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Ultrahigh surface area nanoporous silica particles via an aero-sol-gel process.

We describe a new salt-assisted aero-sol-gel approach to produce spherical nanosized mesoporous silica particles. As an alternative to expensive templating mediums in prior works, salt (NaCl) was employed as a templating medium because it is thermally stable, recyclable, and easily leached. Furthermore, we demonstrate the ability to carry out traditional sol-gel chemistry within an aerosol droplet. The role of salt in sol-gel chemistry and aerosol processing was investigated as a function of hydrolysis time. It was verified that salt accelerates the kinetics of silica gelation, and simultaneously becomes an excellent templating medium to support nano-sized pores inside silica structures in the aerosol processing route. The presence of salt results in a roughly ten-fold increasing in the pore specific surface area and pore volume, subsequent to leaching of the salt matrix. The surface area and pore volume of the as-produced nanoporous silica particles was found to increase with increasing sol-gel hydrolysis time.