The gas-phase formation of tin dioxide nanoparticles in single droplet combustion and flame spray pyrolysis

Tin dioxide (SnO₂) nanoparticles synthesized via flame spray pyrolysis (FSP) have promising applications for gas sensors. The formation of SnO₂ nanoparticles in the gas-phase has been investigated using single droplet combustion and FSP. Precursor solutions of Tin (II) 2-ethylhexanoate dissolved in Xylene with varying Sn concentrations were selected as the precursor-solvent system. The selected precursor-solvent system has its stability and ability to synthesize homogeneous nanoparticles, compared to metal nitrate based precursor solutions. The precursor-solvent system was studied using attenuated total reflection Fourier transform infrared (ATR-FTIR) spectroscopy and thermogravimetric analysis (TGA). The SnO₂ nanoparticles were characterized using X-ray diffraction (XRD), Brunauer-Emmett-Teller (BET), and transmission electron microscopy (TEM). Droplet surface micro-explosions were observed during the single droplet combustion of the precursor solutions. It is because of the heterogeneous vapor-phase nucleation, which is beneath the liquid droplet surface and caused by precursor thermal decomposition. The results show that the size of nanoparticles obtained both from FSP and single droplet combustion increases with increasing metal-precursor concentration. The TEM images of the particles from such droplet combustion reveal two types of nanoparticles with different sizes and morphologies. The current work provides fundamental understanding of precursor decomposition and particle formation during single droplet combustion, which help in-depth understanding of the flame spray pyrolysis.