Effect of quenching conditions on particle formation and growth in thermal plasma synthesis of fine powders

Abstract

The vapor-phase synthesis of ultrafine powders in reactive thermal plasma systems is studied. A mathematical model is developed to determine the effect of quenching conditions on the size characteristics of powders produced. The particle nucleation is considered to be due to both condensation of product vapor and surface reaction between adsorbed reactant species. The particle growth is considered to be exclusively due to further condensation of product vapor. Numerical predictions on powder formation are explored through a case study for the synthesis of zinc oxide powders from zinc vapor and oxygen carried in argon gas. The results of the present srudy indicate that the size characteristics of plasma-produced powders can be significantly enhanced by gradual, regulated quenching, as opposed to the rapid quenching conventionally used in the past. The results further indicate that distribution of the quench gas along the reactor provides an effective means to accomplish the much desired control over the powder properties.