PROCESSES FOR FORMING NANOPARTICLES IN A FLAME SPRAY SYSTEM

摘要

In one aspect, the process includes providing a precursor medium comprising a liquid vehicle and a precursor to a component, and flame spraying the precursor medium under conditions effective to form a population of nanoparticles, wherein the nanoparticles include the component. The population of nanoparticles, as formed, comprises less than about 5 percent by volume particles having a particle size greater than 1.0 µm. A size distribution of the population of nanoparticles may have a d50 value less than about 500 nm, and it may be unimodal. The size distribution may have a geometric standard deviation of less than about 2. The process may occur continuously for at least four hours or more. Greater than about 90 percent by weight of the precursor to the component in the precursor medium may be converted to the component in the nanoparticles. The process typically occurs in an enclosed flame spray reactor.