Computational study of the effect of processing parameters on the formation and growth of ZrO2 nanoparticles in FSP process

•For the first time, the production intensification in FSP process is investigated.•Optimization of different process parameters was studied.•Main aspects of process intensification (PI) were fulfilled.•Using air as dispersion gas improves the production cost and process safety.•The quantitative simulation results can be used as a design guide for FSP process.