Continuous droplet reactor for the production of millimeter sized spherical aerogels

In order to enable future use of aerogels in heterogeneous solid or fluidized bed catalysis a method of production of millimeter sized monolithic Au/Al₂O₃ aerogel spheres by a continuous flow reactor is developed. Flow velocities and synthesis parameters are optimized to produce aerogel spheres in three different sizes. The resulting aerogel spheres exhibit a porous aluminium oxide aerogel matrix with a large specific surface area of 400 m² g^-1 on which gold nanoparticles are evenly distributed. The aerogel spheres are compared to xerogels of the same material in contrast to their surface area, pore size distribution, morphology, crystal structure and thermal properties. The presented method allows a broad access to various mixed aerogel systems of oxidic carrier material and noble metal nanoparticles and is therefore relevant for the shaping of different aerogel catalyst systems.