Flame spray synthesis is investigated as a method for one step synthesis and deposition of porous catalysts onto surfaces and into microreactors. Using a standard photolithographic lift-off process, catalyst can be deposited on flat surfaces in patterns with sub-millimeter feature sizes. With shadow masks, porous catalyst layers can be deposited selectively into microchannels. Using Au/TiO$_2$ as test catalyst and CO-oxidation as test reaction, it is found that the apparent activation energy of the deposited catalyst is similar to what is normally seen for supported gold catalysts in the literature. The surface area of the deposited material is more than twice as large as when the flame-produced material is collected on a filter at the outlet of the flame reactor unit.
Journal of Catalysis, 2004, Vol 223, Issue 2, p. 271-277