New
insights have been gained into chemical transformations occurring
in the initial stages of aerosol-assisted sol–gel (AASG) synthesis
of catalysts. This has been achieved through the combined application
of optical trapping and Raman spectroscopy. AASG is an emerging technology
in catalyst manufacturing that presents numerous advantages over conventional
approaches, including the ability to access unique catalyst morphologies.
However, the processes occurring during synthesis are largely inferred
from bulk-phase analyses due to challenges in conducting in
situ or operando measurements on moving
aerosols within a flow tube. Herein, these obstacles are overcome
through Raman spectroscopic interrogation of a single aerosol droplet
constrained within an optical trap, which acts as a direct analogue
for a particle moving along a flow tube. These studies represent the
first operando investigations of AASG synthesis.
The synthesis of Ni/Al2O3 catalysts has been
studied, with spectroscopic interrogation conducted on each component
of the precursor synthesis solution, where possible, up to and including
a mixture containing all components necessary for catalyst synthesis.
Raman spectroscopy confirms the formation of stable self-assembled
macrostructures within the aerosol and provides direct insights into
the reaction mechanisms. Crucially, evidence was obtained allowing
alternative reaction pathways to be postulated within the confined
environment of an aerosol droplet in comparison to bulk-phase syntheses.
In aerosols where nickel was not present, but contained all other
components, isothermal room-temperature studies showed the formation
of stable but unreactive droplets of ∼1 μm, which were
proposed to contain micelle-type structures. Upon heating, initial
gelation transformations were seen to be achieved at temperatures
higher than ∼56 °C. Notably, little loss of spectral intensity
corresponding to the C–H stretch (ethanol) was observed from
the heated aerosol, implying that evaporation is not a prerequisite
for the reaction. When nickel is present in the synthesis solution
reactive transformations occur at room temperature, proposed to result
in a continuous Al–O–Ni–NO3 structure;
a more rapid transformation takes place at elevated temperatures.
These results provide the first direct evidence of the processes occurring
within aerosols during AASG and shed new light on the mechanistic
understanding of this technology. This therefore facilitates the design
of new synthetic approaches and hence the production of catalysts
and other materials with enhanced properties.