, porous structure and crystallinity to extend potential applications using metal oxide based materials such as titania (TiO₂). However, the porous structure is often deformed and/or destroyed during the process of crystallizing metal oxide frameworks. Herein, the aerosol-assisted synthesis of mesoporous TiO₂ powders was conducted in the presence of high-molecular-weight poly(styrene)-block-poly(ethylene oxide) (PS-b-PEO), which improved the stability of the derivative mesoporous structure with an increase in the thickness of the TiO₂ frameworks. To propose a rational synthetic route for stable and porous metal oxides, the resultant mesoporous structure and the textural morphology of the mesoporous TiO₂ powders were surveyed using PS-b-PEO with different lengths of PS and PEO chains. By a judicious choice of the molecular structure of PS-b-PEO, the morphological design of the fully crystallized anatase phase of TiO₂ from spherical to fibrous ones was achieved with control over the mesopore diameter.

Raspberry Colloid Templated Catalysts Fabricated Using Spray Drying Method

The majority of industrial chemical processes—from production of organic and inorganic compounds to air and water treatment—rely on heterogeneous catalysts. The performance of these catalysts has improved over the past several decades; in parallel, many innovations have been presented in publications, demonstrating increasingly higher efficiency and selectivity. One common challenge to adopting novel materials in real-world applications is the need to develop robust and cost-effective synthetic procedures for their formation at scale. Herein, we focus on the scalable production of a promising new class of materials—raspberry-colloid-templated (RCT) catalysts—that have demonstrated exceptional thermal stability and high catalytic activity. The unique synthetic approach used for the fabrication of RCT catalysts enables great compositional flexibility, making these materials relevant to a wide range of applications. Through a series of studies, we identified stable formulations of RCT materials that can be utilized in the common industrial technique of spray drying. Using this approach, we demonstrate the production of highly porous Pt/Al2O3 microparticles with high catalytic activity toward complete oxidation of toluene as a model reaction.

Macroporous Mannitol Granules Produced by Spray Drying and Sacrificial Templating

In pharmaceutical applications, the porous particles of organic compounds can improve the efficiency of drug delivery, for example into the pulmonary system. We report on the successful preparation of macroporous spherical granules of mannitol using a spray-drying process using polystyrene (PS) beads of ~340 nm diameter as a sacrificial templating agent. An FDA-approved solvent (ethyl acetate) was used to dissolve the PS beads. A combination of infrared spectroscopy and thermogravimetry analysis proved the efficiency of the etching process, provided that enough PS beads were exposed at the granule surface and formed an interconnected network. Using a lab-scale spray dryer and a constant concentration of PS beads, we observed similar granule sizes (~1-3 microns) and different porosity distributions for the mannitol/PS mass ratio ranging from 10:1 to 1:2. When transferred to a pilot-scale spray dryer, the 1:1 mannitol/PS composition resulted in different distributions of granule size and porosity depending on the atomization configuration (two-fluid or rotary nozzle). In all cases, the presence of PS beads in the spray-drying feedstock was found to favor the formation of the α mannitol polymorph and to lead to a small decrease in the mannitol decomposition temperature when heating in an inert atmosphere.

Micro-fluidic Spray Freeze Dried Ciprofloxacin Hydrochloride-Embedded Dry Powder for Inhalation

Active pharmaceutical ingredient (API)-embedded dry powder for inhalation (AeDPI) is highly desirable for pulmonary delivery of high-dose drug. Herein, a series of spray freeze-dried (SFD) ciprofloxacin hydrochloride (CH)-embedded dry powders were fabricated via a self-designed micro-fluidic spray freeze tower (MFSFT) capable of tuning freezing temperature of cooling air as the refrigerant medium. The effects of total solid content (TSC), mass ratio of CH to _L-leucine (Leu) as the aerosol dispersion enhancer, and the freezing temperature on particle morphology, size, density, moisture content, crystal properties, flowability, and aerodynamic performance were investigated. It was found that the Leu content and freezing temperature had considerable influence on the fine particle fraction (FPF) of the SFD microparticles. The optimal formulation (CH/Leu = 7:3, TSC = 2%w/w) prepared at - 40°C exhibited remarkable effective drug deposition (~ 33.38%), good aerodynamic performance (~ 47.69% FPF), and excellent storage stability with ultralow hygroscopicity (~ 1.93%). This work demonstrated the promising feasibility of using the MFSFT instead of conventional liquid nitrogen assisted method in the research and development of high-dose AeDPI.

Recording Temperature with Magnetic Supraparticles

Small-sized temperature indicator additives autonomously record temperature events via a gradual irreversible signal change. This permits, for instance, the indication of possible cold-chain breaches or failure of electronics but also curing of glues. Thus, information about the materials' thermal history can be obtained upon signal detection at every point of interest. In this work, maximum-temperature indicators with magnetic readout based on micrometer-sized supraparticles (SPs) are introduced. The magnetic signal transduction is, by nature, independent of the materials' optical properties. This facilitates the determination of valuable temperature information from the inside, that is, the bulk, even of dark and opaque macroscopic objects, which might differ from their surface. Compared to state-of-the-art optical temperature indicators, complementary magnetic readout characteristics ultimately expand their applicability. The conceptualized SPs are hierarchically structured assemblies of environmentally friendly, inexpensive iron oxide nanoparticles and thermoplastic polymer. Irreversible structural changes, induced by polymer softening, yield magnetic interaction changes within and between the hierarchic sub-structures, which are distinguishable and define the temperature indication mechanism. The fundamental understanding of the SPs' working principle enables customization of the particles' working range, response time, and sensitivity, using a toolbox-like manufacturing approach. The magnetic signal change is detected self-referenced, fast, and contactless.

Modulating the Pore Architecture of Ice-Templated Dextran Microparticles Using Molecular Weight and Concentration

Spray freeze drying (SFD) is an ice templating method used to produce highly porous particles with complex pore architectures governed by ice nucleation and growth. SFD particles have been advanced as drug carrier systems, but the quantitative description of the morphology formation in the SFD process is still challenging. Here, the pore space dimensions of SFD particles prepared from aqueous dextran solutions of varying molecular weights (40-200 kDa) and concentrations (5-20%) are analyzed using scanning electron microscopy. Coexisting morphologies composed of cellular and dendritic motifs are obtained, which are attributed to variations in the ice growth mechanism determined by the SFD system and modulation of these mechanisms by given precursor solution properties leading to changes in their pore dimensions. Particles with low-aspect ratio cellular pores showing variation of around 0.5-1 μm in diameter with precursor composition but roughly constant with particle diameter are ascribed to a rapid growth regime with high nucleation site density. Image analysis suggests that the pore volume decreases with dextran solid content. Dendritic pores (≈2-20 μm in diameter) with often a central cellular region are identified with surface nucleation and growth followed by a slower growth regime, leading to the overall dendrite surface area scaling approximately linearly with the particle diameter. The dendrite lamellar spacing depends on the concentration according to an inverse power law but is not significantly influenced by molecular weight. Particles with highly elongated cellular pores without lamellar formation show intermediate pore dimensions between the above two limiting morphological types. Analysis of variance and post hoc tests indicate that dextran concentration is the most significant factor in affecting the pore dimensions. The SFD dextran particles herein described could find use in pulmonary drug delivery due to their high porosity and biocompatibility of the matrix material.

Enhanced Protein Adsorption Capacity of Macroporous Pectin Particles with High Specific Surface Area and an Interconnected Pore Network

There has been much interest in developing protein adsorbents using nanostructured particles, which can be engineered porous materials with fine control of the surface and pore structures. A significant challenge in designing porous adsorbents is the high percentage of available binding sites in the pores owing to their large surface areas and interconnected pore networks. In this study, continuing the idea of using porous materials derived from natural polymers toward the goal of sustainable development, porous pectin particles are reported. The template-assisted spray drying method using calcium carbonate (CaCO₃) as a template for pore formation was applied to prepare porous pectin particles. The specific surface area was controlled from 177.0 to 222.3 m² g^-1 by adjusting the CaCO₃ concentration. In addition, the effects of a macroporous structure, the specific surface area, and an interconnected pore network on the protein (lysozyme) adsorption capacity and adsorption mechanism were investigated. All porous pectin particles performed rapid adsorption (∼65% total capacity within 5 min) and high adsorption capacity, increasing from 1543 to the highest value of 2621 mg g^-1. The results are attributed to the high percentage of available binding sites located in the macropores owing to their large surface areas and interconnected pore networks. The macroporous particles obtained in this study showed a higher adsorption capacity (2621 mg g^-1) for lysozyme than other adsorbents. Moreover, the rapid uptake and high performance of this material show its potential as an advanced adsorbent for various macromolecules in the food and pharmaceutical fields.

A Sustainable Approach for Preparing Porous Carbon Spheres Derived from Kraft Lignin and Sodium Hydroxide as Highly Packed Thin Film Electrode Materials

A green synthetic strategy to design biomass-derived porous carbon electrode materials with precisely tailored structure and morphology has always been a challenging goal because these materials can fulfill the demands of next-generation supercapacitors and other electrochemical devices. Potassium hydroxide (KOH) is extensively utilized as an activator since it can produce porous carbon with high specific surface area and well-developed porous channels. The exploitation of sodium hydroxide (NaOH) as an activating agent is less referenced in the literature, although it offers some advantages over KOH in terms of low cost, less corrosiveness, and simple handling procedure, all of which are appealing particularly from an industrial viewpoint. The motivation for this present study is to fabricate porous carbon spheres in a sustainable manner via a spray drying approach followed by a carbonization process, using Kraft lignin as the carbon precursor and NaOH as an alternative activation agent instead of the high-cost and high-corrosive KOH for the first time. The structure of carbon particles can be accurately transitioned from a compact to hollow structure, and the surface textural properties can be easily tuned by altering the NaOH concentration. The obtained porous carbon spheres were applied as highly packed thin film electrode materials for supercapacitor devices. The specific capacitance value of porous carbon spheres with a highly compact structure (high packing density) is 66.5 F g^-1, which is higher than that of commercial activated carbon and other biomass-derived carbon. This work provides a green processing for producing low-cost and environment-friendly porous carbon spheres from abundant Kraft lignin and important insight for selecting NaOH as an activator to tailor the morphology and structure, which represents an economical and sustainable approach for energy storage devices.

Spray-Drying and Atomic Layer Deposition: Complementary Tools toward Fully Orthogonal Control of Bulk Composition and Surface Identity of Multifunctional Supraparticles

Spray-drying is a scalable process enabling one to assemble freely chosen nanoparticles into supraparticles. Atomic layer deposition (ALD) allows for controlled thin film deposition of a vast variety of materials including exotic ones that can hardly be synthesized by wet chemical methods. The properties of coated supraparticles are defined not only by the nanoparticle material chosen and the nanostructure adjusted during spray-drying but also by surface functionalities modified by ALD, if ALD is capable of modifying not only the outer surfaces but also surfaces buried inside the porous supraparticle. Simultaneously, surface accessibility in the porous supraparticles must be ensured to make use of all functionalized surfaces. In this work, iron oxide supraparticles are utilized as a model substrate as their magnetic properties enable the use of advanced magnetic characterization methods. Detailed information about the structural evolution upon individual ALD cycles of aluminium oxide, zinc oxide and titanium dioxide are thereby revealed and confirmed by gas sorption analyses. This demonstrates a powerful and versatile approach to freely designing the functionality of future materials by combination of spray-drying and ALD.

Spherical submicron YAG:Ce particles with controllable particle outer diameters and crystallite sizes and their photoluminescence properties

The purpose of this study was to demonstrate the preparation of spherical submicron YAG:Ce particles with controllable particle outer diameters and crystallite sizes and their photoluminescence (PL) properties, which were produced using a flame-assisted spray-pyrolysis method followed by the annealing process. The correlation of particle outer diameter, crystallite size, and PL performance of the prepared particles was also investigated. Experimental results showed that the increases in the particle outer diameters have an impact on the obtainment of higher PL performance. Large particle outer diameters permitted the crystallites to grow more, whereas this is in contrast to the condition for small particle outer diameter having limitations in crystallite growth. This study also found that too large outer diameter (>557 nm) was not effective since crystallites cannot grow anymore and it permits possible scattering problems. This study provides significant information for optimizing synthesis parameters for controlling particle outer diameters and crystallite sizes, which could be relevant to other functional properties, especially for lens, solar cell, and LED applications.

Smart gating porous particles as new carriers for drug delivery

The design of smart drug delivery carriers has recently attracted great attention in the biomedical field. Smart carriers can specifically respond to physical and chemical changes in their environment, such as temperature, photoirradiation, ultrasound, magnetic field, pH, redox species, and biomolecules. This review summarizes recent advances in the integration of porous particles and stimuli-responsive gatekeepers for effective drug delivery. Their unique structural properties play an important role in facilitating the diffusion of drug molecules and cell attachment. Various techniques for fabricating porous materials, with their major advantages and limitations, are summarized. Smart gatekeepers provide advanced functions such as "open-close" switching by functionalized stimuli-responsive polymers on a particle's pores. These controlled delivery systems enable drugs to be targeted at specific rates, time programs, and sites of the human body. The gate structures, gating mechanisms, and controlled release mechanisms of each trigger are detailed. Current ongoing research and future trends in targeted drug delivery, tissue engineering, and regenerative medicine applications are highlighted.

Production and characterization of graphene from carbonaceous rice straw by cost-effect extraction

This paper describes the synthesis of graphene-based activated carbon from carbonaceous rice straw fly ash in an electrical furnace and the subsequent potassium hydroxide extraction. The produced graphene has a proper morphological structure; flakes and a rough surface can be observed. The average size of the graphene was defined as up to 2000 nm and clarification was provided by high-resolution microscopes (FESEM and FETEM). Crystallinity was confirmed by surface area electron diffraction. The chemical bonding from the graphene was clearly observed, with -C=C- and O-H stretching at peaks of 1644 cm^-1 and 3435 cm^-1, respectively. Impurities in the graphene were found using X-ray photoelectron spectroscopy and energy dispersive X-ray spectroscopy. The measured size, according to zeta-potential analysis, was 8722.2 ± 25 nm, and the average polydispersity index was 0.576. The stability of the mass reduction was analyzed by a thermogravimetric at 100 °C, with a final reduction of ~ 11%.

Synthesis of High Specific Surface Area Macroporous Pectin Particles by Template-Assisted Spray Drying

Many types of porous particles containing inorganic and organic substances, such as carbon, metals, metal oxides, inorganic-organic hybrids, and polymers, have been developed. However, natural polymer-derived particles are relatively rare. To our knowledge, this report describes the first synthetic method for obtaining meso-/macroporous particles made from pectin, which is a natural polymer with a wide range of biological activities suitable for active substance support applications. These porous particles were prepared using a template-assisted spray-drying method, followed by a chemical etching process. An organic template [i.e., poly(methyl methacrylate) (PMMA)] or an inorganic template [i.e., calcium carbonate (CaCO₃)] was used to evaluate the resulting formation of macroporous structures in the pectin particles. Furthermore, the concentration of the templates in the precursor solution was varied to better understand the mechanism of porous pectin particle formation. The results showed that the final porous particles maintained the characteristic properties of pectin. The differences between the two templates resulted in two distinct types of porous particles that differed in their particle morphologies (i.e., spherical or wrinkled), particle sizes (ranging from 3 to 8 μm), pore sizes (ranging from 80 to 350 nm), and pore volume (ranging from 0.024 to 1.40 cm³ g^-1). Especially, the porous pectin particles using the CaCO₃ template have a significantly high specific surface area of 171.2 m² g^-1, which is 114 times higher than that of nonporous pectin particles. These data demonstrated the potential for using PMMA and CaCO₃ templates to control and design desired porous materials.

Controllable synthesis of spherical carbon particles transition from dense to hollow structure derived from Kraft lignin

The tailored synthesis of carbon particles with controllable shapes and structures from biomass as a raw material would be highly beneficial to meet the demands of various applications of carbon materials from the viewpoint of sustainable development goals. In this work, the spherical carbon particles were successfully synthesized through a spray drying method followed by the carbonization process, using Kraft lignin as the carbon source and potassium hydroxide (KOH) as the activation agent. As the results, the proposed method successfully controlled the shape and structure of the carbon particles from dense to hollow by adjusting the KOH concentration. Especially, this study represents the first demonstration that KOH plays a crucial role in the formation of particles with good sphericity and dense structures. In addition, to obtain an in-depth understanding of the particle formation of carbon particles, a possible mechanism is also investigated in this article. The resulting spherical carbon particles exhibited dense structures with a specific surface area (1233 m²g^-1) and tap density (1.46 g cm^-3) superior to those of irregular shape carbon particles.

Microalgae-Templated Spray Drying for Hierarchical and Porous Fe3O4/C Composite Microspheres as Li-ion Battery Anode Materials

A method of microalgae-templated spray drying to develop hierarchical porous Fe₃O₄/C composite microspheres as anode materials for Li-ion batteries was developed. During the spray-drying process, individual microalgae serve as building blocks of raspberry-like hollow microspheres via self-assembly. In the present study, microalgae-derived carbon matrices, naturally doped heteroatoms, and hierarchical porous structural features synergistically contributed to the high electrochemical performance of the Fe₃O₄/C composite microspheres, enabling a discharge capacity of 1375 mA·h·g^-1 after 700 cycles at a current density of 1 A/g. Notably, the microalgal frameworks of the Fe₃O₄/C composite microspheres were maintained over the course of charge/discharge cycling, thus demonstrating the structural stability of the composite microspheres against pulverization. In contrast, the sample fabricated without microalgal templating showed significant capacity drops (up to ~40% of initial capacity) during the early cycles. Clearly, templating of microalgae endows anode materials with superior cycling stability.

Production and characterization of silica nanoparticles from fly ash: conversion of agro-waste into resource

A chemical method to synthesize amorphous silica nanoparticles from the incinerated paddy straw has been introduced. The synthesis was conducted through the hydrolysis by alkaline-acidic treatments. As a result, silica particles produced with the sizes were ranging at 60-90 nm, determined by high-resolution microscopy. The crystallinity was confirmed by surface area electron diffraction. Apart from that, chemical and diffraction analyses for both rice straw ash and synthesized silica nanoparticles were conducted by X-ray diffraction and Fourier-transform infrared spectroscopy. The percentage of silica from the incinerated straw was calculated to be 28.3. The prominent surface chemical bonding on the generated silica nanoparticles was with Si-O-Si, stretch of Si-O and symmetric Si-O bonds at peaks of 1090, 471, and 780 cm^-1, respectively. To confirm the impurities of the elements in the produced silica, were analyzed using X-ray photoelectron spectroscopy and energy dispersive X-ray spectroscopy. The stability of silica nanoparticles was investigated using thermogravimetric analysis and zeta potential. The measured size from zeta potential analysis was 411.3-493 nm and the stability of mass reduction was located at 200 °C with final amount of mass reduced ∼88% and an average polydispersity Index was 0.195-0.224.