Flame Spray Pyrolysis Synthesis of Ultra-Small High-Entropy Alloy-Supported Oxide Nanoparticles for CO2 Hydrogenation Catalysts

The synthesis of high-entropy alloys (HEAs) with ultra-small particle sizes has long been a challenging task. The complex and time-consuming synthesis process hinders their practical application and widespread adoption. This study presents the novel synthesis of TiO2 nanoparticles loaded with a quinary high-entropy alloy through flame spray pyrolysis (FSP) for the first time. The extremely fast heating rate of flame combustion makes the precursor fast pyrolysis gasification, high temperature in the flame field promotes the metal vapor mixing uniformly, and the fast quenching process can reduce the particle aggregation sintering, the ultra-small particle size of HEA firmly attached to the TiO2 surface. The catalysts prepared via this gas-to-particle pathway exhibit excellent performance in CO2 hydrogenation, achieving a conversion rate of 62% at 450 °C, and maintaining their activity for over 220 h without significant particle agglomeration. This finding provides valuable insights for the future design of catalytically active materials with enhanced activity and long-term stability.

The Micron-Droplet-Confined Continuous-Flow Synthesis of Freestanding High-Entropy-Alloy Nanoparticles by Flame Spray Pyrolysis

Alloying multiple immiscible elements into a nanoparticle with single-phase solid solution structure (high-entropy-alloy nanoparticles, HEA-NPs) merits great potential. To date, various kinds of synthesis techniques of HEA-NPs are developed; however, a continuous-flow synthesis of freestanding HEA-NPs remains a challenge. Here a micron-droplet-confined strategy by flame spray pyrolysis (FSP) to achieve the continuous-flow synthesis of freestanding HEA-NPs, is proposed. The continuous precursor solution undergoes gas shearing and micro-explosion to form nano droplets which act as the micron-droplet-confined reactors. The ultrafast evolution (<5 ms) from droplets to <10 nm nanoparticles of binary to septenary alloys is achieved through thermodynamic and kinetic control (high temperature and ultrafast colling). Among them, the AuPtPdRuIr HEA-NPs exhibit excellent electrocatalytic performance for alkaline hydrogen evolution reaction with 23 mV overpotential to achieve 10 mA cm-2, which is twofold better than that of the commercial Pt/C. It is anticipated that the continuous-flow synthesis by FSP can introduce a new way for the continuous synthesis of freestanding HEA-NP with a high productivity rate.

Pd Single-Atom Loaded Ce-Zr Solid Solution Catalysts Prepared by Flame Spray Pyrolysis for Efficient CO Catalytic Oxidation

Single-atom catalysts (SACs) exhibit remarkable catalytic activity at each metal site. However, conventionally synthesized single-atom catalysts often possess low metal loading, thereby constraining their overall catalytic performance. Here, a flame spray pyrolysis (FSP) method for the synthesis of a single-atom catalyst with a high loading capacity of up to 1.4 wt.% in practice is reported. CeZrO2 acts as a carrier and provides a large number of anchoring sites, which promotes the high-density generation of Pd, and the strong interaction between the metal and the support avoids atom aggregation. Pd-CeZrO2 series catalysts have excellent CO oxidation performance. When 0.97 wt.% Pd is added, the catalytic activity is the highest, and the temperature can be reduced to 120 °C. This work presented here demonstrates that FSP, as an inherently scalable technique, allows for elevating the single-atom loading to achieve an increase in its catalytic performance. The method presented here more options for the preparation of SACs.

Deep Insight into the Mechanism of Catalytic Combustion of CO and CH4 over SrTi1-xBxO3 (B = Co, Fe, Mn, Ni, and Cu) Perovskite via Flame Spray Pyrolysis

Perovskites have been recognized as affordable substitutes for noble-metal catalysts for their tunable catalytic activity and thermal stability. Nevertheless, the highly demanding synthesis procedure still hinders the application of perovskites in catalytic combustion. In this work, a series of nanostructured SiTiO3 perovskites with B-site partial substitution by Co, Fe, Mn, Ni, and Cu are synthesized via flame spray pyrolysis in one step. The comprehensive characterizations on textural properties of nanostructured perovskites reveal that the flame-made perovskite nanoparticles all exhibit high crystal purity and large specific surface area (∼40 m2/g). Furthermore, the highest catalytic activity is achieved by SrTi0.5Co0.5O3 due to the formation of favorable oxygen vacancies, outstanding reducibility, and oxygen desorption capability. Additionally, the presence of 10 vol % water vapor during long-term testing indicates remarkable durability and water resistance. Finally, the CO oxidation and CH4 dehydrogenation on SrTiO3 incorporating Co atoms are more thermodynamically and kinetically favorable than those on other doped surfaces.

In Situ Determination of Droplet and Nanoparticle Size Distributions in Spray Flame Synthesis by Wide-Angle Light Scattering (WALS)

The investigation of droplet and nanoparticle formation in spray flame synthesis requires sophisticated measurement techniques, as often both are present simultaneously. Here, wide-angle light scattering (WALS) was applied to determine droplet and nanoparticle size distributions in spray flames from a standardized liquid-fed burner setup. Solvents of pure ethanol and a mixture of ethanol and titanium isopropoxide, incepting nanoparticle synthesis, were investigated. A novel method for the evaluation of scattering data from droplets between 2 µm and 50 µm was successfully implemented. Applying this, we could reveal the development of a bimodal droplet size distribution for the solvent/precursor system, probably induced by droplet micro-explosions. To determine nanoparticle size distributions, an appropriate filter and the averaging of single-shot data were applied to ensure scattering from a significant amount of nanoparticles homogeneously distributed in the measurement volume. From the multivariate analysis of the scattering data, the presence of spherical particles and fractal aggregates was derived, which was confirmed by analysis of transmission electron microscopy images. Monte Carlo simulations allowed determining the distribution parameters for both morphological fractions in three heights above the burner. The results showed relatively wide size distributions, especially for the spherical fraction, and indicated an ongoing sintering, from fractal to spherical particles.

CuO Quantum Dots Supported by SrTiO3 Perovskite Using the Flame Spray Pyrolysis Method: Enhanced Activity and Excellent Thermal Resistance for Catalytic Combustion of CO and CH4

As a non-noble-metal catalyst, CuO has great potential in the catalytic combustion of CO and CH₄. In this work, the influence of loading active copper components onto perovskites and essential operating parameters in flame aerosol synthesis has been experimentally and theoretically investigated to optimize the catalytic efficiency for the complete oxidation of lean CO and CH₄. Herein, the CuO-SrTiO₃ nanocatalysts are one-step-synthesized by flame spray pyrolysis with varied copper loadings and precursor feeding rates. The sample under the precursor flow rate of 3 mL/min and the CuO loading of 15 mol % demonstrates optimal catalytic performance. It is primarily attributed to the excellent low-temperature reducibility and improved activity of copper species originated by CuO quantum dots and metal-support interaction. Besides, SrTiO₃ perovskite as a support can effectively inhibit the sintering of CuO quantum dots at high temperatures, which is responsible for the excellent sintering and water deactivation resistances.

Ni-In Synergy in CO2 Hydrogenation to Methanol

Indium oxide (In2O3) is a promising catalyst for selective CH3OH synthesis from CO2 but displays insufficient activity at low reaction temperatures. By screening a range of promoters (Co, Ni, Cu, and Pd) in combination with In2O3 using flame spray pyrolysis (FSP) synthesis, Ni is identified as the most suitable first-row transition-metal promoter with similar performance as Pd-In2O3. NiO-In2O3 was optimized by varying the Ni/In ratio using FSP. The resulting catalysts including In2O3 and NiO end members have similar high specific surface areas and morphology. The main products of CO2 hydrogenation are CH3OH and CO with CH4 being only observed at high NiO loading (≥75 wt %). The highest CH3OH rate (∼0.25 gMeOH/(gcat h), 250 °C, and 30 bar) is obtained for a NiO loading of 6 wt %. Characterization of the as-prepared catalysts reveals a strong interaction between Ni cations and In2O3 at low NiO loading (≤6 wt %). H2-TPR points to a higher surface density of oxygen vacancy (Ov) due to Ni substitution. X-ray photoelectron spectroscopy, X-ray absorption spectroscopy, and electron paramagnetic resonance analysis of the used catalysts suggest that Ni cations can be reduced to Ni as single atoms and very small clusters during CO2 hydrogenation. Supportive density functional theory calculations indicate that Ni promotion of CH3OH synthesis from CO2 is mainly due to low-barrier H2 dissociation on the reduced Ni surface species, facilitating hydrogenation of adsorbed CO2 on Ov.

One-Step Synthesis of Versatile Antimicrobial Nano-Architected Implant Coatings for Hard and Soft Tissue Healing

Dental implant failure remains a prevalent problem around the globe. The integration of implants at the interface of soft and hard tissues is complex and susceptible to instability and infections. Modifications to the surface of titanium implants have been developed to improve the performance, yet insufficient integration and biofilm formation remain major problems. Introducing nanostructures on the surface to augment the implant-tissue contact holds promise for facilitated implant integration; however, current coating processes are limited in their versatility or costs. We present a highly modular single-step approach to produce multicomponent porous bioactive nanostructured coatings on implants. Inorganic nanoparticle building blocks with complex compositions and architectures are synthesized in situ and deposited on the implants in a single step using scalable liquid-feed flame spray pyrolysis. We present hybrid coatings based on ceria and bioglass, which render the implant surfaces superhydrophilic, promote cell adhesion, and exhibit antimicrobial properties. By modifications to the bioglass/ceria nanohybrid composition and architecture that prevent biomineralization, the coating can instead be tailored toward soft tissue healing. The one-step synthesis of nano-architected tissue-specific coatings has great potential in dental implantology and beyond.

Process Engineering to Increase the Layered Phase Concentration in the Immediate Products of Flame Spray Pyrolysis

Flame-spray-pyrolysis (FSP) is a robust and scalable process to synthesize particles at the commodity-scale. FSP has been used to produce the precursor powders which were converted to the layered structure (R3̅m phase) by a postannealing step in making nickel-rich cathode materials (NCMs). Theoretically, the high flame temperature (normally >1500 K) in FSP can provide adequate energy for the phase conversion from rock-salt to layered structures and potentially enables one-step synthesis. However, the high flame temperature is a critical issue to cause lithium loss and structural degradation, preventing the formation of the layered phase. In this work, guided by the gaseous nucleation theory, we implemented several FSP processes with different solution recipes. The layered phase concentration in the as-burned products can be increased with the solution enthalpies. By adding a rapid quench step to suppress the lithium loss and phase degradation, the layered phase can be further increased. This work contributes new ideas to innovating process regarding the process efficiency and throughput of manufacturing cathode materials at a large scale.

Control of Porous Layer Thickness in Thermophoretic Deposition of Nanoparticles

The film thickness plays an important role in the performance of materials applicable to different technologies including chemical sensors, catalysis and/or energy materials. The relationship between the surface and volume of the functional layers is key to high performance evaluations. Here we demonstrate the thermophoretic deposition of different thicknesses of the functional layers designed using flame combustion of tin 2-ethylhexanoate dissolved in xylene, and measurement of thickness by scanning electron microscopy and focused ion beam. The parameters such as spray fluid concentration (differing Sn2+ content), substrate-nozzle distance and time of the spray were considered to investigate the layer growth. The results showed ≈ 23, 124 and 161 μm thickness of the SnO2 layer after flame spray of 0.1, 0.5 M and 1.0 M tin 2-EHA-Xylene solutions for 1200 s. While Sn2+ concentration was 0.5 M for all the flame sprays, the substrates placed at 250, 220 and 200 mm from the flame nozzle had layer thicknesses of 113, 116 and 132 µm, respectively. Spray time dependent thickness growth showed a linear increase from 8.5 to 152.1 µm when the substrates were flame sprayed for 30 s to 1200 s using 0.5 M tin 2-EHA-Xylene solutions. Changing the dispersion oxygen flow (3-7 L/min) had almost no effect on layer thickness. Layers fabricated were compared to a model found in literature, which seems to describe the thickness well in the domain of varied parameters. It turned out that primary particle size deposited on the substrate can be tuned without altering the layer thickness and with little effect on porosity. Applications depending on porosity, such as catalysis or gas sensing, can benefit from tuning the layer thickness and primary particle size.

Lattice Defects Engineering in W-, Zr-doped BiVO4 by Flame Spray Pyrolysis: Enhancing Photocatalytic O2 Evolution

A flame spray pyrolysis (FSP) method has been developed, for controlled doping of BiVO4 nanoparticles with W and Zr in tandem with the oxygen vacancies (Vo) of the BiVO4 lattice. Based on XPS and Raman data, we show that the nanolattice of W-BiVO4 and Zr-BiO4 can be controlled to achieve optimal O2 evolution from H2O photocatalysis. A synergistic effect is found between the W- and Zr-doping level in correlation with the Vo-concentration. FSP- made W-BiVO4 show optimal photocatalytic O2-production from H2O, up to 1020 μmol/(g × h) for 5%W-BiVO4, while the best performing Zr-doped achieved 970 μmol/(g × h) for 5%Zr-BiVO4. Higher W-or Zr-doping resulted in deterioration in photocatalytic O2-production from H2O. Thus, engineering of FSP-made BiVO4 nanoparticles by precise control of the lattice and doping-level, allows significant enhancement of the photocatalytic O2-evolution efficiency. Technology-wise, the present work demonstrates that flame spray pyrolysis as an inherently scalable technology, allows precise control of the BiVO4 nanolattice, to achieve significant improvement of its photocatalytic efficiency.

Flame Pyrolysis Synthesis of Mixed Oxides for Glycerol Steam Reforming

Flame spray pyrolysis was used to produce nanosized Ni-based catalysts starting from different mixed oxides. LaNiO₃ and CeNiO₃ were used as base materials and the formulation was varied by mixing them or incorporating variable amounts of ZrO₂ or SrO during the synthesis. The catalysts were tested for the steam reforming of glycerol. One of the key problems for this application is the resistance to deactivation by sintering and coking, which may be increased by (1) improving Ni dispersion through the production of a Ni-La or Ni-Ce mixed oxide precursor, and then reduced; (2) using an oxide as ZrO₂, which established a strong interaction with Ni and possesses high thermal resistance; (3) decreasing the surface acidity of ZrO₂ through a basic promoter/support, such as La₂O₃; and (4) adding a promoter/support with very high oxygen mobility such as CeO₂. A further key feature is the use of a high temperature synthesis, such as flame spray pyrolysis, to improve the overall thermal resistance of the oxides. These strategies proved effective to obtain active and stable catalysts at least for 20 h on stream with very limited coke formation.

Control of Particle Size in Flame Spray Pyrolysis of Tb-doped Y2O3 for Bio-Imaging

Recently, the use of oxide-based nanomaterials for bio-imaging has received great attention owing to their remarkable stabilities as compared to those of conventional organic dyes. Therefore, the development of scalable methods for highly luminescent oxide materials with fine control of size has become crucial. In this study, we suggested modified flame spray pyrolysis (FSP) as a scalable method to produce a green-light emitting phosphor—Tb–doped Y₂O₃—in the nanometer size range. In our FSP method, an alkali salt (NaNO₃) was found to be highly effective as a size-controlling agent when it is simply mixed with other metal nitrate precursors. The FSP of the mixture solution resulted in oxide composites of Y₂O₃:Tb³⁺ and Na_xO. However, the sodium by-product was easily removed by washing with water. This salt-assisted FSP produced nano-sized and well-dispersed Y₂O₃:Tb³⁺ nanoparticles; their crystallinity and luminescence were higher than those of the bulk product made without the addition of the alkali salt. The nanoparticle surface was further coated with silica for biocompatibility and functionalized with amino groups for the attachment of biological molecules.

Simultaneous Nanothermometry and Deep-Tissue Imaging

Bright, stable, and biocompatible fluorescent contrast agents operating in the second biological window (1000-1350 nm) are attractive for imaging of deep-lying structures (e.g., tumors) within tissues. Ideally, these contrast agents also provide functional insights, such as information on local temperature. Here, water-dispersible barium phosphate nanoparticles doped with Mn5+ are made by scalable, continuous, and sterile flame aerosol technology and explored as fluorescent contrast agents with temperature-sensitive peak emission in the NIR-II (1190 nm). Detailed assessment of their stability, toxicity with three representative cell lines (HeLa, THP-1, NHDF), and deep-tissue imaging down to about 3 cm are presented. In addition, their high quantum yield (up to 34%) combined with excellent temperature sensitivity paves the way for concurrent deep-tissue imaging and nanothermometry, with biologically well-tolerated nanoparticles.

Flame-Made Calcium Phosphate Nanoparticles with High Drug Loading for Delivery of Biologics

Nanoparticles exhibit potential as drug carriers in biomedicine due to their high surface-to-volume ratio that allows for facile drug loading. Nanosized drug delivery systems have been proposed for the delivery of biologics facilitating their transport across epithelial layers and maintaining their stability against proteolytic degradation. Here, we capitalize on a nanomanufacturing process famous for its scalability and reproducibility, flame spray pyrolysis, and produce calcium phosphate (CaP) nanoparticles with tailored properties. The as-prepared nanoparticles are loaded with bovine serum albumin (model protein) and bradykinin (model peptide) by physisorption and the physicochemical parameters influencing their loading capacity are investigated. Furthermore, we implement the developed protocol by formulating CaP nanoparticles loaded with the LL-37 antimicrobial peptide, which is a biological drug currently involved in clinical trials. High loading values along with high reproducibility are achieved. Moreover, it is shown that CaP nanoparticles protect LL-37 from proteolysis in vitro. We also demonstrate that LL-37 retains its antimicrobial activity against Escherichia coli and Streptococcus pneumoniae when loaded on nanoparticles in vitro. Therefore, we highlight the potential of nanocarriers for optimization of the therapeutic profile of existing and emerging biological drugs.

Modulating Activity through Defect Engineering of Tin Oxides for Electrochemical CO2 Reduction

The large-scale application of electrochemical reduction of CO2, as a viable strategy to mitigate the effects of anthropogenic climate change, is hindered by the lack of active and cost-effective electrocatalysts that can be generated in bulk. To this end, SnO2 nanoparticles that are prepared using the industrially adopted flame spray pyrolysis (FSP) technique as active catalysts are reported for the conversion of CO2 to formate (HCOO-), exhibiting a FEHCOO - of 85% with a current density of -23.7 mA cm-2 at an applied potential of -1.1 V versus reversible hydrogen electrode. Through tuning of the flame synthesis conditions, the amount of oxygen hole center (OHC; Sn≡O●) is synthetically manipulated, which plays a vital role in CO2 activation and thereby governing the high activity displayed by the FSP-SnO2 catalysts for formate production. The controlled generation of defects through a simple, scalable fabrication technique presents an ideal approach for rationally designing active CO2 reduction reactions catalysts.

Asymmetrical Double Flame Spray Pyrolysis-Designed SiO2/Ce0.7Zr0.3O2 for the Dry Reforming of Methane

Silica has the potential to enhance the performance of ceria-zirconia as a support for the dry reforming of methane; however, controlling the integration of silica with the ceria-zirconia using flame spray pyrolysis (FSP) is a significant challenge. To address this challenge, an asymmetrically variable double-FSP (DFSP) system was established to control the SiO₂ interaction with Ce_0.7Zr_0.3O₂. The engineered materials were then utilized as supports for Ni for the dry reforming of methane. Initially, silica formation during FSP synthesis was examined where it was revealed that, at a low precursor concentration (<1.5 M tetraethyl orthosilicate in xylenes), the physical characteristics of the silica varied differently in relation to what is typically encountered during FSP synthesis. Explicitly, on using a 0.5 M tetraethyl orthosilicate precursor, increasing the FSP feed rate provided an increase in the specific surface area from 217 m²/g at 3 mL/min to 363 m²/g at 7 mL/min. Adopting this knowledge on silica formation under these conditions, the asymmetrical DFSP system was then exploited to regulate the integration of ceria-zirconia with the silica. To restrict the silica from coating the particles during DFSP, the intersection distance along the silica flame was tuned from 18.5 to 28.5 cm, whereas the distance along the ceria-zirconia flame was fixed at 5 cm. It was found that at short intersection distances the ceria-zirconia provided sites for silica nucleation and growth, resulting in high surface-area silica encapsulating the ceria-zirconia. At large intersection distances, encapsulation of the ceria-zirconia by silica was suppressed. An enhanced oxygen storage capacity and basicity along with the small Ni sizes facilitated by the longer intersection distances produced the most selective catalyst for the dry reforming of methane.

Silica-Coated TiN Particles for Killing Cancer Cells

Photothermal therapy (PTT) using plasmonic nanoparticles for cancer treatment is on the verge of clinical application. Titanium nitride (TiN) nanoparticles offer a promising alternative to commonly used gold-based systems at a fraction of the costs. Little is known, however, about the relationship between TiN particle characteristics and their optical properties in colloidal systems. Here, TiN nanoparticles with closely controlled characteristics are prepared by nitridation of TiO₂, and their use as PTT agents is explored. Emphasis is placed on the particle surface and core oxygen content, which dominate the TiN optical properties. Colloidal suspensions were studied under UV-vis and near-infrared (NIR) laser irradiation and correlated to particle characteristics. High nitridation temperatures and long residence times lead to increased NIR light absorption. Too high nitridation temperatures, however, lead to particle aggregation that deteriorated their optical properties. This was overcome with SiO₂ coating of TiO₂ nanoparticles prior to nitridation: the resulting SiO₂-coated TiN particles exhibited increased plasmonic performance compared to bare TiN, which is attributed to reduced plasmonic coupling effects. The optimized SiO₂-coated TiN had a photothermal efficiency of 58.5% and mass extinction coefficient of 31.6 L g^-1 cm^-1, outperforming commercial gold nanoshells that are used in clinical trials. The potential of SiO₂-coated TiN for photothermal therapy was demonstrated by controllably killing HeLa cells in vitro.

Effect of AuPd Bimetal Sensitization on Gas Sensing Performance of Nanocrystalline SnO2 Obtained by Single Step Flame Spray Pyrolysis

Improvement of sensitivity, lower detection limits, stability and reproducibility of semiconductor metal oxide gas sensor characteristics are required for their application in the fields of ecological monitoring, industrial safety, public security, express medical diagnostics, etc. Facile and scalable single step flame spray pyrolysis (FSP) synthesis of bimetal AuPd sensitized nanocrystalline SnO2 is reported. The materials chemical composition, structure and morphology has been studied by XRD, XPS, HAADFSTEM, BET, ICP-MS techniques. Thermo-programmed reduction with hydrogen (TPR-H2) has been used for materials chemical reactivity characterization. Superior gas sensor response of bimetallic modified SnO2 towards wide concentration range of reducing (CO, CH4, C3H8, H2S, NH3) and oxidizing (NO2) gases compared to pure and monometallic modified SnO2 is reported for dry and humid gas detection conditions. The combination of facilitated oxygen molecule spillover on gold particles and electronic effect of Fermi level control by reoxidizing Pd-PdO clusters on SnO2 surface is proposed to give rise to the observed enhanced gas sensor performance.

Inverted Perovskite Photovoltaics Using Flame Spray Pyrolysis Solution Based CuAlO2/Cu-O Hole-Selective Contact

We present the functionalization process of a conductive and transparent CuAlO₂/Cu-O hole-transporting layer (HTL). The CuAlO₂/Cu-O powders were developed by flame spray pyrolysis and their stabilized dispersions were treated by sonication and centrifugation methods. We show that when the supernatant part of the treated CuAlO₂/Cu-O dispersions is used for the development of CuAlO₂/Cu-O HTLs the corresponding inverted perovskite-based solar cells show improved functionality and power conversion efficiency of up to 16.3% with negligible hysteresis effect.

Guiding Ketogenic Diet with Breath Acetone Sensors

Ketogenic diet (KD; high fat, low carb) is a standard treatment for obesity, neurological diseases (e.g., refractory epilepsy) and a promising method for athletes to improve their endurance performance. Therein, the level of ketosis must be regulated tightly to ensure an effective therapy. Here, we introduce a compact and inexpensive breath sensor to monitor ketosis online and non-invasively. The sensor consists of Si-doped WO₃ nanoparticles that detect breath acetone selectively with non-linear response characteristics in the relevant range of 1 to 66 ppm, as identified by mass spectrometry. When tested on eleven subjects (five women and six men) undergoing a 36-h KD based on the Johns Hopkins protocol, this sensor clearly recognizes the onset and progression of ketosis. This is in good agreement to capillary blood β-hydroxybutyrate (BOHB) measurements. Despite similar dieting conditions, strong inter-subject differences in ketosis dynamics were observed and correctly identified by the sensor. These even included breath acetone patterns that could be linked to low tolerance to that diet. As a result, this portable breath sensor represents an easily applicable and reliable technology to monitor KD, possibly during medical treatment of epilepsy and weight loss.

Highly Selective and Rapid Breath Isoprene Sensing Enabled by Activated Alumina Filter

Isoprene is a versatile breath marker for noninvasive monitoring of high blood cholesterol levels as well as for influenza, end-stage renal disease, muscle activity, lung cancer, and liver disease with advanced fibrosis. Its selective detection in complex human breath by portable devices (e.g., metal-oxide gas sensors), however, is still challenging. Here, we present a new filter concept based on activated alumina powder enabling fast and highly selective detection of isoprene at the ppb level and high humidity. The filter contains high surface area adsorbents that retain hydrophilic compounds (e.g., ketones, alcohols, ammonia) representing major interferants in breath while hydrophobic isoprene is not affected. As a proof-of-concept, filters of commercial activated alumina powder are combined with highly sensitive but rather nonspecific, nanostructured Pt-doped SnO₂ sensors. This results in fast (10 s) measurement of isoprene down to 5 ppb at 90% relative humidity with outstanding selectivity (>100) to breath-relevant acetone, ammonia, ethanol, and methanol, superior to state-of-the-art isoprene sensors. Most importantly, when exposed continuously to simulated breath mixtures (four analytes) for 8 days, this filter-sensor system showed stable performance. It can be incorporated readily into a portable breath isoprene analyzer promising for simple-in-use monitoring of blood cholesterol or other patho/physiological conditions.

One-Step Synthesis of CuO-Cu2O Heterojunction by Flame Spray Pyrolysis for Cathodic Photoelectrochemical Sensing of l-Cysteine

CuO-Cu₂O heterojunction was synthesized via a one-step flame spray pyrolysis (FSP) process and employed as photoactive material in construction of a photoelectrochemical (PEC) sensing device. The surface analysis showed that CuO-Cu₂O nanocomposites in the size less than 10 nm were formed and uniformly distributed on the electrode surface. Under visible light irradiation, the CuO-Cu₂O-coated electrode exhibited admirable cathodic photocurrent response, owing to the favorable property of the CuO-Cu₂O heterojunction such as strong absorption in the visible region and effective separation of photogenerated electron-hole pairs. On the basis of the interaction of l-cysteine (l-Cys) with Cu-containing compounds via the formation of Cu-S bond, the CuO-Cu₂O was proposed as a PEC sensor for l-Cys detection. A declined photocurrent response of CuO-Cu₂O to addition of l-Cys was observed. Influence factors including CuO-Cu₂O concentration, coating amount of CuO-Cu₂O, and applied bias potential on the PEC response toward l-Cys were optimized. Under optimum conditions, the photocurrent of the proposed sensor was linearly declined with increasing the concentration of l-Cys from 0.2 to 10 μM, with a detection limit (3S/N) of 0.05 μM. Moreover, this PEC sensor displayed high selectivity, reproducibility, and stability. The potential applicability of the proposed PEC sensor was assessed in human urine samples.

Safe-by-Design CuO Nanoparticles via Fe-Doping, Cu-O Bond Length Variation, and Biological Assessment in Cells and Zebrafish Embryos

The safe implementation of nanotechnology requires nanomaterial hazard assessment in accordance with the material physicochemical properties that trigger the injury response at the nano/bio interface. Since CuO nanoparticles (NPs) are widely used industrially and their dissolution properties play a major role in hazard potential, we hypothesized that tighter bonding of Cu to Fe by particle doping could constitute a safer-by-design approach through decreased dissolution. Accordingly, we designed a combinatorial library in which CuO was doped with 1-10% Fe in a flame spray pyrolysis reactor. The morphology and structural properties were determined by XRD, BET, Raman spectroscopy, HRTEM, EFTEM, and EELS, which demonstrated a significant reduction in the apical Cu-O bond length while simultaneously increasing the planar bond length (Jahn-Teller distortion). Hazard screening was performed in tissue culture cell lines and zebrafish embryos to discern the change in the hazardous effects of doped vs nondoped particles. This demonstrated that with increased levels of doping there was a progressive decrease in cytotoxicity in BEAS-2B and THP-1 cells, as well as an incremental decrease in the rate of hatching interference in zebrafish embryos. The dissolution profiles were determined and the surface reactions taking place in Holtfreter's solution were validated using cyclic voltammetry measurements to demonstrate that the Cu+/Cu2+ and Fe2+/Fe3+ redox species play a major role in the dissolution process of pure and Fe-doped CuO. Altogether, a safe-by-design strategy was implemented for the toxic CuO particles via Fe doping and has been demonstrated for their safe use in the environment.

Selectivity Enhancement by Using Double-Layer MOX-Based Gas Sensors Prepared by Flame Spray Pyrolysis (FSP)

Here we present a novel concept for the selective recognition of different target gases with a multilayer semiconducting metal oxide (SMOX)-based sensor device. Direct current (DC) electrical resistance measurements were performed during exposure to CO and ethanol as single gases and mixtures of highly porous metal oxide double- and single-layer sensors obtained by flame spray pyrolysis. The results show that the calculated resistance ratios of the single- and double-layer sensors are a good indicator for the presence of specific gases in the atmosphere, and can constitute some building blocks for the development of chemical logic devices. Due to the inherent lack of selectivity of SMOX-based gas sensors, such devices could be especially relevant for domestic applications.

Ultrasensitive NO2 Sensor Based on Ohmic Metal-Semiconductor Interfaces of Electrolytically Exfoliated Graphene/Flame-Spray-Made SnO2 Nanoparticles Composite Operating at Low Temperatures

In this work, flame-spray-made undoped SnO2 nanoparticles were loaded with 0.1-5 wt % electrolytically exfoliated graphene and systematically studied for NO2 sensing at low working temperatures. Characterizations by X-ray diffraction, transmission/scanning electron microscopy, and Raman and X-ray photoelectron spectroscopy indicated that high-quality multilayer graphene sheets with low oxygen content were widely distributed within spheriodal nanoparticles having polycrystalline tetragonal SnO2 phase. The 10-20 μm thick sensing films fabricated by spin coating on Au/Al2O3 substrates were tested toward NO2 at operating temperatures ranging from 25 to 350 °C in dry air. Gas-sensing results showed that the optimal graphene loading level of 0.5 wt % provided an ultrahigh response of 26,342 toward 5 ppm of NO2 with a short response time of 13 s and good recovery stabilization at a low optimal operating temperature of 150 °C. In addition, the optimal sensor also displayed high sensor response and relatively short response time of 171 and 7 min toward 5 ppm of NO2 at room temperature (25 °C). Furthermore, the sensors displayed very high NO2 selectivity against H2S, NH3, C2H5OH, H2, and H2O. Detailed mechanisms for the drastic NO2 response enhancement by graphene were proposed on the basis of the formation of graphene-undoped SnO2 ohmic metal-semiconductor junctions and accessible interfaces of graphene-SnO2 nanoparticles. Therefore, the electrolytically exfoliated graphene-loaded FSP-made SnO2 sensor is a highly promising candidate for fast, sensitive, and selective detection of NO2 at low operating temperatures.

Electrolytically exfoliated graphene-loaded flame-made Ni-doped SnO2 composite film for acetone sensing

In this work, flame-spray-made SnO2 nanoparticles are systematically studied by doping with 0.1-2 wt % nickel (Ni) and loading with 0.1-5 wt % electrolytically exfoliated graphene for acetone-sensing applications. The sensing films (∼12-18 μm in thickness) were prepared by a spin-coating technique on Au/Al2O3 substrates and evaluated for acetone-sensing performances at operating temperatures ranging from 150 to 350 °C in dry air. Characterizations by X-ray diffraction, transmission/scanning electron microscopy, Brunauer-Emmett-Teller analysis, X-ray photoelectron spectroscopy and Raman spectroscopy demonstrated that Ni-doped SnO2 nanostructures had a spheriodal morphology with a polycrystalline tetragonal SnO2 phase, and Ni was confirmed to form a solid solution with SnO2 lattice while graphene in the sensing film after annealing and testing still retained its high-quality nonoxidized form. Gas-sensing results showed that SnO2 sensing film with 0.1 wt % Ni-doping concentration exhibited an optimal response of 54.2 and a short response time of ∼13 s toward 200 ppm acetone at an optimal operating temperature of 350 °C. The additional loading of graphene at 5 wt % into 0.1 wt % Ni-doped SnO2 led to a drastic response enhancement to 169.7 with a very short response time of ∼5.4 s at 200 ppm acetone and 350 °C. The superior gas sensing performances of Ni-doped SnO2 nanoparticles loaded with graphene may be attributed to the large specific surface area of the composite structure, specifically the high interaction rate between acetone vapor and graphene-Ni-doped SnO2 nanoparticles interfaces and high electronic conductivity of graphene. Therefore, the 5 wt % graphene loaded 0.1 wt % Ni-doped SnO2 sensor is a promising candidate for fast, sensitive and selective detection of acetone.

Flame-made Nb-doped TiO2 ethanol and acetone sensors

Undoped TiO₂ and TiO₂ nanoparticles doped with 1–5 at.% Nb were successfully produced in a single step by flame spray pyrolysis (FSP). The phase and crystallite size were analyzed by XRD. The BET surface area (SSA_BET) of the nanoparticles was measured by nitrogen adsorption. The trend of SSA_BET on the doping samples increased and the BET equivalent particle diameter (d_BET) (rutile) increased with the higher Nb-doping concentrations while d_BET (anatase) remained the same. The morphology and accurate size of the primary particles were further investigated by high-resolution transmission electron microscopy (HRTEM). The crystallite sizes of undoped and Nb-doped TiO₂ spherical were in the range of 10–20 nm. The sensing films were prepared by spin coating technique. The mixing sample was spin-coated onto the Al₂O₃ substrates interdigitated with Au electrodes. The gas sensing of acetone (25–400 ppm) was studied at operating temperatures ranging from 300–400 °C in dry air, while the gas sensing of ethanol (50–1,000 ppm) was studied at operating temperatures ranging from 250–400 °C in dry air.

Flame-spray-made undoped zinc oxide films for gas sensing applications

Using zinc naphthenate dissolved in xylene as a precursor undoped ZnO nanopowders were synthesized by the flame spray pyrolysis technique. The average diameter and length of ZnO spherical and hexagonal particles were in the range of 5 to 20 nm, while ZnO nanorods were found to be 5–20 nm wide and 20–40 nm long, under 5/5 (precursor/oxygen) flame conditions. The gas sensitivity of the undoped ZnO nanopowders towards 50 ppm of NO₂, C₂H₅OH and SO₂ were found to be 33, 7 and 3, respectively. The sensors showed a great selectivity towards NO₂ at high working temperature (at 300 °C), while small resistance variations were observed for C₂H₅OH and SO₂, respectively.

H(2) Sensing Response of Flame-Spray-Made Ru/SnO(2) Thick Films Fabricated from Spin-Coated Nanoparticles

High specific surface area (SSA_BET: 141.6 m²/g) SnO₂ nanoparticles doped with 0.2–3 wt% Ru were successfully produced in a single step by flame spray pyrolysis (FSP). The phase and crystallite size were analyzed by XRD. The specific surface area (SSA_BET) of the nanoparticles was measured by nitrogen adsorption (BET analysis). As the Ru concentration increased, the SSA_BET was found to linearly decrease, while the average BET-equivalent particle diameter (d_BET) increased. FSP yielded small Ru particles attached to the surface of the supporting SnO₂ nanoparticles, indicating a high SSA_BET. The morphology and accurate size of the primary particles were further investigated by TEM. The crystallite sizes of the spherical, hexagonal, and rectangular SnO₂ particles were in the range of 3–10 nm. SnO₂ nanorods were found to range from 3–5 nm in width and 5–20 nm in length. Sensing films were prepared by the spin coating technique. The gas sensing of H₂ (500–10,000 ppm) was studied at the operating temperatures ranging from 200–350 °C in presence of dry air. After the sensing tests, the morphology and the cross-section of sensing film were analyzed by SEM and EDS analyses. The 0.2%Ru-dispersed on SnO₂ sensing film showed the highest sensitivity and a very fast response time (6 s) compared to a pure SnO₂ sensing film, with a highest H₂ concentration of 1 vol% at 350 °C and a low H₂ detection limit of 500 ppm at 200 °C.

Sensing Characteristics of Flame-Spray-Made Pt/ZnO Thick Films as H(2) Gas Sensor

Hydrogen sensing of thick films of nanoparticles of pristine, 0.2, 1.0 and 2.0 atomic percentage of Pt concentration doped ZnO were investigated. ZnO nanoparticles doped with 0.2-2.0 at.% Pt were successfully produced in a single step by flame spray pyrolysis (FSP) technique using zinc naphthenate and platinum(II) acetylacetonate as precursors dissolved in xylene. The particle properties were analyzed by XRD, BET, SEM and TEM. Under the 5/5 (precursor/oxygen) flame condition, ZnO nanoparticles and nanorods were observed. The crystallite sizes of ZnO spheroidal and hexagonal particles were found to be ranging from 5 to 20 nm while ZnO nanorods were seen to be 5-20 nm wide and 20-40 nm long. ZnO nanoparticles paste composed of ethyl cellulose and terpineol as binder and solvent respectively was coated on Al(2)O(3) substrate interdigitated with gold electrodes to form thin films by spin coating technique. The thin film morphology was analyzed by SEM technique. The gas sensing properties toward hydrogen (H(2)) was found that the 0.2 at.% Pt/ZnO sensing film showed an optimum H(2) sensitivity of ∼164 at hydrogen concentration in air of 1 volume% at 300 °C and a low hydrogen detection limit of 50 ppm at 300 °C operating temperature.