A new technique to derive particle size distributions and aerosol number concentrations directly from thermophoretic data

The manufacture of many high value-added powders takes place by the decomposition of gaseous precursors in aerosol tube reactors. Historically, process improvements were achieved by making changes on the outside of the reactor and observing what comes out at the end of the pipe. The development of increasingly accurate aerosol dynamics models based on engineering first principles has been limited because models were typically validated on integral properties of ex situ product, instead of particle properties measured at multiple positions inside the reactor. In this study, a model reactor was equipped to capture samples thermophoretically from 15 internal positions. Additional in-line measurements were achieved with a multi-stage inertial impactor and by traditional analysis of ex situ product. Calculations were performed to verify that thermophoresis was the dominant mechanism of particle capture. The thermophoretic samples were analyzed by electron beam microscopy and image analysis to develop particle size distributions at each of the internal positions inside the reactor. An approximation of Talbot's Equation for thermophoretic velocity allowed experimental measurements to be combined with thermophoretic sample data to give predictions of particle number concentration corresponding to the precise sampling locations. The combinations of particle size distributions and number concentrations provide powerful insights on particle nucleation and growth dynamics.