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A vertical spray pyrolysis reactor was designed to produce separated/softly agglomerated oxide nanoparticles by dissolving a large amount of high molecular weight polymer into solutions of nitrous or acetic metals. The polymer played a role as a matrix that prevented the tendency of as-grown nuclei to make contacts inside the polymer ball. Decomposition of the polymer ball at the end stage of the reactor released separated nanoparticles. On the first attempt, we produced particles of zinc oxide and compound oxide of CuO/ZnO/Al2O3 at different parameters of synthesis. We found that the size of the particles decreased, as a fraction of the polymer, as the mass increased. We used a percolation theory to explain the particle separation mechanism inside the polymer ball. Separated nanoparticles were obtained if the volume fraction of the particles was far below the percolation threshold.

Synthesis of Oxide Particles Using a Polymer-Assisted Spray Pyrolysis Reactor, and a Percolation Explanation of Particle Separation