Synthesis of ultra-fine iron powder by combining the flame aerosol synthesis and postreduction
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Synthesis of ultra-fine iron powder by combining the flame aerosol synthesis and postreduction Zili Zhang1, Hui Tian2, Shuiqing Li3,a), Qiuliang Wang4,b) 1
Institute of Electrical Engineering, Chinese Academy of Sciences, Beijing 100190, China Center for Combustion Energy, Department of Energy and Power Engineering, Tsinghua University, Beijing 100084, China 3 Key Laboratory for Thermal Science and Power Engineering of Ministry of Education, Department of Energy and Power Engineering, Tsinghua University, Beijing 100084, China 4 Institute of Electrical Engineering, Chinese Academy of Sciences, Beijing 100190, China; and University of Chinese Academy of Sciences, Beijing 100049, China a) Address all correspondence to these authors. e-mail: [email protected] b) e-mail: [email protected] 2
Received: 4 July 2019; accepted: 17 October 2019
The global market requirement of ultra-fine iron powder (UFIP), with a range size of 0.1–1 lm, is more than 20,000 tons per annum. However, no low-cost nontoxic synthesis route of UFIP is known. In this study, we used the low-cost, rapid, and scalable flame aerosol synthesis (FAS) method to synthesize iron oxide nanoparticles with different size and morphology. Combining with a postreduction heat treatment process, a feasible synthesis route of UFIP which meets the commercial production criteria has been developed. By optimizing the precursor concentration and postreduction heat treatment parameters, the final particle size of UFIP can be controlled. The evolution of the microstructure, phase formation, and magnetic properties during the postreduction heat treatment are systematically investigated, and a feasible reaction model has been established. This work provides an important starting point for the facile commercial synthesis of UFIP and can be readily expanded to other pure metals.
Introduction Ultra-fine iron powder (UFIP) with a range size of 0.1–1 lm [1] has been widely investigated in recent decades [2]. More than 20% of UFIP has been applied to automobile manufacturing [3], which requires more than 3000 t/a. Food added to prevent iron deficiency is another huge market for UFIP powder [4]. FDA already approved one of these kinds of products from International Special Products (New Jersey). It is forecasted that the application requirement is over 1000 t/a. The excellent magnetic properties of UFIP also bring wide application potential in magnetic materials areas such as recording, separation, magnetic fluid, and health care [5, 6, 7]. Microwave absorption is one of the other functions of UFIP, which proves feasible on high-speed aircraft [8]. UFIP synthesis by a low-cost route with high production efficiency is needed to satisfy the market demands. The current synthesis routes include the ball milling method [9], vacuum evaporation [10], and sprays [11]. Most commercializable
ª Materials Research Society 2019
techniques use the carbonyl method with a production of more than 90% UFIP each year. Fe(CO)5 is synthesized and decomposed within a precisely controlled t
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