A simple method to set the spray properties for flame spray pyrolysis production of nanoparticles

The most critical part of the flame spray pyrolysis (FSP) process is the nozzle, since it plays a key role in setting the spray properties. In this study, we developed an approach to adjust the nozzle throat gap size for a desired dispersion gas flow rate and upstream pressure, based on the external size and shape of a two phase external mixing nozzle. An equation was derived and validated by comparing the predicted gas flow rates with the data provided in a commercial nozzle supplier chart. Experiments were also conducted in our lab-scale FSP reactor to test the validity of the predictions. The approach developed here was found to closely predict the gap size necessary to pass the required dispersion gas flow at a desired pressure drop. Error in predictions was found to be less than 3% at an upstream pressure range of 3–10 bars. The isentropic flow assumption for perfect gases across the convergent-divergent nozzle was found to fail below 2 bars, consistent with the theory applied. By using the method here, the nozzle setting for a desired operation in an FSP process can be easily done, minimizing the time-consuming trial and error steps needed otherwise.