Atomization structure and characteristic analysis of catalyst precursor

The preparation technology of catalysts is the key determinant of catalytic efficiency and production costs. This study introduces atomization pyrolysis technology to enable continuous production of catalysts and carbon nanotubes (CNTs), addressing the limitations of conventional batch processes. Using computational fluid dynamics (CFD) simulations, the flow field within the atomizing cavity was analyzed to optimize key operational parameters: atomizing nozzle position, cavity aspect ratio, and gas supply configuration. Results demonstrate that side-positioned nozzles promote uniform droplet distribution in the cavity. Reducing the cavity’s length-to-width ratio shortens droplet flight paths, minimizing mid-air coalescence and accelerating particle formation. Counterflow gas supply effectively disrupts droplet collisions, favoring the generation of small, uniformly dispersed catalyst precursor particles. Parametric optimization achieves precise control over droplet dynamics, facilitating continuous synthesis of fine catalyst particles with narrow size distribution. These findings enhance precursor preparation efficiency and quality, advancing scalable catalyst manufacturing for CNTs growth.