Innovative System for Large Scale, Low Cost Production of High Quality Silicon Nanoparticles

Physical Sciences Inc. proposes to apply its patented microwave driven jet (MIDJet) technology for low cost production of silicon nanopowders. The MIDJet will be used to form a narrow plasma jet from SiH4 gas and via supersonic expansion, nucleate/grow silicon nanopowders with a targeted surface area of 32 to 50 m2/g. The combination of swirl flow injection (confining the plasma to the center of the cavity) in the MIDJet and electrode-less discharge allows high specific energy deposition at high gas pressures with minimal opportunity for contamination/impurity entrainment from the system. The proposed Phase I effort will investigate the impact of the MIDJet"s operating conditions on nucleation and growth of the nanopowder, demonstrate silicon nanopowder formation, estimate the manufacturing cost, and produce 1kg of silicon nanopowder. The Phase I Option will be used to adapt the MIDJet system for continuous in-line coating of the silicon nanoparticles with a passivating layer of CFx. The Phase II effort will lead to the optimization of the nanopowder production system, a cost analysis for large-scale production, repeatability (and variability) of the system, and demonstrate a daily production rate capability of 50 kgs of CFx coated silicon nanopowder meeting the required technical specifications.