Low Cost and Scalable Nano-Silicon Production

The U.S. Army has a need for cheap, high quality nanosilicon powder. With similar energy density and better aging effects than nanoaluminum, silicon is an excellent candidate for use a metal nanofuel. In Phase I, Systems and Materials Research Corporation (SMRC) demonstrated a scalable method for production of nanosized silicon. By the end of Phase I, we have demonstrated that a 5kg/day production rate at a cost of $177/kg is possible. By the end of Phase II, SMRC will have demonstrated a continuous flow process that generates >99% pure silicon with a narrow size distribution around 85nm. The as-produced materials will be passivated and be transported as micron sized powders with no hard agglomerates. SMRC will also demonstrate a path to large scale production at a cost nearing $50/kg. We will first commercialize nanosilicon as a propellant additive and green pyrotechnic materials with the help of our scale-up partners ATK and Esterline. As the purity of these materials increases with process and feed stock controls, we will explore uses such as ink-jetable nanosilicon suspensions for low cost, disposable electronics.