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

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.

From Structure to Power: Monolithic Carbon Air Cathodes with an Optimized Active Distribution for Direct-Formate Fuel Cells

Non-noble metal cathodes often suffer from limited oxygen reduction reaction (ORR) activity due to poor mass transport and insufficient active site availability, which restricts their application. This study presents a carbon-based air cathode featuring a monolithic, binder-free design aimed at enhancing the mass transfer and distribution of active sites. Characterization results indicate that the carbon-based monolithic air cathodes with a thickness of 1.5 mm (Fe@AC-1.5) possess a well-distributed pore structure that improves the oxygen transport capacity, thereby facilitating catalytic activity. Additionally, evaluation of the active site distribution of the cathode with a thickness of 2.4 mm (Fe@AC-2.4) revealed a comparable exponential distribution pattern. Furthermore, the findings demonstrate that the 1.5 mm thick monolithic air cathode prepared with agar (Fe@AC-1.5) contains numerous active sites for the ORR and an optimal pore distribution, resulting in an improved ORR activity. The direct-formate fuel cell utilizing Fe@AC-1.5 achieves a maximum power density of 22.63 mW cm-2. This study introduces easily prepared carbon-based monolithic air cathodes with remarkable ORR properties and offers insights into active site distribution, thereby guiding future enhancements in the ORR performance.

Advances in Aerosol Nanostructuring: Functions and Control of Next-Generation Particles

Nanostructured particles (NSPs), with their remarkable properties at the nanoscale, possess key functions required for unlocking a sustainable future. Fabricating these particles using aerosol methods and spraying processes enables precise control over the particle morphology, structure, composition, and crystallinity during in-flight transformation. In this Perspective, the significant impact of NSPs on technological advancement for energy and environmental applications is discussed. Furthermore, incorporating in situ/operando assessment techniques alongside machine and deep learning is explored. Finally, the future development trends and the perspective on the advancing NSPs synthesis via aerosol process are elaborated for further driving innovations for supersmart and carbon-neutral society.

Enhancement of zinc-ion storage capability by synergistic effects on dual-ion adsorption in hierarchical porous carbon for high-performance aqueous zinc-ion hybrid capacitors

Aqueous zinc-ion capacitors (AZICs) are considered potential energy storage devices thanks to their ultrahigh power density, high safety, and extended cycling life. Carbon-based materials widely used as cathodes in AZICs face challenges, such as inappropriate pore sizes, poor electrolyte-electrode wettability, and insufficient vacancy defects and active sites. These limitations hinder efficient energy storage capacity and long-term stability. To address these issues, the B and F co-doped hierarchical porous carbon cathode materials (BFPC) are constructed through a facile annealing treatment process. The BFPC-2//Zn device exhibited high capacities of 222.4 and 118.3 mAh g-1 at current densities of 0.2 and 10 A g-1, respectively. Notably, the BFPC-2//Zn device demonstrated long-term cycling stability with a high capacity retention of 96.9 % after 20,000 cycles at 10 A g-1. Additionally, the assembled BFPC-2 based AZICs displayed a maximum energy density of 175.8 Wh kg-1 and an ultrahigh power density of 17.3 kW kg-1. Mechanism studies revealed that the exceptional energy storage ability and charge-transfer process of the BFPC cathode are attributed to the synergistic effect of B and F heteroatoms and the coupling effect between vacancy defects and pore size. This work presents a novel design strategy by incorporating B and F active sites into hierarchical porous carbon materials, providing enhanced energy storage capabilities for practical application in AZICs.

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.

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.

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.

Construction of Functional Phenolic Resin and Carbon Hollow Spheres by Manipulating Structural Inhomogeneity

Hollow carbonaceous spheres are extraordinarily attractive for their unique structural features and wide applications in various fields. Herein, a facile and effective synthesis methodology based on the extended Stöber process for construction of phenolic resin hollow spheres has been presented. Combined with a series of characterization techniques, the synthesis process was systematically investigated, and a possible synthesis mechanism was proposed. It is revealed that the structural inhomogeneity of the polymer product achieved by using dodecylamine and alkane is responsible for the formation of hollow architecture, which depends on spontaneous selective dissolution during the synthesis process. Different metal-doped carbonaceous hollow spheres can be obtained by introducing corresponding precursors into the synthetic system and meeting requirements of different application fields. This work presented a novel synthesis strategy of hollow carbonaceous spheres, which is significant for building a new platform of advanced functional carbon-based composites.

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.

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.

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.

Controllable synthesis of Fe3C-reinforced petal-like lignin microspheres with boosted electrochemical performance and its application in high performance supercapacitors

One more effective measure to solve the energy crisis caused by the shortage of fossil energy is to convert natural renewable resources into high-value chemical products for electrochemical energy storage. Lignin has broad application prospects in this field. In this paper, three kinds of lignin with different molecular weights were obtained by the ethanol/water grading of Kraft lignin (KL). Then, different surface morphology lignin microspheres were prepared by spray drying. Finally, petal-like microspheres were successfully prepared by mixing and grinding the above four kinds of surface morphology lignin microspheres with potassium ferrate and cyanogen chloride and carbonizing at 800 °C and were later used as electrode materials for supercapacitors. Compared with the other microspheres, LMS-F3@Fe3C has the highest specific surface area (1041.42 m2 g-1), the smallest pore size (2.36 nm) and the largest degree of graphitization (ID/IG = 1.06). At a current density of 1 A g-1, the maximum specific capacitance is 786.7 F g-1. At a power density of 1000 W kg-1, the high energy density of 83.3 Wh kg-1 is displayed. This work provides a novel approach to the modulation of surface morphology and structure of lignin microspheres.

Synthesis of Submicron-Sized Spherical Silica-Coated Iron Nickel Particles with Adjustable Shell Thickness via Swirler Connector-Assisted Spray Pyrolysis

Silica-coated iron nickel (FeNi@SiO2) particles have attracted significant attention because of their potential applications in electronic devices. In this work, submicron-sized spherical FeNi@SiO2 particles with precisely controllable shell thickness were successfully synthesized for the first time using a swirler connector-assisted spray pyrolysis system, comprising a preheater, specific connector, and main heater. The results indicated that the thickness of the SiO2 shell can be tuned from 3 to 23 nm by adjusting the parameter conditions (i.e., preheater temperature, SiO2 supplied amount). Furthermore, our fabrication method consistently yielded a high coating ratio of more than 94%, indicating an excellent quality of the synthesized particles. Especially, to gain an in-depth understanding of the particle formation process of the FeNi@SiO2 particles, a plausible mechanism was also investigated. These findings highlight the importance of controlling the preheater and SiO2 supplied amount to obtain FeNi@SiO2 particles with desirable morphology and high coating quality.

3D Framework Carbon for High-Performance Zinc-Ion Capacitors

Given the rapid progress and widespread adoption of advanced energy storage devices, there has been a growing interest in aqueous capacitors that offer non-flammable properties and high safety standards. Consequently, extensive research efforts have been dedicated to investigating zinc anodes and low-cost carbonaceous cathode materials. Despite these efforts, the development of high-performance zinc-ion capacitors (ZICs) still faces challenges, such as limited cycling stability and low energy densities. In this study, we present a novel approach to address these challenges. We introduce a three-dimensional (3D) conductive porous carbon framework cathode combined with zinc anode cells, which exhibit exceptional stability and durability in ZICs. Our experimental results reveal remarkable cycling performance, with a capacity retention of approximately 97.3% and a coulombic efficiency of nearly 100% even after 10,000 charge-discharge cycles. These findings represent significant progress in improving the performance of ZICs.

NiS Nanosheets Decorated on Hollow Carbon Spheres from Liquefied Wood for Supercapacitors

Carbon-based supercapacitors with high performance have a wide foreground among various energy storage devices. In this work, wood-based hollow carbon spheres (WHCS) were prepared from liquefied wood through the processes of emulsification, curing, carbonization, and activation. Then, the hydrodeposition method was used to introduce nickel sulfide (NiS) to the surface of the microspheres, obtaining NiS/WHCS as the supercapacitor electrode. The results show that NiS/WHCS microspheres exhibited a core-shell structure and flower-like morphology with a specific surface (307.55 m² g^-1) and a large total pore volume (0.14 cm³ g^-1). Also, the capacitance could be up to 1533.6 F g^-1 at a current density of 1 A g^-1. In addition, after 1000 charge/discharge cycles, the specific capacitance remained at 72.8% at the initial current density of 5 A g^-1. Hence, NiS/WHCS with excellent durability and high specific capacitance is a potential candidate for electrode materials.

Nitrogen and Sulfur Codoped Porous Carbon Directly Derived from Potassium Citrate and Thiourea for High-Performance Supercapacitors

By introducing a heteroatom into carbon material, an effective improvement in capacitance can be realized owing to surface oxidation and reduction reactions of pseudocapacitors. Herein, a simple one-pot carbonization activation method was proposed to convert potassium citrate into three-dimensional interconnected porous carbon (PC). Then, an effective double heteroatom doping method by thiourea was used to prepare nitrogen-sulfur-doped PC (N,S-PC). This porous structure facilitates the storage of a large number of ions and reduces their diffusion path. The synthesized N,S-PC nanomaterial has a capacitance of 674 F/g at 1 A/g in a 1 M H₂SO₄ electrolyte, can retain 94.41% of the initial capacitance after 10 000 cycles at 5 A/g, and has a long cycle life. More importantly, a symmetric supercapacitor assembled with this material can exhibit an energy density of up to 32.6 (W·h)/kg at a high-power density of 750 W/kg. This is due to the high performance of N,S-PC in supercapacitor electrode materials.

The Practical Utility of Imidazolium Hydrogen Sulfate Ionic Liquid in Fabrication of Lignin-Based Spheres: Structure Characteristic and Antibacterial Activity

In this study, lignin-based spherical particles (Lig-IL) with the use of 1-(propoxymethyl)-1H-imidazolium hydrogen sulfate were prepared in different biopolymer and ionic liquid (IL) weight ratios. The application of IL during the preparation of spherical particles is an innovative method, which may be beneficial for further applications. The particles were obtained with the use of the soft-templating method and their chemical, structural and morphological characterization was performed. The spherical shape of products and their size (91–615 nm) was confirmed with the use of scanning electron microscopy (SEM) images and the particle size distribution results. The attenuated total reflectance-Fourier transform infrared (ATR-FTIR) spectra were analyzed to identify functional groups of all precursors and produced material and it was confirmed, that all materials exhibit characteristic hydroxyl and carboxylic groups, but the presence of carbonyl group was detected. Moreover, the zeta potential analysis was performed to evaluate the electrokinetic behavior of obtained materials. It was confirmed, that all materials are colloidally stable in pH above 4. Produced lignin-based spherical particles were used for evaluation of their antibacterial properties. Particles were tested against Staphylococcus aureus (S. aureus), a gram-positive bacterium, and Escherichia coli (E. coli), a gram-negative one. It was observed, that only the material with the highest addition of IL showed the antibacterial properties against both strains. A reduction of 50% in the number of microorganisms was observed for particles with the addition of hydrogen sulfate ionic liquid in a 1:1 ratio after 1 h. However, all prepared materials exhibited the antibacterial activity against a gram-positive bacterium.