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Liquid atomization determines the initial conditions for flame formation and particle synthesis. Without a stable flame, high droplet velocities and thus short droplet residence time in the flame may lead to droplets being injected into an extinguished flame, which influences synthesis and final particle output. An experimental investigation of spray formation and flame stability is performed through high-speed visualization. Targeted variation of nozzle geometry is applied to improve spray-flame interaction and compared to a standardized burner. Timescales of spray density and flame fluctuations are quantified and compared, where the latter were significantly larger and hence not correlated. Instead, dispersion gas forms a barrier between spray phase and pilot flame; hence, ignition depends on large liquid lumps with high radial momentum to break through the dispersion gas for spray ignition. Angling of dispersion gas flow increases radial shear and turbulence and leads to refined atomization and improved flame stability. To investigate the nozzle influence on particle formation, particle characteristics are examined by online and offline analytics with focus on particle structures and product purity. The modified nozzle produced smaller primary particle sizes, thus indicating a sensitivity of sintering dominance on the nozzle geometry. Impurities impact the examination of particle structures and general particle functionality. Carbon contamination was apparent in synthesized particles and also indicated sensitivity to nozzle geometry. Discrepancies to literature data are discussed regarding differences in flame activity and droplet characteristics. The report highlights, how product characteristics can differ crucially due to changes in nozzle geometry despite comparable operating conditions. Graphic abstract

Influence of angled dispersion gas on coaxial atomization, spray and flame formation in the context of spray-flame synthesis of nanoparticles