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Volume 109
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Key factors in liquid-route synthesis of photovoltaic front-side silver micro-powder: Particle growth modeling coupled with CFD
Zepeng Zhu a, Qian Zhang b *, Yiyang Zhang c *, Yaqin Liao b, Qingqing Qiu b, Zhong Chen b, Shuiqing Li a
a Department of Energy and Power Engineering, Tsinghua University, Beijing, China
b Dongfang Electric Academy of Science and Technology Co. Ltd, Chengdu, China
c Institute of Nuclear and New Energy Technology, Tsinghua University, Beijing, China
10.1016/j.partic.2025.12.008
Volume 109, February 2026, Pages 270-281
Received 31 July 2025, Revised 9 December 2025, Accepted 10 December 2025, Available online 2 January 2026, Version of Record 16 January 2026.
E-mail: zhangq9916@dongfang.com; zhangyiyang@mail.tsinghua.edu.cn
Highlights

• A CFD-PBM model for front-side silver micro-powder synthesis considering flow, reaction, particle growth is proposed.

• Dominant periods of growth processes and their effects on silver powder synthesis are analyzed.

• Controlling hierarchy of key factors linking synthesis conditions to output size distribution is elucidated.

• Suggestions for adjusting synthesis are proposed according to parametric studies of input conditions.


Abstract

The performance of photovoltaic cell grids critically depends on the quality of front silver paste, which is significantly influenced by the particle size of the silver powder. Liquid-route continuous synthesis is a highly promising option for the silver micro-powder production. To identify the key factors in synthesis processes impacting on the particle size of the final product, a comprehensive understanding of the continuous liquid-route reduction synthesis mechanisms is required. This study presents a coupled CFD-PBM framework of silver micro-powder synthesis that incorporates flow dynamics, chemical reactions, nucleation, and surface growth processes. The results indicate that the initial reduction rate influences the nucleation of silver powder formation, thereby determining the number of final products. The reduction rate of following stage affects the surface growth, ultimately determining the average size of the products. In a synthesis system with a fixed total reducible silver content, a high initial reduction rate tends to a larger number of smaller silver powder particles produced. Particularly in the ascorbic acid-silver nitrate reduction system, the pH value is a critical factor controlling the distribution of reaction rates. The findings reveal how the reduction rate regulates the final particle size through its influence on nucleation and growth processes, providing insights into controlling powder particle size characteristics by manipulating reaction rates within the continuous synthesis system.

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