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

纳米颗粒的喷雾火焰合成对于工业应用具有高度的兴趣，因为适当的工艺控制允许使用具有成本效益的起始材料并且可以开发经济的合成路线。实际上，工业规模生产的材料的宽尺寸分布阻止了尺寸依赖性的调节。缩小研究和工业化之间差距的一个重要步骤是建立试验规模的工厂。在这里，可以修改工艺参数，从而在模拟，测量和实验室实验的支持下修改颗粒特性。然而，到目前为止，由于缺乏对基本物理化学过程的了解，这种工业化前规模的缩放失败了，因为从实验室规模的过程的直接“成比例”缩放通常是不可能的，因为确定过程的相似性参数不能作为规则保持。除了实验和工艺工程问题外，开发合适的模拟方法来预测颗粒特性，如粒度、粒度分布和团聚度，对于将现有工艺从实验室成功扩展到工业规模至关重要。SPP1980 SpraySyn定义了实验室规模的喷雾火焰合成标准工艺。在平行的标准燃烧器“SpraySyn”（实验室规模）的物理调查，物理和工艺工程问题的放大检查。由于科学和经济原因，连续的升级是重要的，因此，代表了这个合作研究项目的主要目标。项目合作伙伴ISTA和AER将从第一个供资期开始贡献他们的经验，而IUTA（以前作为相关合作伙伴参与）的积极研究是在试验工厂规模上实施颗粒合成的逻辑联系。IUTA的核心能力是纳米颗粒合成以及大颗粒反应堆的操作和测量。ISTA为气流、喷雾形成和燃烧器开发的表征贡献了非侵入式测量技术的深刻知识。AER在反应流数值描述领域的专业知识将实验结果与理论原理相结合，从而大大有助于理解缩放喷雾火焰过程中的颗粒形成。在项目期间，将通过实验和数值方法对不同的纳米颗粒合成方法进行评估，并最终通过在反应器操作中生产高度特定的纳米颗粒进行评估。

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.