Energy-Efficient Templating Method for the Industrial Production of Porous Carbon Particles by a Spray Pyrolysis Process Using Poly(methyl methacrylate)

Macroporous Structures of Nb-SnO2 Particles as a Catalyst Support Induce High Porosity and Performance in Polymer Electrolyte Fuel Cell Catalyst Layers

Macroporous niobium-doped tin oxide (NTO) is introduced as a robust alternative to conventional carbon-based catalyst supports to improve the durability and performance of polymer electrolyte fuel cells (PEFCs). Metal oxides like NTO are more stable than carbon under PEFC operational conditions, but they can compromise gas diffusion and water management because of their denser structures. To address this tradeoff, we synthesized macroporous NTO particles using a flame-assisted spray-drying technique employing poly(methyl methacrylate) as a templating agent. X-ray diffraction analysis and scanning electron microscopy confirmed the preservation of crystallinity and revealed a macroporous morphology with larger pore volumes and diameters than those in flame-made NTO nanoparticles, as revealed by mercury porosimetry. The macroporous NTO particles exhibited enhanced maximum current density and reduced gas diffusion resistance relative to commercial carbon supports. Our findings establish a foundation for integrating macroporous NTO structures into PEFCs to optimize durability and performance.

Nanostructuring silica-iron core-shell particles in a one-step aerosol process

Silica-coated iron (Fe@SiO2) particles have attracted considerable interest as a potential powder core material due to their distinctive advantages, including higher magnetic saturation and enhanced electrical resistance. In this study, the submicron-sized core-shell Fe@SiO2 particles were successfully synthesized in a single step via an aerosol process using a spray pyrolysis method assisted by a swirler connector for the first time. Changing the reducing agent concentration (supplied H2) and tuning the number of core (Fe) particles were investigated to achieve the desired Fe@SiO2 particles. The results indicated that an excessive number of cores led to the appearance of FeO crystals due to insufficient reduction. Conversely, an insufficient number of cores resulted in a thicker SiO2 shell, which hindered the penetration of the supplied H2 gas. Furthermore, the produced Fe@SiO2 particles exhibited soft-ferromagnetic characteristics with an excellent magnetic saturation value of 2.04 T, which is close to the standard theoretical value of 2.15 T. This work contributes new insights into the production of core-shell Fe@SiO2 particles, expanding their applicability to advanced soft-magnetic materials.

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.

Bimetallic-Coordinated Covalent Triazine Framework-Derived FeNi Alloy Nanoparticle-Decorated Coral-Like Nanocarbons for Oxygen Electrocatalysis

It is highly desirable to fabricate transition bimetallic alloy-embedded porous nanocarbons with a unique nanoarchitecture for the oxygen evolution reaction (OER) and oxygen reduction reaction (ORR) in rechargeable zinc-air batteries. In this work, we introduce a template-assisted in situ alloying synthesis of FeNi alloy nanoparticle-decorated coral-like nanocarbons (FeNi-CNCs) as efficient OER/ORR dual-functional electrocatalysts. The present materials are produced through polycondensation of a covalent triazine framework (CTF), the coordination of Ni and Fe ions, and sequential pyrolytic treatment. Through the pyrolysis process, the nanolamellar FeNi-CTF precursors can be facilely converted into FeNi alloy nanoparticle-decorated nanocarbons. These nanocarbons possess a distinctive three-dimensional (3D) coral-like nanostructure, which is favorable for the transport of oxygen and the diffusion of electrolyte. As a result, FeNi-CNC-800 with the highest efficiency exhibited remarkable electrocatalytic performance and great durability. Additionally, it also can be assembled into rechargeable zinc-air batteries that can be assembled in both liquid and solid forms, offering a superior peak power density, large specific capacity, and outstanding reusability during charging/discharging cycles (e.g., 5160 charging-and-discharging cycles at 10 mA cm-2 for the liquid forms). These traits make it a highly promising option in the burgeoning field of wearable energy conversion.

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 Carbon-Coated SiOx Particles through a Simultaneous Reaction between the Hydrolysis-Condensation of Tetramethyl Orthosilicate and the Polymerization of 3-Aminophenol

Core-shell particles are desirable for many applications, but the precise design and control of their structure remains a great challenge. In this work, we developed a strategy to fabricate carbon-coated SiO_x (SiO_x@C) core-shell particles via a sol-gel method using the simultaneous hydrolysis-condensation of tetramethyl orthosilicate (TMOS), the polymerization of 3-aminophenol and formaldehyde in the presence of ammonia as a basic catalyst, and cetyltrimethylammonium bromide (CTAB) as a cationic surfactant in the mixed solution of water and methanol followed by the carbonization process. Results from this study provide new insight into the design of core-shell particles by using TMOS as an effective silica precursor for the first time with a well-controlled reaction rate and spherical morphology. To obtain an in-depth understanding of the formation of core-shell structure, a possible mechanism is also proposed in this article. When tested as an anode material for lithium ion batteries (LIBs), the obtained SiO_x@C particles delivered a reversible capacity of 509.2 mAh g^-1 at a current density of 100 mA g^-1. This electrochemical performance is significantly better than those of similar composites without the core-shell structure. The capacity retention after 100 cycles was approximately 80%. These results suggest great promise for the proposed SiO_x@C particles with core-shell structure, which may have potential applications in the improvement of various energy-storage materials.

TEMPO-oxidized cellulose nanofiber (TOCN) decorated macroporous silica particles: Synthesis, characterization, and their application in protein adsorption

Effective protein adsorption has attracted attention for broad application in the biomedical field. In this study, we introduce the synthesis of a TEMPO-oxidized cellulose nanofiber (TOCN) decorated macroporous SiO₂ (TOCN@macroporous SiO₂) particle and its protein adsorption performance. The TOCN@macroporous SiO₂ particles have a unique cellulose nanofiber network structure on the macroporous, highly-negative zeta potential (-62 ± 2 mV) and high surface area (30.8 m²/g) for dried-state cellulose based particles. These characteristics provide sites that are rich in electrostatic interaction to exhibit an outstanding adsorption capacity of lysozyme (1865 mg/g). Furthermore, the TOCN@macroporous SiO₂ particles have remarkably high reusability (>90% adsorption capacity) and good release of adsorbate (>80%) after 10 times of use. The material proposed in this paper has the potential for application in drug delivery, protein adsorption, biosensors, and other biomedical fields.