Modelling of a Non-Transferred Plasma Torch Used for Nano-Silica Powders Production

In this study, a two-dimensional numerical model was developed to simulate operation conditions in the non-transferred plasma torch, used to synthesis nanosilica powder. The turbulent magnetohydrodynamic model was presented to predict the nitrogen plasma flow and heat transfer characteristics inside and outside the plasma torch. The continuity, momentum, energy, current continuity equations, and the turbulence model were expressed in cylindrical coordinates and numerically solved by COMSOL Multiphysics software with a finite element method. The operation conditions of the mass flow rate of ionized gas ranging from 78 sccm to 240 sccm and the current varying between 50 A to 200 A were systematically analyzed. The variation in the electrothermal efficiency with the gas flow rate, the plasma current, and the enthalpy was also reported. The results revealed that the increase in working current lead to a raise in the effective electric power and then an increase in the distribution of plasma velocity and temperature. The efficiency of the torch was found to be between 36% and 75%. The plasma jet exited the nozzle torch with a larger fast and hot core diameter with increasing current. The numerical results showed good correlation and good trends with the experimental measurement. This study allowed us to obtain more efficient control of the process conditions and a better optimization of this process in terms of the production rate and primary particle size. X-ray diffraction (XRD) and transmission electron microscopy (TEM) were used to characterize the primary nanosilica powder that was experimentally collected. The arc plasma method enabled us to produce a spherical silicon ultra-fine powder of about 20 nm in diameter.