{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,9,9]],"date-time":"2026-09-09T14:01:27Z","timestamp":1788962487278,"version":"build-2803163510"},"reference-count":38,"publisher":"MDPI AG","issue":"10","license":[{"start":{"date-parts":[[2026,5,12]],"date-time":"2026-05-12T00:00:00Z","timestamp":1778544000000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"DOI":"10.13039\/501100001809","name":"National Natural Science Foundation of China","doi-asserted-by":"publisher","award":["22262017"],"award-info":[{"award-number":["22262017"]}],"id":[{"id":"10.13039\/501100001809","id-type":"DOI","asserted-by":"publisher"}]},{"DOI":"10.13039\/501100001809","name":"National Natural Science Foundation of China","doi-asserted-by":"publisher","award":["52274409"],"award-info":[{"award-number":["52274409"]}],"id":[{"id":"10.13039\/501100001809","id-type":"DOI","asserted-by":"publisher"}]},{"award":["22262017"],"award-info":[{"award-number":["22262017"]}],"id":[{"id":"https:\/\/ror.org\/01h0zpd94","id-type":"ROR","asserted-by":"publisher"}]},{"award":["52274409"],"award-info":[{"award-number":["52274409"]}],"id":[{"id":"https:\/\/ror.org\/01h0zpd94","id-type":"ROR","asserted-by":"publisher"}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Materials"],"abstract":"<jats:p>Ultrafine spherical Ag powders with narrow particle size distribution, high tap density, and limited agglomeration are important conductive fillers for advanced photovoltaic paste formulation. Current liquid-phase reduction scale-up is limited by uncontrolled nucleation, secondary agglomeration, and precursor passivation. This study investigates a process-integrated synthesis chain from precursor preparation to pilot-scale powder production from precursor preparation to kilogram-scale production. A flow-field-enhanced dissolution process (70\u201380 \u00b0C, 30\u201340% HNO3) alleviates silver ingot passivation, while a multi-stage NaOH spray system reduces NOx emissions to 186 mg\/m3, meeting GB31573-2015 standards. Ascorbic acid kinetically decouples nucleation and growth per the LaMer model. Molecular dynamics simulations and RDF analysis reveal a synergistic dispersion mechanism involving PVP and gum arabic. A purpose-built 20 L pilot reactor with optimized fluid dynamics and high-pressure cleaning eliminates supersaturation heterogeneity. Subsequent ethanol displacement and supersonic jet milling yield 1 kg-scale powder with D50 = 1.90 \u00b5m, tap density = 6.0 g\/mL, specific surface area = 0.6 m2\/g, and LOI (538 \u00b0C) = 0.98%. The obtained powder shows powder-level characteristics relevant to subsequent photovoltaic paste formulation, rather than direct device-level validation.<\/jats:p>","DOI":"10.3390\/ma19102010","type":"journal-article","created":{"date-parts":[[2026,5,12]],"date-time":"2026-05-12T16:04:36Z","timestamp":1778601876000},"page":"2010","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":1,"title":["Scalable Synthesis of High-Density Ultrafine Spherical Silver Powders"],"prefix":"10.3390","volume":"19","author":[{"given":"Xi","family":"He","sequence":"first","affiliation":[{"name":"State Key Laboratory of Complex Nonferrous Metal Resources Clean Utilization, Faculty of Metallurgical and Energy Engineering, Kunming University of Science and Technology, Kunming 650093, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Jiangyong","family":"Pei","sequence":"additional","affiliation":[{"name":"School of Metallurgy, Northeastern University, Shenyang 110819, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Xiaocai","family":"He","sequence":"additional","affiliation":[{"name":"National Key Laboratory of Nonferrous Metal Reinforced Metallurgy New Technology, Nonferrous Metals Research Institute Co., Ltd., Aluminum Corporation of China, Kunming 650021, China"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-7062-3092","authenticated-orcid":false,"given":"Ruidong","family":"Xu","sequence":"additional","affiliation":[{"name":"State Key Laboratory of Complex Nonferrous Metal Resources Clean Utilization, Faculty of Metallurgical and Energy Engineering, Kunming University of Science and Technology, Kunming 650093, China"}],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"1968","published-online":{"date-parts":[[2026,5,12]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","first-page":"358","DOI":"10.1007\/s12209-022-00336-9","article-title":"Review on metallization approaches for high-efficiency silicon heterojunction solar cells","volume":"28","author":"Zeng","year":"2022","journal-title":"Trans. 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