Simulation and experimental observation of silicon particles' vaporization in RF thermal plasma reactor for preparing Si nano-powder

Progress in Preparation of ZrB2 Nanopowders Based on Traditional Solid-State Synthesis

ZrB₂ is of particular interest among ultra-high temperature ceramics because it exhibits excellent thermal resistance at high temperature, as well as chemical stability, high hardness, low cost, and good electrical and thermal conductivity, which meet the requirements of high-temperature components of hyper-sonic aircraft in extreme environments. As raw materials and basic units of ultra-high temperature ceramics and their composites, ZrB₂ powders provide an important way for researchers to improve material properties and explore new properties by way of synthesis design and innovation. In recent years, the development of ZrB₂ powders’ synthesis method has broken through the classification of traditional solid-phase method, liquid-phase method, and gas-phase method, and there is a trend of integration of them. The present review covers the most important methods used in ZrB₂ nanopowder synthesis, focusing on the solid-phase synthesis and its improved process, including modified self-propagating high-temperature synthesis, solution-derived precursor method, and plasma-enhanced exothermic reaction. Specific examples and strategies in synthesis of ZrB₂ nano powders are introduced, followed by challenges and the perspectives on future directions. The integration of various synthesis methods, the combination of different material components, and the connection between synthesis and its subsequent application process is the trend of development in the future.

RF Thermal Plasma Synthesis of Ultrafine ZrB2-ZrC Composite Powders

Ultrafine ZrB₂-ZrC composite powders were synthesized via a radiofrequency (RF) thermal plasma process. Numerical simulation and thermodynamic analysis were conducted to predict the synthesis process, and experimental work was performed accordingly to demonstrate its feasibility. The as-prepared samples were characterized by XRD, FESEM, particle size analyzer, nitrogen/oxygen analyzer, Hall flowmeter, and the Brunner-Emmet-Teller (BET) measurements. The thermodynamic analysis indicated that ZrB₂ was preferentially generated, rather than ZrC, and numerical simulation revealed that the solid raw materials could disperse well in the gaseous reactants, and experimental work showed that free carbon particles were easily removed from the products and the elements of Zr, B, C, and O exhibited a uniform distribution. Finally, ZrB₂-ZrC composite powders with a particle size of about 100 nm were obtained, the surface area of which was 32.15 m²/g and the apparent density was 0.57 g/cm³.

Critical barriers to the large scale commercialization of silicon-containing batteries

Silicon has received a considerable amount of attention in the last few years because of its large lithiation capacity. Its widespread utilization in real-life lithium-ion batteries has so far been prevented by the plethora of challenges presented by this material. This review discusses the most promising technologies that have been put forward to address these issues. While silicon is now much closer to being compatible with commercial-grade storage devices, some critical barriers still deserve further attention. Most importantly, device performance is strongly dependent on particle size and size distribution, with these parameters strongly controlled by the particle synthesis technique. Moreover, the nanoparticle synthesis technique ultimately controls the material manufacturing cost and compatibility with large-scale utilization. These issues are discussed in detail, and recommendations to the community are provided.

Modeling and Selection of RF Thermal Plasma Hot-Wall Torch for Large-Scale Production of Nanopowders

Fouling is a great problem that significantly affects the continuous operation for large-scale radio-frequency (RF) thermal plasma synthesizing nanopowders. In order to eliminate or weaken the phenomenon, numerical simulations based on FLUENT software were founded to investigate the effect of operation parameters, including feeding style of central gas and sheath gas, on plasma torches. It is shown that the tangential feeding style of central gas brings serious negative axial velocity regions, which always forces the synthesized nanopowders to "back-mix", and further leads to the fouling of the quartz tube. Moreover, it is shown that sheath gas should be tangentially fed into the plasma reactor to further eliminate the gas stream's back-mixing. However, when this feeding style is applied, although the negative axial velocity region is decreased, the plasma gas and kinetic energy of the vapor phase near the wall of the plasma reactor are less and lower, respectively; as a result, that plasma flame is more difficult to be arced. A new plasma arcing method by way of feeding gun instead of torch wall was proposed and put in use. The fouling problem has been well solved and plasma arcing is well ensured, and as a result, the experiment on large-scale production of nanopowders can be carried out for 8 h without any interruption, and synthesized Si and Al₂O₃ nanopowders exhibit good dispersion and sphericity.