A droplet-based microfluidic reaction scheme is developed where the chemical reactants are dispensed with precise volume control into pairs of droplets. The reaction is activated by coalescing droplet pairs and fast mixing inside the coalesced droplets. Furthermore, the pre-processing of the chemical products is included in the microfluidic device. This reaction scheme allows the performing of precisely volume controlled reactions and long operation times without any clogging even if precipitates or sticky gels are formed during the reaction. Using this approach and optimizing the reaction parameters, we generate mesoporous silica microspheres from a rapid gelation optimized sol-gel synthesis route. The produced silica particles have a superior surface area of 820 m(2) g(-1) and a narrow pore radius distribution of around 2.4 nm.

We describe here the use of liquid-feed flame spray pyrolysis (LF-FSP) to produce high surface area, nonporous, mixed-metal oxide nanopowders that were subsequently subjected to high-throughput screening to assess a set of materials for deNO(x) catalysis and hydrocarbon combustion. We were able to easily screen some 40 LF-FSP produced materials. LF-FSP produces nanopowders that very often consist of kinetic rather than thermodynamic phases. Such materials are difficult to access or are completely inaccessible via traditional catalyst preparation methods. Indeed, our studies identified a set of Ce(1-x)Zr(x)O(2) and Al(2)O(3)-Ce(1-x)Zr(x)O(2) nanopowders that offer surprisingly good activities for both NO(x) reduction and propane/propene oxidation both in high-throughput screening and in continuous flow catalytic studies. All of these catalysts offer activities comparable to traditional Pt/Al(2)O(3) catalysts but without Pt. Thus, although Pt-free, they are quite active for several extremely important emission control reactions, especially considering that these are only first generation materials. Indeed, efforts to dope the active catalysts with Pt actually led to lower catalytic activities. Thus the potential exists to completely change the materials used in emission control devices, especially for high-temperature reactions as these materials have already been exposed to 1500 degrees C; however, much research must be done before this potential is verified.

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