J. Am. Ceram. Soc., 85 [5] 1127–32 (2002)
journal
Morphological Control of Zirconia Nanoparticles through
Combustion Aerosol Synthesis
Amit U. Limaye and Joseph J. Helble
Department of Chemical Engineering, University of Connecticut, Storrs, Connecticut 06269–3222
gaseous20,22–24 precursors for ceramic oxide particle production
using flames or high-temperature furnaces7,9 has been reported.
Although the chlorides of silicon and titanium are relatively
volatile and have been used as gaseous precursors for oxide
particle formation, the low vapor pressure of zirconium chloride
limits its use as a precursor. Consequently, liquid precursors, such
as aqueous solutions or organometallic compounds of zirconium,
have been used in flame12,21 and spray-drying systems7,25 for
zirconia nanoparticle synthesis. Unagglomerated particles can be
formed using liquid precursors with the final particle size governed
by the precursor droplet size when a spray-drying furnace is used
for processing.7,25 Experimental trends observed in spray pyrolysis
systems have been explained reasonably well by a model reported
in the literature.25 The model compares the rates of solute diffusion
within the droplet and solvent vaporization from the droplet
surface and explains their effect on the particle morphology. Large
particles (micrometer scale) are formed, however, if dilute precur-
sor concentrations are not used in these systems. Although typical
flame-based processes produce agglomerated particles, unagglom-
erated particles also can be formed in a flame-based system using
liquid precursors. The final particle sizes, however, are not directly
dependent on the droplet sizes12,21 in these systems, unlike in
spray pyrolysis. The mechanism of particle formation when liquid
precursors are used in flame-based systems is not yet fully
understood. In processes using fine particles of metals as the
precursor, it is suggested that the oxide particle growth occurs
predominantly by vapor condensation,16 whereas particle growth
occurs by collision and coalescence when gaseous precursors are
used.19
Ceramic oxide nanoparticles produced by flame-based pro-
cesses are typically agglomerated, which can limit their use in
some applications. In this paper, a novel combustion synthesis
method that utilizes the spraying of combustible droplets into
a premixed flame to produce nanoscale crystalline particles of
agglomerated and unagglomerated morphologies is described.
Although the same flame-based experimental setup is used in
both cases, variation in peak flame temperatures results in a
corresponding variation between fractallike agglomerates and
single isolated spherical particles. TEM/ED analysis shows
that both classes of particles are the tetragonal crystal phase of
zirconia. In the case of the unagglomerated spherical particles,
results indicate that each precursor solution droplet, which
acts as the feed, produces multiple spherical ceramic nanopar-
ticles with a number mean diameter of 90 nm. The use of an
inertial impaction stage in the precursor feed line to eliminate
large feed droplets leads to a decrease in the number mean
diameter to 60 nm, suggesting that crystalline spherical nano-
particles can be produced in a continuous flame-based process
through control of the feed droplet size.
I. Introduction
ARTICLES having features with dimensions ranging from a few
P
to a few hundred nanometers are often referred to as nanopar-
ticles. Nanoparticles of zirconia, which have a broad range of
applications, including high-strength ceramics, thermal barrier
coatings, paints, textiles, refractories, transformation-toughened
ceramics, oxygen sensors, and fuel cells,1–4 have been produced
by a variety of techniques. Vapor deposition, mechanical milling,
laser ablation, flame-based methods, spray pyrolysis, sol–gel, and
microwave plasma synthesis have been used to produce ceramic
particles ranging from a few nanometers to a few micrometers in
size and of varied degrees of crystallinity.5–9 Flame-based methods
are of potential commercial importance, because they are relatively
low cost and can be operated as continuous single-step process-
es.10–24 Although very small particles (5–10 nm) can be produced
by these methods, hard agglomerates are generally formed, result-
ing in “fractallike” branched structures that are undesirable in
many applications. Attempts have been made to control agglom-
eration using electric fields,22 but only moderate success has been
achieved, with partial agglomeration always present. In addition,
special burner and gas-flow configurations are often required in
these processes,12 because fuel–oxidizer mixing and flame struc-
ture affect the final particle morphology and size.14,23
In this article, we present the results of a novel droplet
combustion process for the synthesis of nanoparticles with con-
trollable morphology and particle size. Using liquid precursors
sprayed into a premixed methane–oxygen flame, we have elimi-
nated the dependence of particle size on fuel–oxidizer mixing and
flame structure. Details of the process are provided below.
II. Experimental Procedure
An experimental system was designed to provide flames of
varying and controllable temperature profile, resulting in variable
residence time of the combustion gases in the reactor. A schematic
diagram of this experimental setup is shown in Fig. 1. A flat-flame,
water-cooled, porous-plug stainless-steel burner (McKenna Prod-
ucts, Inc., Sebastopol, CA) was used as the heat source and the
main component of the system. Methane, oxygen, and nitrogen
were premixed within the burner, and the resulting two-
dimensional flame was anchored on the porous plug. A shroud of
nitrogen around the porous plug eliminated fluctuations in the
flame caused by external disturbances. Ceramic precursors were
introduced into the flame by spraying a combustible precursor
solution through a feed tube located centrally in the burner.
Zirconium(IV) n-butoxide (Strem Chemicals, Inc., Newburyport,
MA) dissolved in 99.8% anhydrous butanol (Sigma Chemicals,
Inc., St. Louis, MO) was used as the precursor feed stock. To
prepare the feed solution, the zirconium(IV) n-butoxide was added
to butanol with moderate stirring under nitrogen in a glove box to
avoid reaction with water present in the air. The spray was
In high-temperature synthesis methods, such as flame-based
methods, the type of precursor also is important in determining the
final particle characteristics. The use of solid,13,16 liquid,12,15,21 or
K. Bowman—contributing editor
Manuscript No. 187375. Received October 24, 2001; approved February 12, 2002.
Supported by the National Science Foundation under CAREER Grant No.
CTS-9733234.
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