Page 1
Particle Formation in Premixed and Diffusion Flames
Dr. Frank Ernst
[email protected]
phone: 044 632 25 10
Office hour:
Thursdays after the lecture
Department of Mechanical and Process Engineering
ETH Zurich, www.ptl.ethz.ch
Verbrennung und chemisch reaktive Prozesse in der Energie- und Materialtechnik
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2
Particle formation revisited
Pre-mixed flames
particle formation
diagnostics
Diffusion flames
flame types
Particle formation in vapor-fed flames
Scale-up of diffusion flames
Particle morphology
Lecture outline
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3
Particle formation & growth – key steps
Chemical reaction
Source of
monomer
species
Nucleation
Formation of clusters
Aggregation
Spherical particles form
via particle-particle
collisions
Collisions between
spherical particles form
chains
Coagulation
TiO2 TiCl4 + 2O2 TiO2 + Cl2
Decreasing number concentration
Increasing size and mass
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4
TiCl4
TiCl4
TiCl4 H2
H2 H2 O2
O2 O2
TiO2
TiO2
TiO2 TiO2
H2O
H2O H2O
HCl
HCl
Chemical reaction
Nucleation
Aggregation
Coagulation
T (K)
25
00
20
00
15
00
10
00
50
0 Particle formation & growth – in flames
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5
Premixed flames
Simple construction but particle
formation in these flames is
narrowly controlled.
Safety is an issue.
Excellent for basic
understanding and for
manufacture of a specific
product day in and day out.
Chemical reactions kinetics & thermodynamics
Fluid flow Laminar & turbulent
Temperature Particle
dynamics
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6
Monitoring particle dynamics
by intrusive thermophoretic sampling
Burner
TI
t
Hood
Filter
Iris
X
Y
Fourier transform
infrared (FTIR) spectrometer
IR
CH 4 , O 2 , N 2
HMDSO in N 2
Shield N 2
Detector
e FTIR
Detector
N 2
Control
box
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7
TEM
grid
5 bar N2 pressure
tres = 50 ms
Thermophoretic particle sampler (original design by Dobbins and Megaridis, 1987)
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8
Image Analysis
TEM
Particle size analysis in the flame
Thermophoretic Sampling
(Height: 33 mm)
0
10
20
30
40
50
60
0 1 2 3 4
Distance from the burner, cm
Av
era
ge
pri
ma
ry p
art
icle
dia
me
ter,
nm
.
TiO2 data by thermophoretic
sampling
42 ± 11 nm
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9
Sampling position
Burner
TI
Hood
Filter
X
Y CH 4 , O 2 , N 2
HMDSO in N 2
Shield N 2
N 2
Control
box
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10
TiO2
.5 mm 23 mm
Filter
-8 mm
200 nm
Kammler et al. (2001) Chem.
Eng. Technol. 24, 83.
13 mm
40 mm
55 mm
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11
SiO2
Kammler et al. (2001) Chem.
Eng. Technol. 24, 83.
5 mm HAB
200 nm
10 mm HAB
20 mm HAB
30 mm HAB
40 mm HAB
50 mm HAB
70 mm HAB
90 mm HAB
110 mm HAB
150 mm HAB
Filter
200 nm
130 mm HAB
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12
SiO2
Kammler et al. (2001) Chem.
Eng. Technol. 24, 83.
50 mm HAB, r = 0 mm r = 3 mm r = 6 mm
r = 9 mm r = 12 mm r = 15 mm
200 nm
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13
Diffusion flames
Simple construction but
particle formation in these
flames is a complex
system
Requires detailed
understanding of key
processes and their
interaction
Chemical reactions kinetics & thermodynamics
Fluid flow Laminar & turbulent
Temperature Particle
dynamics
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14
Diffusion flame Premixed flame
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15
Diffusion flame
Turbulent diffusion flames are frequently
used in industry
Safety
Fuel and oxygen do not mix until furnace
Scale up
Up to several tonnes per hour
Simplicity
Flexibility in controlling product particle
characteristics
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16
Co-flow diffusion flames
Simplicity
Safe
Concentric pipes
Fuel, air and precursor in
each pipe CH4
Air
Air
TiCl4
CH4
CH4
CH4
Air Air
TiCl4
TiCl4
TiCl4
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17
Materials made in vapor-fed flames
Product
Particles
Carbon black
Titania
Fumed Silica
Volume
t/y
8 M
2 M
0.2 M
Ind.Process
(dominant)
Vapor Flame
Vapor Flame
Vapor Flame
Use
(exemplary)
Inks, Rubber
Paints
Toothpaste, Tires
Chemical Economics Handbook, 2001; direct industrial quotes
• A wide range of interesting applications
• Significantly large commercial markets
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18
Pratsinis, Zhu, Vemury, Powder Technol. 86, 87-93 (1996)
Johannessen, Pratsinis, Livberg, ibid., 118, 242-250 (2001).
CH4
Air
Air
TiCl4
CH4
CH4
CH4
Air Air
TiCl4
TiCl4
TiCl4
A few possible configurations…
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19
Pratsinis, Zhu, Vemury, Powder Technol. 86, 87-93 (1996)
Johannessen, Pratsinis, Livberg, ibid., 118, 242-250 (2001).
CH4
Air
Air
TiCl4
CH4
CH4
CH4
Air Air
TiCl4
TiCl4
TiCl4
CFD flow fields
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20
CH4
Air
Air
TiCl4
CH4
CH4
CH4
Air Air
TiCl4
TiCl4
TiCl4
Pratsinis, Zhu, Vemury, Powder Technol. 86, 87-93 (1996)
Johannessen, Pratsinis, Livberg, ibid., 118, 242-250 (2001).
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21
Particle formation in vapor-fed flames
Gaseous
Precursor
Molecules
Nucleation
Primary
Particles
Coagulation
and Sintering
Agglomerated
Particles Non-Agglomerated
Particles
t
100nm
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22
Methane
Air
Argon / TiCl4FIC
FIC
FIC
Argon
Methane
Air
TiCl4
Flame Reactor
Hood
Filter Assembly
Pump
NaOH Solution
Pratsinis, Zhu, Vemury, Powder Technology 86, 87-93 (1996)
Particle Morphology:
Set-up for SiO2/TiO2 production (lab scale)
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23
Oxygen flow rate
Silica producing flame (17 g/h)
2.5 l/min 4.7 l/min 8.5 l/min 13.3 l/min 24 l/min
5 cm
Effect of oxidant flow on flame
Mueller R., Kammler H.K., Pratsinis S.E., Vital A., Beaucage G., Burtscher P., Powder Technol., 140, 40-48 (2004).
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Particle Size Control by O2 flow
THMDSO: 5°C
N2 = 2.9 l/min
CH4 = 1.4 l/min
100
80
60
40
20
0
BE
T-e
qu
iva
len
t p
art
icle
dia
me
ter
[nm
]
2520151050
Oxygen flow rate [l/min]
Silica Production Rate 17 g/h
Mueller R., Kammler H.K., Pratsinis S.E., Vital A., Beaucage G., Burtscher P., Powder Technol., 140, 40-48 (2004).
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25
Particle Size Control by O2 flow
9 g/h 100
80
60
40
20
0
BE
T-e
qu
iva
len
t p
art
icle
dia
me
ter
[nm
]
2520151050
Oxygen flow rate [l/min]
Silica Production Rate
17 g/h
9 g/h
THMDSO: 5°C
Production rate 17 g/h:
• N2 = 2.9 l/min
• CH4 = 1.4 l/min
Production rate 9 g/h:
• N2 = 1.4 l/min
• CH4 = 0.7 l/min
Mueller R., Kammler H.K., Pratsinis S.E., Vital A., Beaucage G., Burtscher P., Powder Technol., 140, 40-48 (2004).
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Fourier transformed infrared spectrometer
t
Hood
Iris
Fourier transform infrared
(FTIR) spectrometer
IR
Detector
eFTIR
Detector
Y
X
Filter
Diffusion
Burner
30 mm
N2
O2
N2/HMDSO
CH4
Chimney
Mueller R., Kammler H.K., Pratsinis S.E., Vital A., Beaucage G., Burtscher P., Powder Technol., 140, 40-48 (2004).
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27
O2: 2.5 l/min
Conversion of Fuel Absorption Spectra 0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
Ab
so
rba
nc
e
3000 2500 2000 1500 1000
Wavenumber [cm-1
]
no combustion
10 mm HAB
50 mm HAB
90 mm HAB
150 mm HAB
CO2
CH4, HMDSO CH4, HMDSO
HMDSO
SiO2
SiO2
100
75
50
25
0
Co
nv
ers
ion
of
CH 4 a
nd
HM
DS
O,
%
1007550250
Height above burner (HAB) [mm]
Oxygen2.5 l/min
Flame Characterization
Mueller R., Kammler H.K., Pratsinis S.E., Vital A., Beaucage G., Burtscher P., Powder Technol., 140, 40-48 (2004).
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28
2.5 l/min
Conversion of Fuel Axial Flame Temperature 100
75
50
25
0
Co
nv
ers
ion
of
CH 4 a
nd
HM
DS
O,
%
1007550250
Height above burner (HAB) [mm]
Oxygen2.5 l/min
2500
2000
1500
1000
500
Av
era
ge
fla
me
te
mp
era
ture
[K
]
350300250200150100500
Height above burner (HAB) [mm]
Oxygen2.5 l/min
Flame Characterization
Mueller R., Kammler H.K., Pratsinis S.E., Vital A., Beaucage G., Burtscher P., Powder Technol., 140, 40-48 (2004).
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29
17 g/h
Conversion of Fuel Axial Flame Temperature 100
75
50
25
0
Co
nv
ers
ion
of
CH 4 a
nd
HM
DS
O,
%
1007550250
Height above burner (HAB) [mm]
Oxygen2.5 l/min
4.7 l/min
8.5 l/min
13.3 l/min
24 l/min
2500
2000
1500
1000
500
Av
era
ge
fla
me
te
mp
era
ture
[K
]
350300250200150100500
Height above burner (HAB) [mm]
Oxygen2.5 l/min
4.7 l/min
8.5 l/min
13.3 l/min
24 l/min
Flame Characterization
Mueller R., Kammler H.K., Pratsinis S.E., Vital A., Beaucage G., Burtscher P., Powder Technol., 140, 40-48 (2004).
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30
17 g/h
Conversion of Fuel Axial Flame Temperature 100
75
50
25
0
Co
nv
ers
ion
of
CH 4 a
nd
HM
DS
O,
%
1007550250
Height above burner (HAB) [mm]
Oxygen2.5 l/min
4.7 l/min
8.5 l/min
13.3 l/min
24 l/min
2500
2000
1500
1000
500
Av
era
ge
fla
me
te
mp
era
ture
[K
]
350300250200150100500
Height above burner (HAB) [mm]
Oxygen2.5 l/min
4.7 l/min
8.5 l/min
13.3 l/min
24 l/min
2000 K
2250 K
Flame Characterization
Mueller R., Kammler H.K., Pratsinis S.E., Vital A., Beaucage G., Burtscher P., Powder Technol., 140, 40-48 (2004).
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Effect of O2 flow on Particle Size
2.5 l/min 4.7 l/min
8.5 l/min 13.3 l/min
24 l/min Degussa OX-
50
dBET = 44 nm
dBET = 55 nm
dBET = 78 nm
dBET = 41 nm
dBET = 23 nm dBET = 55 nm
17 g/h
Mueller R., Kammler H.K., Pratsinis S.E., Vital A., Beaucage G., Burtscher P., Powder Technol., 140, 40-48 (2004).
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Scale up:
Variation of Burner Geometry
5.6
4.1
2.8
Burner 1
5.7
7.6
10
Burner 2
6.0
12.0
27.0
Burner 3
Dimensions in mm
Wegner K., Pratsinis S.E., Chem. Eng. Sci. 58, 4581-4589 (2003).
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33
Oxygen Flow Rate, L/min
0 2 4 6 8 10BE
T-e
qu
iva
len
t P
art
icle
Dia
me
ter,
nm
0
20
40
60
80
100
Control of Silica Primary Particle
Diameter by the O2 Flow Rate
Burner 1
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34
Oxygen Flow Rate, L/min
0 10 20 30 40 50BE
T-e
qu
iva
len
t P
art
icle
Dia
me
ter,
nm
0
20
40
60
80
100
Burner 1
2
3
Conditions:
CH4: 0.5
L/min
Ar: 0.3 L/min
SiO2: 5 g/h
Separate Operation Lines for each Burner
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35
Single Operation Line dp = f(Dv)
Dv = vOx
- vFuel
, m/s
0 5 10 15 20 25 30
BE
T -
equiv
ale
nt P
art
icle
Dia
mete
r, n
m
0
20
40
60
80
100
Burner 1
Silica
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36
Single Operation Line dp = f(Dv)
Dv = vOx
- vFuel
, m/s
0 5 10 15 20 25 30
BE
T -
equiv
ale
nt P
art
icle
Dia
mete
r, n
m
0
20
40
60
80
100
Burner 1
2
Silica
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37
Single Operation Line dp = f(Dv)
Dv = vOx
- vFuel
, m/s
0 5 10 15 20 25 30
BE
T -
equiv
ale
nt
Part
icle
Dia
mete
r, n
m
0
20
40
60
80
100
Burner 1
2
3
Silica
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38
Dv = vOx
- vFuel
, m/s
0 5 10 15 20 25 30BE
T-e
qu
iva
lent P
art
icle
Dia
mete
r, n
m
0
20
40
60
80
100C-Flame
Operation Line for Silica synthesis
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39
Dv = vOx
- vFuel
, m/s
0 5 10 15 20 25 30BE
T-e
quiv
ale
nt P
art
icle
Dia
mete
r, n
m
0
20
40
60
80
100C-Flame
Briesen et al., 1998
Operation Line for Silica synthesis
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40
Dv = vOx
- vFuel
, m/s
0 5 10 15 20 25 30BE
T-e
quiv
ale
nt P
art
icle
Dia
mete
r, n
m
0
20
40
60
80
100C-Flame
Premixed Flame
Briesen et al., 1998
Operation Line for Silica synthesis
0, premixed
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41
Dv = vOx
- vFuel
, m/s
0 5 10 15 20 25 30BE
T-e
quiv
ale
nt
Part
icle
Dia
mete
r, n
m
0
20
40
60
80
100
D-Flame, Burner 1
C-Flame
D-Flame, Burner 2
Premixed Flame
Briesen et al., 1998
Operation Line for Silica synthesis
0, premixed
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42
Dv = vOx
- vFuel
, m/s
0 5 10 15 20 25 30BE
T-e
qu
iva
len
t P
art
icle
Dia
me
ter,
nm
0
20
40
60
80
100Methane
Propane
Hydrogen
Different Fuels – Same Flame Enthalpy 25 g/h SiO2, 38 kJ/min by variation of fuel flow rate
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43
CH4
Air
Air
TiCl4
CH4
CH4
CH4
Air Air
TiCl4
TiCl4
TiCl4
Pratsinis, Zhu, Vemury, Powder Technol. 86, 87-93 (1996)
Johannessen, Pratsinis, Livberg, ibid., 118, 242-250 (2001).
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44
Air
O2/N2
50/50
O2
Air CH 4
TiCl 4
Air
CH 4
TiCl 4
Flame
Mixing B
Flame
Mixing C
Zhu and Pratsinis, 1996
Effect of oxidant composition on TiO2
morphology
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Degree of Agglomeration matters...
Agglomerated:
fillers
catalysts
lightguide performs
particles for chemical mechanical polishing (CMP)
catalysts
…
Non-Agglomerated:
pigments
composites (e.g. for dental applications)
electronics
…
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46
Particle formation revisited
Particle growth in premixed flames: axial and radial effects
Diffusion flames: particle formation in co-flow flames
Morphology
Diffusion flame: Effects on particle size: dilution effect, residence time at
high T, precursor concentration
Scale-up: difference in gas velocities is decisive for particle size
Further reading
Kammler H.K., Mädler L., Pratsinis S.E. Flame synthesis of nanoparticles. Chemical Engineering
Technology 24, 6 (2001).
Kammler H.K., Jossen R., Morrison P.W., Pratsinis S.E., Beaucage G. The effect of external electric
fields during flame synthesis of titania. Powder Technology 135-136, 310-320 (2003).
Pratsinis S.E., Zhu W., Vemury S. The role of gas mixing in flame synthesis of titania powders. Powder
Technology 86, 97-93 (1996).
Johannessen T., Pratsinis S.E., Livbjerg H. Computational analysis of coagulation and coalescence in
the flame synthesis of titania particles. Powder Technology 118, 242-250 (2001).
Lecture summary
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47
Further reading
Chung S.-L., Katz J.L., The Counterflow Diffusion Flame Burner: A New Tool for the Study of the
Nucleation of Refractory Compounds. Combustion and Flame 61, 271-284 (1985).
Xing Y., Kole T.P., Katz J.L., Shape-controlled synthesis of iron oxide nanoparticles. J. Materials Science
Letters 22, 787-790 (2003).
Santoro R.J., Miller J.H., Soot Particle Formation in Laminar Diffusion Flames. Langmuir 3 (2), 244-259
(1987).
Pratsinis S.E., Zhu W., Vemury S., Teh role of gas mixing in flame synthesis of titania powder. Powder
Technol. 86, 87-93 (1996).
Mueller R., Kammler H.K., Pratsinis S.E., Vital A., Beaucage G., Burtscher P., Non-agglomerated dry
silica nanoparticles. Powder Technol. 140, 40-48 (2004).
Wegner K., Pratsinis S.E., Scale-up of nanoparticle synthesis in diffusion flame reactors. Chem. Eng.
Sci. 58, 4581-4589 (2003).
Pratsinis S.E., Zhu W., Vemury S. The role of gas mixing in flame synthesis of titania powders. Powder
Technology 86, 97-93 (1996).
Johannessen T., Pratsinis S.E., Livbjerg H. Computational analysis of coagulation and coalescence in
the flame synthesis of titania particles. Powder Technology 118, 242-250 (2001).
Wegner K., Stark W.J., Pratsinis S.E., Flame-nozzle synthesis of nanoparticles with closely controlled
size, morphology and crystallinity. Materials Letters 55, 318 (2002).
Wegner K., Pratsinis S.E., Nozzle-quenching process for controlled flame synthesis of titania
nanoparticles. AIChE J. 49, 1667-1675 (2003).