High surface area Ag-ZnO catalysts have been made by flame spray pyrolysis (FSP) and characterized by X-ray diffraction (XRD), nitrogen adsorption, UV-vis spectroscopy and electron microscopy (SEM and transmission electron microscopy (TEM)) combined with energy dispersive X-ray spectroscopy (EDXS) for elemental mapping. Silver metal clusters deposited directly on ZnO nanocrystals were obtained from this process. The Ag loading (1-5 at.%) controlled the Ag cluster size from 5 to 25 mn but did not influence the ZnO crystal size. Photodegradation of 10 ppm methylene blue (MB) solution was used to evaluate the performance of these FSP-made Ag-ZnO and was compared to wet-made Ag-ZnO and reference titania photocatalysts. The rate of photodegradation was optimal for Ag loading around 3 at.%. The best photocatalytic performance was exhibited by flame-made Ag-ZnO produced at the longest high-temperature residence times having high crystallinity as determined by XRD and UV-vis. (c) 2005 Elsevier B.V. All rights reserved.