Nanotechnology has great potential to transform science and industry in the fields of energy, material, environment, and medicine. At the same time, more concerns are being raised about the occupational health and safety of nanomaterials in the workplace and the implications of nanotechnology on the environment and living systems. Studies on environmental, health, and safety (EHS) issues of nanomaterials have a strong influence on public acceptance of nanotechnology and, eventually, affect its sustainability. Oversight and regulation by government agencies and non-governmental organizations (NGOs) play significant roles in ensuring responsible and environmentally friendly development of nanotechnology. The EHS studies of nanomaterials can provide data and information to help the development of regulations and guidelines. We present research results on three aspects of EHS studies: physico-chemical characterization and measurement of nanomaterials; emission, exposure, and toxicity of nanomaterials; and control and abatement of nanomaterial releases using filtration technology. Measurement of nanoparticle agglomerates using a newly developed instrument, the Universal NanoParticle Analyzer (UNPA), is discussed. Exposure measurement results for silicon nanoparticles in a pilot scale production plant are presented, as well as exposure measurement and toxicity study of carbon nanotubes (CNTs). Filtration studies of nanoparticle agglomerates are also presented as an example of emission control methods.

Silicon based thermoelectrics are promising candidates for high temperature energy scavenging applications. We present the properties of thermoelectrics made from highly boron doped silicon nanoparticles. The particles were produced by a continuous gas phase process in a scaled‐up synthesis plant enabling production rates in the kg h−1 regime. The silicon nanoparticles were compacted by direct current assisted sintering to yield nanocrystalline bulk silicon with average crystallite size between 40 and 80 nm and relative densities above 97% of the density of single crystalline silicon. The influence of the sintering temperature on the thermoelectric properties is investigated. It was found that high sintering temperatures are beneficial for an enhancement of the power factor, while the thermal conductivity was only moderately affected. The optimization of the compaction procedure with respect to the transport properties leads to zT values of the p‐type nanosilicon of 0.32 at 700 °C, demonstrating the potential of our method.

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The silicon age that started in the 60s of the last century has changed the world profoundly, mainly related to the invention and development of microprocessor technology. Meanwhile, the demand for silicon is driven by the photovoltaics industry that consumes about 80% of the high-purity silicon produced worldwide. Independent of the final product, all high-purity silicon has passed through a couple of gas-phase reactions for purification. The most important gaseous species within this production chain are chlorosilanes and monosilane. We will discuss the direct formation of crystalline silicon by homogeneous gas-phase reactions as a direct and highly economical way to produce the required high-purity raw material for silicon solar cells. The direct formation of solid silicon particles from monosilane requires only a fraction of the energy compared to the established Siemens process based on the chemical vapor deposition of silanes. We have developed a method to synthesize nanocrystalline silicon powder using a hot-wall reactor, and the technology was scaled up to the pilot-plant scale. While an economical production strategy is decisive for solar cell production, the structure of the gas-phase product allows for additional, highly promising applications benefiting from the specific properties of the nanoscale particulate material. Both, thermoelectric generators as well as lithiumion batteries benefit from the nanocrystalline structure of the gas-phase product due to high phonon scattering and short diffusion lengths, respectively. First successful examples with regard to these two topics will be discussed. In these fields, silicon finds potential new markets for sustainable energy technology because of its abundant availability and low-cost production.

Emission into the workplace was measured for the production process of silicon nanoparticles in a pilot-scale facility at the Institute of Energy and Environmental Technology e.V. (IUTA). The silicon nanoparticles were produced in a hot-wall reactor and consisted of primary particles around 60 nm in diameter. We employed real-time aerosol instruments to measure particle number and lungdeposited surface area concentrations and size distribution; airborne particles were also collected for off-line electron microscopic analysis. Emission of silicon nanoparticles was not detected during the processes of synthesis, collection, and bagging. This was attributed to the completely closed production system and other safety measures against particle release which will be discussed briefly. Emission of silicon nanoparticles significantly above the detection limit was only observed during the cleaning process when the production system was open and manually cleaned. The majority of the detected particles was in the size range of 100-400 nm and were silicon nanoparticle agglomerates first deposited in the tubing then re-suspended during the cleaning process. Appropriate personal protection equipment is recommended for safety protection of the workers during cleaning.

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The formation of iron particles without and with carbon coating was studied in a hot wall flow reactor. The precursors ironpentacarbonyl (IPC, Fe(CO)5) and ethylene (C2H4) both diluted in N2 were used in a concentric tubular flow arrangement and were heated to temperatures between 570 and 1170 K at pressures between 50 and 500 mbar. In experiments without C2H4, either individual iron particles in the size range of or long iron chains composed of several hundreds of individual iron particles were found depending on the reaction conditions. In experiments with C2H4 addition, these particles or particle chains were covered by a thin carbon/carbide layer. The size of the primary particles was measured in situ by time-resolved laser-induced incandescence (TR-LII) and ex situ by rapid thermophoretic particle probing and TEM imaging.

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