Experimental and Numerical Investigation of Spray Flame Synthesis in Pilot Scale Facilities

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The spray flame synthesis of nanoparticles is of high interest for industrial applications, since appropriate processes control allows fot the use of cost-effective starting materials and an economical synthesis route can be developed. Actually, the adjustment of size-dependent properties is prevented by the wide size distribution of the materials produced on the industrial scale. An important step towards bridging the gap between research and industrialization are plants on a pilot scale. Here, it is possible to modify process parameters and thus modify particle properties with the support of simulation, measurement and laboratory experiment. However, scaling to this pre-industrial scale has so far failed due to a lack of insight into the basic physico-chemical processes, since a direct "proportional" scaling of the processes from the laboratory scale is generally not possible since process-determining similarity parameters can not be kept as a rule. In addition to the experimental and process engineering problems, the development of suitable simulation methods for the predictive determination of the particle properties such as size, size distribution and agglomeration degree is essential for the successful scaling of the existing processes from the laboratory to the industrial scale.The SPP1980 SpraySyn defines a standard process for spray flame synthesis in the laboratory scale. In parallel to the intended physical investigation on the standard burner "SpraySyn" (laboratory scale), physical and process engineering problems about up-scaling are examined. The successive up-scaling is important for scientific and economic reasons and, therefore, represents the main goal of this collaborative research project. The project partners ISTA and AER will contribute their experience from the first funding period, while the participation in active research of IUTA (previously involved as an associated partner) is the logical link to the implementation of particle synthesis on a pilot plant scale. The core competences of IUTA are nanoparticle synthesis and the operation of and measurements in large particle reactors. ISTA contributes profound knowledge of non-intrusive measurement techniques for the characterization of gas flows, spray formation and burner development. The expertise of the AER in the field of numerical description of reactive flows combines experimental findings with theoretical principles and thus contributes significantly to the understanding of particle formation in the scaled spray flame process. Different approaches for scale-up nanoparticle synthesis will be evaluated experimentally and numerically during the project and finally evaluated by producing highly specific nanoparticles in reactor operation.