Numerically Analyzing High Production Rates

The flame spray pyrolysis (FSP) method is a promising technique for producing nanomaterials. One of the main challenges in using this method is controlling particle size when scaling up production. ANSYS Fluent was utilized to simulate the FSP process sequentially with MATLAB for particle growth and formation calculations. The model was validated against published experimental data for nano-zirconium production, demonstrating accurate particle size predictions. This validated model was employed to understand how to maintain particle size while increasing zirconium production. The production increase was achieved at a constant gas to liquid flow ratio (GLFR). Simulation results indicated that with a GLFR value of 615, production can be boosted from 4 Kg/h to 10 Kg/h of nano-zirconium while keeping the primary particle diameter at approximately 25 nanometers.