Energy consumption during nanoparticle production: How economic is dry synthesis?

The production of oxide nanoparticles by selected wet-chemistry or dry processes is compared in terms of energy requirements. Clear differences arise for production using electricity-intensive plasma processes, organic- or chloride-derived flame synthesis and liquid based precipitation processes. In spite of short process chains and elegant reactor design, many dry methods inherently require vastly bigger energy consumption than the multi-step wet processes. Product composition strongly influences the selection of the preferred method of manufacturing in terms of energy requirement: Metal oxide nanoparticles of light elements with high valency, e.g. titania demand high volumes of organic precursors and traditional processes excel in terms of efficiency. Products with heavier elements, more complex composition and preferably lower valency such as doped ceria, zirconia, and most mixed oxide ceramics may be readily manufactured by recently developed dry processes.