Ultrasonic Spray Pyrolysis (USP) starts with the formation of uniform aerosol droplets from a solution containing selected precursors that are subsequently carried by an appropriate (inert or reactive) gas into a simple tube furnace. As the droplets pass through the reactor, solvent evaporates and the dissolved substances react, precipitate, or decompose to form product as uniform spherical powder carried by the gas stream. A major advantage of USP is that each droplet and consequently each particle formed is subjected to the same reaction conditions, so that the chemical and phase composition of all the particles are the same. The particles may be trapped in a liquid or alternatively may be used to coat a solid surface (i.e. essentially a nanoparticle analog to chemical vapor deposition).
However, in previous work all materials obtained by USP lay in the near one micron size region, ~ 0.2 – 2.0 mm. The Irilliant technology has broken through this critical barrier of USP and extended the range all the way to the synthesis of nanoparticles in the quantum confinement realm. One of the main differences between the traditional USP technique and its proprietary modification employed by Irilliant is that in our reaction mixture, we use high boiling point solvents with surfactants that stabilize the particles during their growth and chemical reactions. The temperature within the reactor is lower than the boiling point of the solvent, so the solvent does not evaporate and the synthesis reaction proceeds in small droplets of this high boiling point solvent. We call this method a chemical aerosol-flow synthesis or CAFS. The figure above depicts differences between traditional USP and CAFS methods.
Using CAFS techniques, Irilliant was able for the first time to synthesize Cadmium Sulfide (CdS) nanocolloids from water solutions and high quality Cadmium Selenide, Cadmium Telluride (CdTe) and Zinc Oxide (ZnO) nanoparticles of different morphology from organic solvents. Many other nanomaterials and nanocomposites have been produced in our facility.
Other patent pending manufacturing methods for the synthesis of nanomaterials are also being practiced
>>read more about the nanomaterials we make
Our technology has many advantages that will allow:
- The synthesis to proceed in isolated nanoscale reactors (i.e. liquid droplets) carried in a gas phase at controllable (high) temperatures.
- The reaction zone to be separate from the initial solution, which is kept at lower (or room) temperature.
- Nanocrystals to be obtained in any desired quantity with high quality and reproducibility.
- The resultant nanoparticles to be easily deposited on desired surfaces or collected at low temperatures in desired solvents.
Scalability – The currently available competing processes of small scale production of nanoparticles in solution in small chemical glassware is difficult if not impossible to scale-up. The Irilliant aerosol-based method is scalable just like many other industrial processes for synthesis that are aerosol or spray based.
Good quality – The quality of our products is comparable to the quality of nanomaterials obtained in small scale glassware. In many instances, it is actually better than what other competitors offer.
Versatility – The CAFS method can be applied for the synthesis of practically any material that can be synthesized in a chemical lab.
Price – Since the CAFS method of production is continuous and simple, the cost for the equipment, service, and eventually, that of the final product will be much lower than the final product obtained by competing batch methods.
Unprecedented cost reduction:
A reduction of cost from 100 to 10,000 times lower than existing manufacturing methods can be achieved using Irilliant’s scaled up production technology.