Industrial Scale Engineering of Photocatalytic Nanomaterials by Flame Spray Pyrolysis (F.S.P.)

Abstract

Flame Spray Pyrolysis is an attractive technology for the synthesis of nanosized materials with distinct characteristics. Industry leaders such as Cabot, Cristal, DuPont, Evonik, and Ishihara manufacture flame-made materials in millions of tons per year including carbon blacks. Herein we exemplify the application of large-scale FSP process for the synthesis of highly active photocatalysts, able to achieve high H2, O2 production yields from H2O. Precise control of W-doping along with controlled Scheelite-phase BiVO4 is a benchmark oxygen-evolving nanocatalyst. Double-Nozzle FSP is demonstrated to allow the production of highly efficient {noble metal} TiO2 heterostructures. Key-Performance-Indicators that allow transition of Lab-Scale to Industrial-Scale engineering of semiconductors are discussed, including cost-analysis and environmental impact of the production process.