SBIR Phase I: Advanced Thermal Chemical Reactor for the Manufacture of Complex Nanopowders

This Small Business Innovation Research Phase I project addresses the development of an advanced Thermal Chemical Reactor (ATCR) for the Manufacture of Complex Nanopowders.The ATCR being developed represents a major departure and advancement in manufacturing technology for producing complex metal oxide nanopowders. The ATCR is unique in that it is a high temperature, convectively heated, turbulently mixed, gas/solid/liquid phase reactor that utilizes externally heated reactant gases for reaction with the precursor feedstock. This innovative reactor utilizes a well-stirred turbulent reaction zone driven by externally heated reaction gases. This innovative method of mixing and heating allows the precursors to rapidly react in a region of uniform temperature and stoichiometry, a capability currently not available with existing flame and plasma reactor systems. Gas, solid and liquid precursors can be utilized, thus providing tremendous flexibility with regard to the nature and variety of ceramic oxide products that can be produced. The primary objective of this Phase I project is to demonstrate the technical viability of the ATCR to produce nanosize zirconia/alumina powders suitable for processing into wire bonding capillaries and other specialty ceramic components. This viability is to be demonstrated via the evaluation of pressed and sintered test specimens. Commercially, these powders will enhance the performance of a wide range of specialty ceramic applications including: mechanical components (e.g. wire bonding capillaries, micro-surgical instruments, water-jet cutting tools, fiber optic connectors); electronic materials (e.g. solid electrolytic membranes, dielectrics, ferrites); specialty abrasives; and high performance catalysts. The enhancements in the micro-electronics industry can positively impact virtually every major industry in the United States from farming and medicine to mining, chemicals production, aerospace, metals production, transportation and information technology.