Scale-up of Nanoparticle Production

Synthesis of numerous high-performance nanomaterials for active devices has been demonstrated at laboratory-scale flame aerosol reactors. Bringing such products to consumer market requires cost-effective large-scale production. For scale-up, simulations are often preferred over experimental trial-and-error approach to reduce the involved time and material cost of prototyping. The process simulations have to account for all important mechanisms influencing particle formation and growth to yield useful predictions and to elucidate the underlying phenomena while appropriate simplifications have to be made to limit the computational cost. First, model results have to be compared with experiments. Therefore, it is very important that fluid, combustion and particle growth dynamics for exemplary benchmark processes can be characterized unambiguously and with high accuracy. The validated model can then be used to determine optimal reactor geometry and process conditions for the desired application.

Recent, relevant references:

A.J. Gröhn, S.E. Pratsinis, K. Wegner, "Fluid-Particle Dynamics During Combustion Spray Aerosol Synthesis of ZrO2", Chemical Engineering Journal, 191, 491-502 (2012).
A.J. Gröhn, B. Buesser, J.K. Jokiniemi, S.E. Pratsinis, "Design of Turbulent Flame Aerosol Reactors by Mixing-Limited Fluid Dynamics", Industrial & Engineering Chemistry Research, 50, 3159-3168 (2011).
M.C. Heine, S.E. Pratsinis, "Droplet and Particle Dynamics During Flame Spray Synthesis of Nanoparticles", Industrial and Engineering Chemistry Research, 44, 6222-6232 (2005).
K. Wegner, B. Schimmoeller, B. Thiebaut, C. Fernandez, T.N. Rao, "Pilot Plants for Industrial Nanoparticle Production by Flame Spray Pyrolysis", Kona Powder and Particle Journal, 251-265 (2011).