A tutorial review of flame aerosol technology for manufacture of ceramic powders is presented. In the mid-20th century this field was driven by industrial research and development for production of commodities such as fumed silica and pigmentaty titania. With highly competitive market growth, inexpensive scale-up of existing units is required. In addition, the introduction of this technology to manufacture optical fibers and its potential for cheap synthesis of ultrafine particles (e.g. nanoparticles) has renewed research interest in flame aerosol reactors.
In this review, emphasis is placed in synthesis of particles with controlled size and crystallinity. After an overview of its history, the fundamentals of this technology are summarized, specific applications in the manufacture of fumed silica, pigmentary titania, alumina, composite and non-oxide powders are reviewed and finally research needs are highlighted. With major recent advances in process instrumentation and understanding in both combustion and aerosol science and engineering, this field is ready for a new leap forward.