What is Spray Pyrolysis Equipment?

Spray pyrolysis equipment is a device that forms tiny droplets by spraying a solution, and then rapidly evaporates the solvent and pyrolyzes the solute in a high-temperature environment to prepare various materials. It combines spray technology and pyrolysis process, and can effectively control the synthesis of materials.

• Principle: First, a solution containing a precursor (the initial compound of the target material) is atomized into tiny droplets by a spray device (such as a nozzle). These droplets are surrounded by high-temperature gas (usually generated by a heating element) in a pyrolysis furnace. As the solvent evaporates rapidly, the precursor solute undergoes a thermal decomposition reaction at high temperature and decomposes into the target material and some volatile by-products. The by-products are discharged with the air flow, while the target material is deposited on a collection device or collected in the form of powder. For example, when preparing metal oxide nanoparticles, a metal salt solution is used as a precursor. After spray pyrolysis, the metal salt decomposes to produce metal oxides and some gaseous acids and other by-products.

1. Equipment components Spray system: Nozzle type: There are a variety of nozzles to choose from, such as pressure nozzles and ultrasonic nozzles. Pressure nozzles form droplets by applying pressure, which is suitable for low-viscosity solutions; ultrasonic nozzles use ultrasonic vibration to generate droplets, which can produce smaller and more uniform droplets, and also have a better atomization effect on high-viscosity solutions.

• Solution supply unit: including liquid storage tank, delivery pipeline and pump. The liquid storage tank is used to store the precursor solution, and its material should be selected according to the chemical properties of the solution to prevent corrosion. The delivery pipeline should ensure the smooth delivery of the solution, and the pump is used to provide power and accurately control the flow rate of the solution, which has an important impact on the spray quality.
• Pyrolysis system: Heating method: Common ones are resistance heating and induction heating. Resistance heating generates heat by passing current through the heating element (such as the heating wire). The temperature control is relatively simple and stable, and can provide a more uniform temperature distribution; induction heating uses the principle of electromagnetic induction to make the material in the reactor generate heat itself, and the heating speed is fast, which is suitable for reactions with high heating speed requirements.
• Reactor body: It is the place where the pyrolysis reaction occurs. Its internal structure design should take into account factors such as the uniformity of the thermal field and the flowability of the gas. The furnace body material is usually resistant to high temperature and corrosion, and has good thermal insulation performance to reduce heat loss.
• Product collection and tail gas treatment system: Collection device: used to collect the prepared materials. If the prepared material is a powder material, it is generally collected by a filtering device (such as a ceramic filter, a metal filter); if it is a thin film material, it can be collected by deposition on a substrate.
• Tail gas treatment unit: Treat the byproduct gas generated during the pyrolysis process. These gases may contain harmful components, such as acidic gases or organic volatiles, and need to be purified by washing, adsorption, catalytic conversion, etc. to meet environmental protection requirements.

3. Application field Nanomaterial preparation: Metal nanomaterials: Metal nanoparticles such as gold, silver, and copper can be prepared. For example, using metal organic compounds as precursors, through spray pyrolysis equipment, at appropriate temperature and atmosphere, metal nanoparticles with small particle size and uniform distribution can be obtained. These nanoparticles are widely used in catalysis, electronics, optics and other fields.

• Metal oxide nanomaterials: used to prepare ceramic nanomaterials such as titanium dioxide and zinc oxide. During the preparation process, by selecting appropriate precursors and reaction conditions, ceramic nanomaterials with high purity and good crystallinity can be obtained. These materials play an important role in photocatalysis, sensors, biomedicine and other fields.
• Preparation of thin film materials: The products obtained by spray pyrolysis can be deposited on a substrate to form a thin film. For example, when preparing a transparent conductive film for a solar cell, a solution containing a conductive material precursor is sprayed and thermally cracked by a spray pyrolysis device, so that the product is deposited on a glass or other transparent substrate to form a film with good conductivity and transparency.
• Preparation of catalysts: Many catalysts can be prepared by spray pyrolysis equipment. For example, using metal salts and carrier precursors as raw materials, during the thermal cracking process, the metal components can be evenly dispersed on the carrier material to form a high-performance catalyst. These catalysts are used in the fields of chemical industry, environmental protection, etc. to accelerate and selectively control various chemical reactions.

About Cheersonic

Cheersonic is the leading developer and manufacturer of ultrasonic coating systems for applying precise, thin film coatings to protect, strengthen or smooth surfaces on parts and components for the microelectronics/electronics, alternative energy, medical and industrial markets, including specialized glass applications in construction and automotive.

Our coating solutions are environmentally-friendly, efficient and highly reliable, and enable dramatic reductions in overspray, savings in raw material, water and energy usage and provide improved process repeatability, transfer efficiency, high uniformity and reduced emissions.

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