Fundamentals and recent applications of catalyst synthesis using flame aerosol technology

Commercial implementation of new catalysts is often limited by scale-up. Flame aerosol processing, a proven scalable method for industrial manufacturing of nanoparticles, has received broad attention for use in catalyst synthesis over the past two decades. This review aims to provide a straightforward understanding of the flame aerosol synthesis of catalysts and summarize recent and emerging applications of the resulting catalysts. We begin with a brief description of the catalyst formation mechanism and show how catalyst structures can be controlled by varying process parameters and reactor configuration. We then summarize the most recent progress on thermal catalysts, photocatalysts, and electrocatalysts synthesized by flame aerosol processing and analyze current trends in catalyst development by this approach. Finally, we discuss the advantages and limitations of flame-made catalysts and suggest likely promising future directions for research in this field.