The burning characteristics of fuel droplets containing nano and micron-sized aluminum particles were investigated. Particle size, surfactant concentration, and the type of base fluid were varied. In general, nanosuspensions can last much longer than micron suspensions, and ethanol-based fuels were found to achieve much better suspension than n-decane-based fuels. Five distinctive stages (preheating and ignition, classical combustion, microexplosion, surfactant flame, and aluminum droplet flame) were identified for an n-decane/nano-Al droplet, while only the first three stages occurred for an n-decane/micron-Al droplet. For the same solid loading rate and surfactant concentration, the disruption and microexplosion behavior of the micron suspension occurred later with much stronger intensity. The intense droplet fragmentation was accompanied by shell rupture, which caused a massive explosion of particles, and most of them were burned during this event. On the contrary, for the nanosuspension, combustion of the large agglomerate at the later stage requires a longer time and is less complete because of formation of an oxide shell on the surface. This difference is mainly due to the different structure and characteristics of particle agglomerates formed during the early stage, which is a spherical, porous, and more-uniformly distributed aggregate for the nanosuspension, but it is a densely packed and impermeable shell for the micron suspension. A theoretical analysis was then conducted to understand the effect of particle size on particle collision mechanism and aggregation rate. The results show that for nanosuspensions, particle collision and aggregation are dominated by the random Brownian motion. For micron suspensions, however, they are dominated by fluid motion such as droplet surface regression, droplet expansion resulting from bubble formation, and internal circulation. And the Brownian motion is the least important. This theoretical analysis explains the different characteristics of the particle agglomerates, which are responsible for the different microexplosion behaviors that were observed in the experiments. (C) 2010 The Combustion Institute. Published by Elsevier Inc. All rights reserved.