Silica powders with spherical shape and narrow size distribution were prepared by large-scale ultrasonic spray pyrolysis applying the droplet classification apparatus. On the other hand, silica powders prepared by large-scale ultrasonic spray pyrolysis without droplet classification apparatus had broad size distribution. Droplet classification apparatus used in this paper applied the principles of cyclone and dispersion plate with small holes. The droplets formed from the ultrasonic spray generator applying the droplet classification apparatus had narrow size distribution. The droplets with fine and large sizes were eliminated by droplet classification apparatus. The optimum flow rate of the carrier gas and diameter of the hole of the dispersion plate were studied to reduce the size distribution of the silica powders prepared by large-scale ultrasonic spray pyrolysis. The size distribution of the silica powders prepared by large-scale ultrasonic spray pyrolysis at the optimum preparation conditions was 0.76.