Formation of individually dispersed nanoparticles or compactly aggregated nanoparticles front sols via a spray-drying route at low pressure was investigated experimentally. Silica sol was used as a sample material. Effects of operating temperature, colloid size, sol concentration, pressure, pH and zeta potential of sols on the morphology of product particles were investigated. From the experimental results, it was shown that dispersed nanoparticles could be obtained at a relatively low pressure (20 Torr) and low temperature (200 degrees C). The experiment also showed that dispersed nanoparticles could be achieved by careful control of the interfacial energy (pH value) of the colloidal precursor. A possible mechanism of sol-to-dry-particle formation in the spray-drying process at low pressure is suggested. based on the experimental results and the available theories. This mechanism was able to explain the experimental results well. (c) 2005 Elsevier Inc. All rights reserved.