A review of flame aerosol synthesis technology for the synthesis of nanoparticles and functional energy materials

• Published in: Journal of solid state chemistry 2024-08, Vol.336, p.124774, Article 124774
• Main Authors: Zhang, Haoyu, Goh, Brandon Han Hoe, Chong, Cheng Tung, Zhang, Yiran, Lee, Chew Tin, Gao, Yi, Tian, Bo, Tran, Manh-Vu, Mohd Yasin, Mohd Fairus, Ng, Jo-Han
• Format: Article
• Language: English
• Subjects: Elemental doping; Flame aerosol synthesis; Functional material; Nanomaterials; Spray flame synthesis
• ISSN: 0022-4596; 1095-726X
• DOI: 10.1016/j.jssc.2024.124774

The outstanding performance of nanomaterials in chemical, magnetic, electrical, catalytic, and mechanical properties has paved the way for the huge market in material fabrication, energy storage, electronics, and many other industries. Traditional synthesis methods are relatively stunted in industrial applicability and scalability due to complex manufacturing processes and long preparation times, hampering the development and commercialisation of nanomaterials. On the other hand, the flame synthesis method emerges as an inexpensive, efficient, and easily scalable method for the commercial production of nanoparticles. The present review aims to highlight the research status and applications of the nanomaterials synthesised by the flame aerosol method. The advancement of flame aerosol synthesis technologies is reviewed, with emphasis on the state-of-the-art flame reactor configuration and design. Critical flame parameters that govern the formation of nanoparticles in the flame are reviewed to provide an understanding of the formation criteria and growth of nanomaterials in the flame environment. The properties and characteristics of carbon-based, platinum group metal, metal oxide, bimetallic nanoparticles, perovskite and high entropy oxide nanomaterials produced by flame synthesis are extensively reviewed. In addition, commercial manufacturing of flame-synthesised materials along with applications of the nanomaterials in the field of thermal or photocatalytic energy storage, fuel cells, and gas sensing are presented. Synthesis of nanomaterials using flame aerosol technologies and applications of the nanomaterials in the field of thermal or photocatalyst, energy storage, fuel cell, thermochemical catalyst and gas sensing. [Display omitted] •Flame aerosol technology has the advantage of rapid production and scalability.•Formation of complex nanoparticles with multi-component is feasible with flame aerosol method.•Bimetallic materials production can be achieved by optimizing the processing parameters in flame.•The residence time of precursor in flame may affect the product crystallisation.•The applications of different flame-synthesised nanomaterials in the energy applications are reviewed.