Photocatalytic diatom-based microstructures using spray pyrolysis
A scalable spray pyrolysis process for fabricating photocatalytic titania and iron-doped titania coatings on diatom frustules. Leverages the high surface area and nanoscale surface features of diatoms to create biodegradable photocatalytic materials for household and consumer remediation applications.
Overview
This technology offers a scalable manufacturing approach for producing photocatalytic microstructures based on diatom frustules coated with titania or iron-doped titania. Diatoms are naturally derived, biodegradable single-celled algae whose silica frustules feature nanoscale channels, ridges, and pores that significantly enhance catalyst surface area and activity. By immobilizing titania on these high-surface-area biological templates, the technology enables the development of photocatalytic materials suitable for household and consumer remediation applications.
Technical specifications
- Spray pyrolysis fabrication: An ultrasonic nebulizer-based spray pyrolysis system deposits titania and iron-doped titania coatings onto diatom frustules.
- Diatom frustule templates: Silica frustules (2–100 microns) from approximately 100,000 identified diatom species provide natural high-surface-area scaffolds with nanoscale (10² nm) patterned features including channels, ridges, and pores.
- Iron-doped titania coatings: Dopant incorporation modifies band gap properties to enhance photocatalytic performance under visible and ultraviolet light.
- Property-performance database: Chemical and functional characterization data guide material design and process optimization.
- Validation methods: Scanning electron microscopy for reproducibility assessment, Fourier transform infrared spectroscopy for chemical bonding analysis, X-ray diffraction for phase identification and crystal size, X-ray photoelectron spectroscopy for elemental analysis, and ultraviolet-visible spectroscopy for coating thickness and band gap determination.
- Photocatalytic testing: Benchtop studies assess functional performance of coated high-aspect-ratio structures.
Technology readiness level
The technology is at an early-to-mid stage of development. Prior work by the research team demonstrated titanium oxide coatings on nanoporous alumina membranes using atomic layer deposition, which exhibited antibacterial activity against pathogenic organisms including Escherichia coli and Staphylococcus aureus under ultraviolet light. The current effort focuses on scaling up fabrication via spray pyrolysis and building a property-performance database to guide photocatalytic material development. Future validation will include comprehensive structural, chemical, and functional characterization to assess reproducibility and photocatalytic functionality of the coated frustule structures.
About North Carolina State University
North Carolina State University is a large, comprehensive public land‑grant research university in Raleigh. Its on‑campus research and technology park co‑locates corporate R&D groups, government partners, and faculty labs, enabling shared facilities, prototyping, and agile contracting. Located in North Carolina’s Research Triangle, partners tap a dense regional ecosystem while engaging through a statewide extension network and a mature co‑op program that deliver field deployment and workforce pipelines. Multiple pilot and demonstration facilities support scale‑up and validation toward pre‑commercial readiness. Research is supported by competitive funding from major federal agencies, including NSF, USDA, DOE, and DOD, and a dedicated technology transfer office with clear IP pathways helps accelerate commercialization.
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