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On Preparation of Non‐Disrupted Particles by Spray Pyrolysis

Using spray pyrolysis, solid fully‐filled zirconia particles were synthesized at relatively high reactor temperatures (∼ 400 °C) by adding NaCl as impurities to zirconium hydroxychloride (ZHC) precursor that would have lead to the formation of hollow disrupted particles otherwise. FE‐SEM images show that at comparable concentration of NaCl and ZHC both cubic and spherical NaCl/ZrO2 particles form. The particle characteristics were varied by varying solute concentration, type, and solvent content. Addition of NaCl caused the formation of both cubic and spherical particles which were non‐disrupted at even high temperatures. According to the EDS compositional analysis, the cubic particles had more Na content while the spherical ones had higher Zr content. It is concluded that growth mechanism of NaCl particles is different from that of zirconia particles. Drying of the former even at high temperatures leads to the formation of solid, fully‐filled, porous particles, whereas hollow, disrupted particles are formed using the latter.