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Material Synthesis by Aerosol Process. Reporter: Liao Lingzhi April.17 th 2012 . Outline. Aerosol Application Aerosol Process Gas-to-Particle Conversion Droplet-to-Particle Conversion Comparison of Reactors Measurement Techniques. Aerosol Application. Environment Climate Acid rain
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Material Synthesis by Aerosol Process Reporter: Liao Lingzhi April.17th 2012
Outline • Aerosol Application • Aerosol Process • Gas-to-Particle Conversion • Droplet-to-Particle Conversion • Comparison of Reactors • Measurement Techniques
Aerosol Application Environment Climate Acid rain Ozone hole Smog Energy Fuel injection engines Coal combustion Metallic Fuels Turbine combustion Flue gas cleaning Health Asbestosis Smoking Medicine Allergies Aerosol Materials Carbon Blacks Titania pigments Zinc oxide Fumed silica Ni, Fe, Pt, Zn2SiO4 Astrophysics Planet formation Star dust
Aerosol Application http://topnews.net.nz/content/23603-new-spray-make-men-warmer-discovered-german-researchers http://www.chericherie.com/ http://italian-ceramics-art.com/elegant-dishes-gifts/Ceramic-Majolica-Cappuccino-Cup-Saucer-FDL-Yellow-Red.html http://www.weallscheme.com/2009/12/22/introducing-the-aston-martin-carbon-black-special-edition-2/
Outline • Aerosol Application • Aerosol Process • Gas-to-Particle Conversion • Droplet-to-Particle Conversion • Comparison of Reactors • Measurement Techniques
Aerosol Process • Gas-to-Particle Conversion • Droplet-to-Particle Conversion Tearing Down Building Up S.E. Pratsinis, Tutorial session at the 14th Annual Meeting of the AAAR, Pittsburgh, Pa, 9 October 1995.
Aerosol Process Desired Properties: • Fine particle size (<1μm, or even nonascale) • Narrow or monodispersedistribution • Spherical or equiaxial particle shape • No agglomeration or soft agglomerates • High purity of chemical composition • Single phase
Outline • Aerosol Application • Aerosol Process • Gas-to-Particle Conversion • Droplet-to-Particle Conversion • Comparison of Reactors • Measurement Techniques
Gas-to-Particle Conversion S.E. Pratsinis, Tutorial session at the 14th Annual Meeting of the AAAR, Pittsburgh, Pa, 9 October 1995. H. Sodano, Ceramic Processing Classnotes, FL, April 2012
Gas-to-Particle Conversion • Flame Reactor • Furnace Reactor • Laser Reactor • Plasma Reactor • Evaporation/Condensation Unit with or without Chemical Reaction
Flame Reactor http://www.youtube.com/watch?v=s1phxdEcUmI S.E. Pratsinis, Tutorial session at the 14th Annual Meeting of the AAAR, Pittsburgh, Pa, 9 October 1995. Counter-flow Diffusion FR Premixed FR Co-flow Diffusion FR Mn/Si Ti/Si • W.J. Stark, S.E. Pratsinis, Aerosol flame reactors for manufacture of nanoparticles. Powder Technology. 126, 103-108 (2002) 11
Flame Reactor • Advantages: • High product purity • Produce in large-scale, inexpensive • Flexibility in the product of the primary particle size (3-600 μm) • Disadvantages: • Hard agglomerates • Broad particle size distribution • Volatile precursor
Furnace Reactor S.E. Pratsinis, Tutorial session at the 14th Annual Meeting of the AAAR, Pittsburgh, Pa, 9 October 1995.
Furnace Reactor • Advantages: • Precise control of temperature and residence time • Good control of the product particle size • High product purity • Disadvantages: • Less energy efficient than flame reactors • Temperature up to 2100 ℃ • Deposits of powders on reactor wall
Outline • Aerosol Application • Aerosol Process • Gas-to-Particle Conversion • Droplet-to-Particle Conversion • Comparison of Reactors • Measurement Techniques
Droplet-to-Particle Conversion S.E. Pratsinis, Tutorial session at the 14th Annual Meeting of the AAAR, Pittsburgh, Pa, 9 October 1995.
Droplet-to-Particle Conversion • Droplet Generation • Spray Pyrolysis • Spray Drying • Freeze Drying
Droplet Generation S.E. Pratsinis, Tutorial session at the 14th Annual Meeting of the AAAR, Pittsburgh, Pa, 9 October 1995.
Spray Pyrolysis • S. Allen, Spray pyrolysis presentation, University of Geulph Precursors----Evaporation----Drying ----Droplet Coagulation ----In situ solid reactions and sintering
Spray Pyrolysis • Advantage: • High product purity • Multicomponent ceramic powders • Cost effective (few unit operations) • Disadvantage: • Particle size distribution highly depend on spread of droplet generator • Porous or hollow particles formed
Particle Formation Solution Droplet Solid Shell with liquid inside Evaporation, precipitation and reaction Explosion Broken shell and Solution droplets Hollow particles Reaction Solid particle S.E. Pratsinis, Tutorial session at the 14th Annual Meeting of the AAAR, Pittsburgh, Pa, 9 October 1995. 22
Outline • Aerosol Application • Aerosol Process • Gas-to-Particle Conversion • Droplet-to-Particle Conversion • Comparison of Reactors • Measurement Techniques
Comparison of Aerosol Process • P.A. Baron, W. Klaus, Aerosol Measurement: principles, techniques, and applications (Wiley-Interscience, c2005), pp 721-743. [second edition]
Outline • Aerosol Application • Aerosol Process • Gas-to-Particle Conversion • Droplet-to-Particle Conversion • Reactors • Measurement Techniques
Characterizations need to be measured • Physical • Size • Shape • Microstructure • porosity • Chemical • Phase composition • Thermophysical • Thermochemical • Surface properties
Summary of Characterization Tech • P.A. Baron, W. Klaus, Aerosol Measurement: principles, techniques, and applications (Wiley-Interscience, c2005), pp 721-743. [second edition]
Particle Size Analysis Tech • P.A. Baron, W. Klaus, Aerosol Measurement: principles, techniques, and applications (Wiley-Interscience, c2005), pp 721-743. [second edition]
Summary of Characterization Tech • P.A. Baron, W. Klaus, Aerosol Measurement: principles, techniques, and applications (Wiley-Interscience, c2005), pp 721-743. [second edition]
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