High-rate production of non-agglomerated nanoparticles by flame synthesis

We have developed a continuous nanopowder production process, called Chemical Vapor Condensation (CVC), which involves precursor pyrolysis and condensation in a reduced pressure environment. We have further introduced a flat-flame combustor unit, operable at low pressures, as a heat source in place of the original hot wall reactor. The modified process, called Combustion Flame-Chemical Vapor Condensation (CF-CVC), has been used to produce a range of non-agglomerated nanoparticles (3-50 nm average particle size) of oxide ceramics at very high production rate (≈ 50 g/hr). Examples include SiO₂, Al₂O₃, and TiO₂. In situ laser diagnostics, which is an essential part of process optimization, has been used to characterize the flame.