Aero-sol-gel Reactor for Nano-powder Synthesis

This paper discusses a new approach to the synthesis of nano-structured oxides where sol-gel reactions are carried out in aerosol droplets. This aero-sol-gel (ASG) reactor allows for manipulation of the structure, chemical composition and surface area of silica powders through variation of process parameters. ASG powders differ in nanostructure from other continuous process powders such as pyrolytic and solution-route powders. ASG powders contain mesopores (>2-nm) and micropores (<2-nm), the mesopores being responsible for high surface areas measured by nitrogen adsorption using BET theory. Primary particles of close to molecular scale are believed to lead to exceedingly large specific surface areas on the order of 600-m2/g. These primary particles aggregate into nanometer scale mass-fractal aggregates that cluster in micron scale agglomerates. Under controlled reaction conditions the powder structure is reproducible as measured by small-angle X-ray scattering, SAXS, analysis. The ASG reactor displays transport effects similar to those previously seen in laminar flame reactors as evidenced by the effect of reactor geometry and reactant concentration on product structure