Abstract: The invention concerns a process for the spheroidisation, densification and purification of powders through the combined action of plasma processing, and ultra-sound treatment of the plasma-processed powder. The ultra-sound treatment allows for the separation of the nanosized condensed powder, referred to as ‘soot’, from the plasma melted and partially vaporized powder. The process can also be used for the synthesis of nanopowders through the partial vaporization of the feed material, followed by the rapid condensation of the formed vapour cloud giving rise to the formation of a fine aerosol of nanopowder. In the latter case, the ultra-sound treatment step serves for the separation of the formed nanopowder form the partially vaporized feed material.