GOALI: Flame-based Synthesis of Metal Nanoparticles at Millisecond Residence Times

主要研究者：Swihart，Mark机构：纽约州立大学布法罗分校提案编号：1066945标题：GOALI：毫秒驻留时间内基于火焰的金属纳米颗粒合成PI计划将其布法罗大学（SUNY）和普莱克斯团队的专业知识结合起来，开发一种新的基于火焰的金属纳米颗粒生产工艺。印刷电子、抗菌塑料和金属纳米颗粒的其他应用正在迅速增长。目前，这些颗粒是使用大量溶剂、高价值表面活性剂和聚合物制备的。如果气相火焰法能够充分控制粒度、粒度分布和团聚程度，则它将为这些纳米材料提供一种成本更低、更环保的途径。大多数大规模生产的金属氧化物纳米材料（TiO 2、ZrO 2等）由于这些原因，炭黑在火焰法中制备。然而，对于大多数金属来说，情况并非如此，因为它们在火焰中氧化。这里所追求的方法基于普莱克斯开发的热喷嘴技术，提供了金属纳米颗粒生产所需的高温、短停留时间、快速混合和还原条件。喷嘴和下游反应器为颗粒生长提供了高度均匀的环境，与其他气相工艺相比，改善了对颗粒尺寸、尺寸分布和形态的控制。最重要的是，这种方法将前体化学与火焰化学分开，允许使用前体，例如不能用于其他基于火焰的方法的低成本含水盐，并允许独立于火焰动力学控制颗粒形成的停留时间。本研究的具体目标是：1。系统研究关键操作参数对单组分纳米粒子粒径分布和形貌的影响，优化产率，控制粒径分布.探索多组分（合金和核壳）纳米颗粒、涂层金属纳米颗粒以及包括树枝状碳在内的其他新型纳米材料的生产和结构控制。3.开发，验证和应用计算反应器模型，以了解实验结果的物理化学基础，并实现预测，合理的工艺改进. 4.完成成本分析和市场分析，以确定商业化的途径。智力价值：这项工作的智力价值来自于对现有技术的新颖适应，用于有前途的和非常不同的新目的。热喷嘴反应器在其简单性方面是优雅的;它仅仅通过使热燃烧产物通过会聚-发散喷嘴来将燃烧与颗粒形成分离。由此产生的热气射流提供了液体前体的有效雾化和非常快速的混合。颗粒形成的快速启动和终止（通过加热和淬火）是在气相中以高通量生产纳米颗粒的关键，而这正是该系统所提供的。此外，PI将研究该系统中合金和核壳颗粒以及新型碳纳米材料的形成，可能产生无法通过其他方法获得的结构。最先进的气溶胶动力学建模将与实验并行进行，为粒子形成过程提供基本的见解。UB和普莱克斯团队的专业知识对项目的成功至关重要。更广泛的影响：这项工作将导致开发一种新的高通量低成本金属纳米颗粒生产工艺。这将通过降低成本和扩大这些材料的应用范围而产生技术影响。通过这项工作，一个博士。学生、硕士生和本科生将接受纳米材料气溶胶合成方面的培训，并发展跨学科的化学、材料科学和化学工程技能。所有参与者都将受益于学术-工业合作。本科生将通过NSF REU计划和其他有针对性的计划，如麦克奈尔学者和路易斯斯托克斯少数民族参与联盟（LS-AMP）计划参与。该项目将使PI在招募少数民族参与者方面取得越来越大的成功，并通过与高中学生和教师的外联来扩大它。该项目的变革性质：该项目有可能改变金属和其他非氧化物材料的纳米颗粒的生产方式。这是一种新型的纳米材料毫秒停留时间反应器。这一过程对纳米材料加工和气溶胶反应工程的影响可以很好地匹配其他毫秒接触时间反应器的影响（例如，兰尼施密特等人开发的反应器）。在重整和部分氧化反应工程中的应用，影响着科学研究和工业实践的方向。

PI: Swihart, Mark Institution: SUNY at Buffalo Proposal Number: 1066945Title: GOALI: Flame-based Synthesis of Metal Nanoparticles at Millisecond Residence TimesThe PIs plan to apply the combined expertise of their University at Buffalo (SUNY) and Praxair teams to develop a new flame-based process for producing metal nanoparticles. Printed electronics, antimicrobial plastics and other applications of metal nanoparticles are rapidly growing. Currently, these particles are prepared using large quantities of solvents, high-value surfactants and polymers. A gas-phase flame-based process will provide a lower-cost, more environmentally friendly route to these nanomaterials if it can provide sufficient control of size, size distribution, and degree of agglomeration. Most large-scale production of metal oxide nanomaterials (TiO2, ZrO2, etc.) and carbon black is done in flame processes for these reasons. However, this is not the case for most metals, because they oxidize in the flame. The approach pursued here, based on a thermal nozzle technology developed at Praxair, provides the high temperature, short residence time, rapid mixing, and reducing conditions needed for metal nanoparticle production. The nozzle and downstream reactor provide a highly uniform environment for particle growth, improving control of particle size, size distribution, and morphology compared to other gas-phase processes. Most importantly, this approach decouples the precursor chemistry from the flame chemistry, allowing use of precursors such as low-cost aqueous salts that cannot be used in other flame-based methods, and allowing the residence time for particle formation to be controlled independently of the flame dynamics. Specific aims of the proposed research are to:1. Systematically study the effects of key operating parameters on single-component nanoparticle size distribution and morphology, to optimize yield and control particle size distribution.2. Explore production and structure control of multicomponent (alloy and core-shell) nanoparticles, coated metallic nanoparticles, and additional novel nanomaterials including dendritic carbon.3. Develop, validate and apply computational reactor models to understand the physico-chemical basis of the experimental results and enable predictive, rational process improvement.4. Complete a cost analysis and market analysis to identify pathways to commercialization.Intellectual Merit: The intellectual merit of this work derives from the novel adaptation of an existing technology for a promising and very different new purpose. The thermal nozzle reactor is elegant in its simplicity; it merely separates combustion from particle formation by passing the hot combustion products through a converging-diverging nozzle. The resulting hot gas jet provides effective atomization of liquid precursors and extraordinarily fast mixing. Rapid initiation and termination of particle formation (by heating and quenching) are the keys to the production of nanoparticles in the gas phase at high throughput, and this is exactly what this system provides. Moreover, the PIs will investigate the formation of alloy and core-shell particles and novel carbon nanomaterials in this system, potentially generating structures that cannot be obtained by other methods. State-of-the-art aerosol dynamics modeling will be performed in parallel with experiments, providing fundamental insight into the particle formation process. The combined expertise of the UB and Praxair teams is essential to the success of the project.Broader Impacts: The work will lead to development of a new high-throughput low-cost process for the production of metallic nanoparticles. This will have technological impact by lowering costs and expanding the range of application of these materials. Through this work, a Ph.D. student, MS students, and undergraduates will be trained in aerosol synthesis of nanomaterials and develop cross-disciplinary chemistry, materials science, and chemical engineering skills. All participants will benefit from the academic-industrial collaboration. Undergraduates will participate through the NSF REU program, and additional targeted programs such as the McNair Scholars and Louis Stokes Alliance for Minority Participation (LS-AMP) programs. This project will allow the PIs to build on their growing success in recruiting minority participants, and expand it with outreach to high-school students and teachers.Transformative Nature of this Project: This project has potential to transform the way nanoparticles of metals and other non-oxide materials are produced. This is a novel millisecond residence-time reactor for nanomaterials. The impact of this process on nanomaterials processing and aerosol reaction engineering could very well match the impact of other millisecond contact-time reactors (e.g. those developed by Lanny Schmidt et al.) on reaction engineering for reforming and partial oxidation, affecting directions of both scientific research and industrial practice.