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

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.

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.

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.

Polymerization-Induced Hierarchical Hybrid Particles from Siloxane Emulsification Endowing Polyurethane Composite Coating with Superhydrophobicity, Thermal Insulation, and Fluorescence

Hierarchically structural particles (HSPs) are highly regarded as favorable nanomaterials for superhydrophobic coating due to their special multiscale structure and surface physicochemical properties. However, most of the superhydrophobic coatings constructed from HSPs are monofunctional, constraining their broader applications. Moreover, traditional methods for constructing HSPs mostly rely on complicated chemical routes and template removal. Herein, we propose an innovative strategy (one-pot method) for producing multifunctional hierarchical hybrid particles (HHPs). Polysilsesquioxane (PSQ), generated from hydrolysis condensation of methyltriethoxylsilane, is used as the sole stabilizer to anchor on the surface of styrene and short fluoroalkyl compound tridecafluorooctyl acrylate comonomers droplets, forming a mesoporous PSQ shell. Subsequently, the comonomers inside of the shell perform restricted polymerization to generate the HHP due to the driving of the mesoporous capillary force. The HHP is then mixed with waterborne polyurethane (WPU) to develop a robust nanocomposite coating (WPU-HHP). Through the deliberate design of the HHP components, the WPU-HHP coating has thermal insulation, photoluminescence properties, and the ability to achieve a wettability transition during abrasion. Our research has achieved the integration of multifunctionality in one waterborne hybrid system, broadening the application areas of nanocomposite coatings.

Controlling the Magnetic Responsiveness of Cellulose Nanofiber Particles Embedded with Iron Oxide Nanoparticles

2,2,6,6-tetramethylpiperidine-1-oxyl (TEMPO)-oxidized cellulose nanofiber (TOCN) particles, an innovative biobased material derived from wood biomass, have garnered significant interest, particularly in the biomedical field, for their distinctive properties as biocompatible particle adsorbents. However, their microscopic size complicates their separation in liquid media, thereby impeding their application in various domains. In this study, superparamagnetic magnetite nanoparticles (NPs), specifically iron oxide Fe3O4 NPs with an average size of 15 nm, were used to enhance the collection efficiency of TOCN-Fe3O4 composite particles synthesized through spray drying. These composite particles exhibited a remarkable ζ-potential (approximately -50 mV), indicating their high stability in water, as well as impressive magnetization properties (up to 47 emu/g), and rapid magnetic responsiveness within 60 s in water (3 wt % Fe3O4 to TOCN, 1 T magnet). Furthermore, the influence of Fe3O4 NP concentrations on the measurement of the speed of magnetic separation was quantitatively discussed. Additionally, the binding affinity of the synthesized particles for proteins was assessed on a streptavidin-biotin binding system, offering crucial insights into their binding capabilities with specific proteins and underscoring their significant potential as functionalized biomedical materials.

Bioinspired High-Magnesium Calcite for Efficiently Reducing Chemical Oxygen Demand in Lake Water

Organic matter accumulation in water can cause serious problems such as oxygen depletion and quality deterioration of waters. While calcium carbonate has been used as green and low-cost adsorbent for water treatment, its efficiency in reducing the chemical oxygen demand (COD) of water, which is a measure of organic pollution, is restrained by the limited specific surface area and chemical activity. Herein, inspired by the high-magnesium calcite (HMC) found in biological materials, a feasible method to synthesize fluffy dumbbell-like HMC with large specific surface area is reported. The magnesium inserting increases the chemical activity of the HMC moderately but without lowering its stability too much. Therefore, the crystalline HMC can retain its phase and morphology in aqueous environment for hours, which allows the establishment of adsorption equilibrium between the solution and the adsorbent that retains its initial large specific surface area and improved chemical activity. Consequently, the HMC exhibits notably enhanced capability in reducing the COD of lake water polluted by organics. This work provides a synergistic strategy to rationally design high-performance adsorbents by simultaneously optimizing the surface area and steering the chemical activity.

BaSO4-Epoxy Resin Composite Film for Efficient Daytime Radiative Cooling

Conventional cooling methods are based on active cooling technology by air conditioning, which consumes a large amount of energy and emits greenhouse gases. Radiative cooling is a novel promising passive cooling technology that uses external space as the cooling source and requires no additional energy consumption. Herein, we propose an approach to prepare highly dispersed BaSO4 nanoparticles (NPs) using a direct precipitation method combined with the in situ surface modification technology. The as-prepared PVP-modified BaSO4 NPs with an average size of 20 nm can be stably dispersed in ethanol for more than 6 months and then were used as building blocks to prepare spherical BaSO4 clusters with an average size of 0.9 μm using a scalable spray drying technique. The BaSO4 NPs/clusters (mass ratio 1:1) were used for preparing radiative cooling epoxy resin film, showing a high solar reflectance of 71% and a high sky window emissivity of 0.94. More importantly, this composite film displays superior radiative cooling performance, which can reduce the ambient temperature by 13.5 °C for the indoor test and 7 °C for the outdoor test. Compared with the commercial BaSO4 filled film, our BaSO4-epoxy resin composite film offers advantages not only in radiative cooling but also in mechanical properties with a 16.6% increase of tensile strength and 40.1% increase of elongation at break, demonstrating its great application potential in the field of building air conditioning.

Macropore-Size Engineering toward Enhancing the Catalytic Performance of CO Oxidation over Three-Way Catalyst Particles

In recent years, transportation-related air pollution has escalated into a global concern, necessitating the development of a three-way catalyst (TWC) technology to address harmful emissions. However, the efficiency of TWC's performance in mitigating these emissions has been hindered because of limited mass transfer efficiency within their structures. Thus, this study attempted to overcome the existing issue by synthesizing a series of macroporous TWC particles exhibiting various macropore sizes via a template-assisted spray process, aiming to achieve optimal mass transfer efficiency and catalytic performance. The synthesis incorporated various template particles (size of 67-381 nm) to obtain various macroporous structures. Thereafter, these macroporous particles were assessed for their carbon monoxide (CO) oxidation performance, revealing a substantial influence of the macropore size on the catalytic performance of TWC structures. Interestingly, among the investigated samples, those containing the smallest and largest macropores demonstrated the highest CO oxidation performances. Based on these results, a plausible reactant diffusion mechanism was proposed to explain the effect of the macropore size on the diffusion efficiency within the macroporous structures. This work may have significant implications in optimizing the macroporous structure to enhance catalytic performance in the gas purification process.

Water Adsorption on Hydrophilic Fibers and Porous and Deliquescent Materials: Cellulose, Polysaccharide, Silica, Inorganic Salt, Sugar Alcohol, and Amino Acid

Water adsorption isotherms are systematically summarized by using celluloses and polysaccharides as hydrophilic crystal/amorphous materials with functional groups, silicas as hydrophilic porous materials, and inorganic salts, sugar alcohols, and amino acids as hygroscopic deliquescent materials. For hydrophilic fibers such as celluloses and polysaccharides, water was adsorbed on amorphous solids, and water clusters were formed around functional groups. For porous materials such as silicas, capillary condensation occurred in the micropores of silicas. For deliquescent materials such as inorganic salts, sugar alcohols, and amino acids, water adsorption rapidly increased stepwise at a specific threshold relative humidity, accompanied with a structure transformation to a liquid state. In addition, the water activity (Aw) of materials used in packed products was able to be estimated from the water adsorption isotherms of the pure component. This indicated that the deliquescent materials have a great effect on the depression of Aw for the suppression of microbial growth at an extremely high water content. The deliquescent materials could be useful to develop new environmentally and sustainable products and technologies with the mediation of water vapor and/or hydration.

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.

Drug-Facilitated Crystallization of Spray-Dried CD-MOFs with Tunable Morphology, Porosity, And Dissolution Profile

Metal-organic frameworks (MOFs) with versatile functionalities have applications in environmental science, sensor separation, catalysis, and drug delivery. In particular, MOFs used in drug delivery should be biodegradable and easy to control. In this study, spray-dried cyclodextrin-based MOFs (CD-MOFs) with tunable crystallinity, porosity, and dissolution properties were fabricated. The spray-drying precursor properties, such as ethanol volume ratio, incubation time, and precursor concentration, were optimized for controlled crystallization. On the basis of the morphology, X-ray diffraction peak intensity, and specific surface areas of the spray-dried CD-MOF products, they were categorized as amorphous, partially crystalline, and highly crystalline. An active pharmaceutical ingredient ketoconazole (KCZ) was introduced into the precursor to prepare KCZ-containing CD-MOFs. The surface areas of these products were greater by 3-fold (292 m2/g) than that of the plain CD-MOF (94.1 m2/g) prepared using the same parameters. The presence of KCZ in the hydrophobic cavity between the two γ-CD molecules was correlated to the CD-MOF crystal growth. Additionally, CD-MOF particles exhibited different dissolution behaviors on the basis of the position of KCZ in the MOF. These spray-dried CD-MOFs with tunable morphology, specific surface area, and dissolution could have potential applications in various fields.

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.

Fabrication and characterization of novel macroporous hydrogels based on the polymerizable surfactant AAc-Span80 and their enhanced drug-delivery capacity

In this study, macroporous pH-sensitive poly[N-isopropylacrylamide-co-acrylic acid-sorbitan monooleate] hydrogels, termed as PNIPAM-co-AAc-Span80 hydrogels, with an enhanced hydrophobic property and a rich pore structure were prepared by free-radical polymerization in an ethanol/water mixture. The polymerizable surfactant AAc-Span80 was obtained by the esterification of acrylic acid (AAc) and sorbitan monooleate (Span80), which was used to copolymerize with N-isopropylacrylamide (NIPAM). The chemical structure, thermal stability, morphology, and amphipathy of the PNIPAM-co-AAc-Span80 hydrogels were characterized. The results showed that the polymerizable surfactant AAc-Span80 macromolecule introduced into the hydrogels could not only increase the hydrophobic property but also ameliorate the porous network morphology, which was conducive to high adsorption capacity for adriamycin hydrochloride (DOX). The adsorption results showed that the equilibrium adsorption capacity of DOX reached 467.5 mg g⁻¹ within 48 h at pH 7.4, and the hydrophobic interactions and intermolecular hydrogen bonds were the main force in the adsorption process of DOX. The release results demonstrated that the macroporous pH-sensitive hydrogels loaded with DOX could release 98.7% of DOX at pH 5.0, which would be highly beneficial for the release of anti-cancer drugs in the environment of cancer cells. All the results demonstrate that the PNIPAM-co-AAc-Span80 hydrogels have great potential for the delivery of anti-cancer drugs.

PNIPAM-co-AAc-Span80 shows an enhanced hydrophobic property, rich pore structure, and good adsorption performance for DOX. The desorption results demonstrate that 98.7% of DOX can be released efficiently in an acidic environment.

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.