Abstract
This article presents new findings regarding the effects of precursor drop size and precursor concentration on product particle size and morphology in ultrasonic spray pyrolysis. Large precursor drops (diameter > 30 μm) generated by ultrasonic atomization at 120 kHz yielded particles with holes due to high solvent evaporation rate, as predicted by the conventional one particle per drop mechanism. Precursor drops 6–9 μm in diameter, generated by an ultrasonic nebulizer at 1.65 MHz and 23.5 W electric drive power, yielded uniform spherical particles 90 nm in diameter with proper control of precursor concentration and residence time. Moreover, air-assisted ultrasonic spray pyrolysis at 120 kHz and 2.3 W yielded spherical particles about 70% of which were smaller than those produced by the ultrasonic spray pyrolysis of the 6–9 μm precursor drops, despite much larger precursor drop size (28 μm peak diameter versus 7 μm mean diameter). These particles are much smaller than predicted by the conventional one particle per drop mechanism, suggesting that a gas-to-particle conversion mechanism may also be involved in spray pyrolysis.
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