Flame-made airborne V 2 O 5 /TiO 2 nanoparticles were deposited directly onto mullite foam supports to create ready-to-use catalysts for the o-xylene conversion to phthalic anhydride. These particles containing 10% (w/w) V 2 O 5 were created by combustion of liquid precursor sprays and characterized by transmission electron microscopy, nitrogen adsorption, X-ray diffraction (XRD), temperature-programmed reduction (TPR), and Raman spectroscopy. The specific surface area, anatase content, and dominantly monomeric vanadia species on titania were thermally stable up to 450 • C. Catalyst structure was controlled in situ during deposition by the particle-laden gas flow rate through the foam, resulting in homogeneous to patchy V 2 O 5 /TiO 2 coatings. The catalytic activity and selectivity were affected by both coating texture and particle morphology. These flamecoated foams showed superior catalytic activity and selectivity at high conversions than classic, wet-made V 2 O 5 /TiO 2 catalysts.
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